Engine Removal And Overhaul Procedures - Opel Zafira B MPV 2006 Owners Workshop Manual

2 Part E:
ngine removal and overhaul procedures
Section number
Crankshaft - inspection . . . . . . . ......... , . . . . . . . . . . . . . . . . . 13
Crankshaft - refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Crankshaft - removal ..................................... 10
Cylinder block - cleaning and inspection. . . . . . . . . . . . . . ...... 11
Cylinder head - dismantling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cylinder head - reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cylinder head and valves - cleaning and inspection . . . . . . . . . . . 7
Engine - initial start-up after overhaul ........................ 19
Engine and transmission unit - removal and refitting. . . . . . . . . . . . 4
Engine overhaul - dismantling sequence. . . . . . . . . . . . . . . . . . . . . . 5
Degrees of difficulty
Section number
Engine overhaul - general information. . . . . . . . . . . . . . . . . . . . . . . . 2
Engine overhaul - reassembly sequence. . . . . . . ............. 15
Engine removal - methods and precautions . . . . . . . . . . . . . . . . . . 3
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Main and big-end bearings - inspection ...................... 14
Piston rings - refitting. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . 16
Pistons/connecting rods - inspection ..............•........ 12
Pistons/connecting rods - refitting ........................... 18
Pistons/connecting rods - removal . . . . . . . . . . . . . . . . . . . . . . . • . . 9
Easy, suitable for
novice with little
experience
~
I
Fairly easy, suitable
~
I
Fair1y difficult,
~
I
Difficult, suitable
~
I
Very difficult,
~
~
for beginner with
~
suitable for competent~ for experienced DIV
§
suitable for expert
§
~
some experience
~
DIV mechanic
~
mechanic
~
DIV or professional
~
Specifications
Engine identification
Engine type
1.6 litre (1598 cc) DOHC 16-valve petrol engine ................. .
1.8 litre (1796 cc) DOHC 16-valve petrol engine ................. .
2.2 litre (2198 cc) DOHC 16-valve petrol engine ................. .
1.9 litre (191 O cc) SOHC 8-valve diesel engine . . . . . . . .......... .
1.9 litre (1910 cc) DOHC 16-valve diesel engine . . . . . . . . . . . . . . .. .
1.6 litre petrol engines
Manufacturer's engine code
Z16XEP and 216XE1
218XER
222YH
219DT and Z19DTL
Z19DTH
Note: Where specifications are given as NIA, no information was available at the time of writing.
Refer to your Vauxha/1/0pel dealer for the latest information available.
Cylinder head
Maximum gasket face distortion . . . . . . . . . . . . . . . . . . . . . . . ..... .
Cylinder head height . . . . . . . . ............................. .
Valve seat angle in cylinder head . . . . . . . . . . . . . . . . . ........... .
Valve seat width in cylinder head:
Intake valve. . ......................................... .
Exhaust valve . . . . . . . . . . . . . .......................... .
Maximum permissible valve stem play in guide:
Intake valve ............................................ .
Exhaust valve . . ....................................... .
Valves and guides
Stem diameter:
Intake valve. . . . . . . . . . . . . . . . . . . ....................... .
Exhaust valve . . . . . . . . . . . . . . . . . . . . . ................ .
Valve head diameter:
Intake valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... .
Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... .
Valve length:
Intake valve. . . . . . . . . .................................. .
Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... .
Valve clearances (cold):
Intake valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. .
Exhaust valve . . . . . . . . . . . . . . . . .................... .
0.05 mm
NIA
90° 30'
1.0 to 1.4 mm
1.4 to 1.8 mm
0.030 to 0.061 mm
0.050 to 0.081 mm
4.955 to 4.970 mm
4.935 to 4.950 mm
30. 70 to 30.80 mm
27.10 to 27.20 mm
117.10 to 117.30 mm
116.16 to 116.36 mm
0.21 to 0.29 mm
0.26 to 0.35 mm