Camshaft Cover - Removal And Refitting; Align The Camshaft Sprocket Timing Marks On 1.6 Litre Engines; Notch On Crankshaft Pulley Rim With Mark At Base Of Timing Belt Cover; Locate Rubber Seal Into Grooves Of Camshaft Cover - Opel Zafira B MPV 2006 Owners Workshop Manual

2A•4 1.6 and 1.8 litre petrol engine in-car repair procedures
3.5a Align the camshaft sprocket timing
marks (arrowed) on 1.6 litre engines .•.
the right-hand front roadwheel, then remove
the wheel arch liner inner cover for access to
the crankshaft pulley.
5 Using a socket and extension bar on the
crankshaft pulley bolt, rotate the crankshaft
until the timing marks on the camshaft
sprockets are facing towards each other,
and an imaginary straight line can be drawn
through the camshaft sprocket bolts and the
timing marks. With the camshaft sprocket
marks correctly positioned, align the notch
on the crankshaft pulley rim with the mark at
the base of the timing belt lower cover (see
illustrations). The engine is now positioned
with No 1 piston at TDC on its compression
stroke.
6 If the crankshaft pulley and lower timing
belt cover have been removed, the timing
mark on the crankshaft sprocket can be used
instead of the mark on the pulley. The mark
on the crankshaft sprocket must align with the
corresponding mark on the oil pump housing.
1.6 litre engines
Removal
1 Remove the air cleaner assembly and intake
ducts as described in Chapter 4A.
2 Remove the ignition module from the spark
plugs as described in Chapter 58.
4.11 Locate the rubber seal into the
grooves of the camshaft cover, ensuring
that it is fully seated
3.5b ... and 1.8 litre engines .•.
3 Remove the timing belt upper cover as
described in Section 6.
4 Release the fitting and disconnect the
breather hose from the camshaft cover.
5 Unclip the wiring harness trough from the
vicinity of the camshaft cover and move it to
one side.
6 Unscrew the three camshaft cover retaining
bolts at the timing belt end of the cover. Pull
the captive bolts upward from the cover as
far as possible and retain them in this position
with adhesive tape.
7 Unscrew the remaining six bolts securing
the camshaft cover to the cylinder head.
8 Lift the camshaft cover away from the
cylinder head and recover the rubber seal.
Examine the seal for signs of wear or damage
and renew if necessary.
Refitting
9 Ensure that the camshaft cover grove and
rubber seal are clean and dry with all traces
of oil removed. If necessary, degrease the
seal and cover groove with brake cleaner or a
similar product.
10 Clean the mating surface of the cylinder
head and the area around the camshaft
bearing caps at the timing belt end, ensuring
that all traces of oil are removed.
11 Locate the rubber seal into the grooves
of the camshaft cover, ensuring that it is fully
seated, with no chance of it falling out as the
cover is fitted (see illustration).
12 Carefully manoeuvre the camshaft cover
into position, taking great care to ensure the
seal remains correctly seated. Locate the
4.19 Lift the wiring harness out of the
support on the camshaft cover -
1.8 litre engines
3.5c ••• and the notch on the crankshaft
pulley rim with the mark at the base of the
timing belt lower cover (arrowed)
flywheel end of the camshaft cover on the
cylinder head, then carefully bring the timing
belt end of the cover down onto the head.
13 Remove the adhesive tape from the three
timing belt end retaining bolts. Screw in all the
cover retaining bolts and tighten them to the
specified torque, working in a spiral pattern
from the centre outwards.
14 Clip the wiring harness trough back into
position, then reconnect the engine breather
hose.
15 Refit the timing belt upper cover as
described in Section 6.
16 Refit the ignition module to the spark
plugs as described in Chapter 58.
17 Refit the air cleaner assembly and intake
ducts as described in Chapter 4A.
1.8 litre engines
Removal
18 Remove the ignition module from the
spark plugs as described in Chapter 58.
19 Lift the wiring harness up and out of the
support on the right-hand end of the camshaft
cover (see illustration).
20 Unclip the wiring harness trough from the
rear of the camshaft cover (see illustration).
21 Pull out the retaining wire clip and
disconnect the breather hose from the
camshaft cover (see illustration).
22 Unscrew the eleven bolts securing the
camshaft cover to the cylinder head.
23 Lift the camshaft cover away from the
cylinder head and recover the rubber seal.
4.20 Unclip the wiring harness trough from
the rear of the camshaft cover -
1.8 litre engines