Sump; Oil Pump; Tighten Cylinder Head Bolts To Specified Stage 1 Torque Setting; Remove Securing Screws And Withdraw Oil Pump Cover From Rear Housing - Opel Zafira B MPV 2006 Owners Workshop Manual

angle, using a socket and extension bar. It is
recommended that an angle-measuring gauge
is used during this stage of the tightening, to
ensure accuracy (see illustration).
32 Working in the specified sequence, go
around again and tighten all bolts through the
specified Stage 3 angle.
33 Working again in the specified sequence,
go around and tighten all bolts through the
specified Stage 4 angle.
34 Finally go around in the specified
sequence again and tighten all bolts through
the specified Stage 5 angle.
35 Using new gaskets, refit the metal coolant
pipe to the coolant pump and thermostat
housing, tightening the bolts securely.
36 Reconnect the coolant hose to the radiator
and thermostat housing.
37 Reconnect the coolant hoses to the heater
matrix unions on the engine compartment
bulkhead.
38 Refit the intake and exhaust manifolds as
described in Chapter 4A.
39 Reconnect the wiring to the components
listed in paragraph 1 i, then secure the wiring
with cable ties.
40 Refer to Chapter 4A and refit the exhaust
front pipe to the exhaust manifold. Refit the
mounting rubbers.
41 Refit the rear timing belt cover with
reference to Section 6.
42 Refit the camshaft sprockets, timing belt
tensioner, and the timing belt idler roller, with
reference to Section 8.
43 Refit the timing belt as described in
Section 7.
44 Refit the spark plugs as described in
Chapter 1A.
45 Refit the camshaft cover as described in
Section 4.
46 Refit the wheel arch liner inner cover and
front roadwheel, then lower the vehicle to the
ground.
47 Reconnect the battery negative terminal.
48 Check that all relevant hoses, pipes and
wires, etc, have been reconnected. Check the
security of the fuel hose connections.
49 Refill and bleed the cooling system with
reference to Chapter 1 A.
50 When the engine is started, check for
signs of oil or coolant leakage.
Removal
1 Disconnect the battery negative terminal
(refer to Disconnecting the battery in the
Reference Chapter).
2 Apply the handbrake, then jack up the front
of the vehicle and support it on axle stands
(see Jacking and vehicle support). Remove the
right-hand front roadwheel and the wheel arch
liner inner cover for access to the right-hand
side of the engine.
1.6 and 1.8 litre petrol engine in-car repair procedures 2A•13
13.30b Tighten the cylinder head bolts to
the specified Stage 1 torque setting ..•
3 Drain the engine oil as described in Chap-
ter 1
A,
then fit a new sealing washer and refit
the drain plug, tightening it to the specified
torque (Chapter iA).
4 Remove the exhaust system as described
in Chapter 4A.
5 Disconnect the wiring connector from the
oil level sensor.
6 Undo the retaining bolt and remove the oil
dipstick guide tube.
7 Slacken and remove the bolts securing the
sump flange to the transmission housing.
8 On early models, remove the rubber plugs
from the transmission end of the sump flange
to gain access to the sump end retaining
bolts.
9 Progressively slacken and remove the bolts
securing the sump to the base of the cylinder
block/oil pump. Using a wide-bladed scraper
or similar tool inserted between the sump and
cylinder block, carefully break the joint, then
remove the sump from under the car.
Refitting
10 Thoroughly clean the sump and baffle
plate, then remove all traces of sealer and
oil from the mating surfaces of the sump and
cylinder block.
11 Apply a smear of suitable sealant (available
form Vauxhall/Opel dealers) to the areas of
the cylinder block mating surface around the
areas of the of the oil pump housing and rear
main bearing cap joints.
12 Apply a bead of suitable sealant (available
from Vauxhall/Opel dealers) approximately
2.5 mm thick to the sealing surface of the
sump. Around the No 5 main bearing cap area,
increase the thickness of the bead to 3.5 mm.
13 Offer up the sump, and loosely refit all the
retaining bolts. Working out from the centre in
a diagonal sequence, progressively tighten the
bolts securing the sump to the cylinder block/
oil pump to their specified torque setting.
14 Tighten the bolts securing the sump flange
to the transmission housing to their specified
torque settings. Refit the rubber plugs to the
sump flange cut-outs (where fitted).
15 Refit the oil dipstick guide tube.
16 Refit the exhaust system (see Chapter 4A)
and reconnect the oil level sender wiring
connector.
17 Refit the wheel arch liner inner cover and
front roadwheel, then lower the vehicle to
13.31 •.. and then through the various
specified angles as described in the text
the ground. Fill the engine with fresh oil, with
reference to Chapter 1A.
1.6 litre engines
Removal
1 Remove the alternator as described in
Chapter 5A.
2 Remove the timing belt as described in
Section 7.
3 Remove the timing belt tensioner and Idler
pulley as described in Section 8.
4 Remove the sump as described in Sec-
tion 14.
5 Undo the two bolts securing the metal
coolant pipe to the rear of the coolant pump.
6 Slacken and remove the eight retaining
bolts (noting their different lengths) then slide
the oil pump housing assembly off of the end
of the crankshaft, taking great care not to lose
the locating dowels. Remove the housing
gasket and discard it.
Overhaul
7 Remove the securing screws/bolts and
withdraw the oil pump cover from the rear of
the oil pump housing (see illustration).
8 Remove the inner and outer rotor from the
pump housing, noting which way round they
are fitted, and wipe them clean. Also clean the
rotor location in the oil pump housing.
15. 7 Remove the securing screws and
withdraw the oil pump cover from the rear
of the housing