Undo The Retaining Bolts And Remove The Tension Rail And Guide Rails; Using A Drift To Lock The Balance Shaft Sprocket; Refit The Timing Chain Crankshaft Sprocket; Turning The Camshaft Slightly Using An Open-Ended Spanner - Opel Zafira B MPV 2006 Owners Workshop Manual

2.2 litre petrol engine in-car repair procedures 28•9
8.16 Undo the retaining bolts and remove the tension rail and
guide rails
8.18 Using a drift to lock the balance shaft sprocket
A Tension rail B Guiderails
timing chain, tension rail and guides, balance
shaft chain tensioner and all the drivegears/
sprockets the components must always be
renewed as a complete assembly.
14 Remove the camshaft timing chain and
sprockets as described in paragraphs 1 to 13.
15 Undo the two retaining bolts and remove
the balance shaft chain tensioner from the
cylinder block.
16 Undo the securing bolts and remove the
tension rail and the two guide rails from the
cylinder block (see illustration).
17 Lift the balance shaft timing chain from
the sprockets and remove.
18 Using a suitable drift, lock the balance
shaft sprockets and undo the retaining bolts,
then remove the sprocket from the balance
shaft (see illustration). Use new bolts when
refitting.
19 Slide the crankshaft drivegear/sprocket
(and spring washer, where fitted) off the
Woodruff key on the crankshaft. Note: FRONT
is marked on the outer face of the gear.
20 Lock the coolant pump drivegear with
a suitable screwdriver, and undo the three
securing bolts. Remove the drivegear from the
coolant pump.
Inspection
21 Examine the teeth on the sprockets for
any sign of wear or damage such as chipped,
hooked or missing teeth. If there is any sign of
wear or damage on any sprockeVgear, all the
sprockets/gears and the relevant chain should
be renewed as a set.
22 Inspect the links of each timing chain for
signs of wear or damage on the rollers. The
extent of wear can be judged by checking
the amount by which the chain can be bent
sideways; a new chain will have very little
sideways movement. If there is an excessive
amount of side play in a timing chain, it must
be renewed.
23 Note that it is a sensible precaution to
renew the timing chains, regardless of their
apparent condition, if the engine has covered
a high mileage, or if it has been noted that the
chain(s) have sounded noisy when the engine
running. It is advised renewing the chains
and sprockets as a matched set, since it is
false economy to run a new chain on worn
sprockets and vice versa. If there is any doubt
about the condition of the timing chains and
sprockets, seek the advice of a Vauxhall/Opel
dealer service department, who will be able
to advise you as to the best course of action,
based on their previous knowledge of the
engine.
24 Examine the chain guide(s) and tensioner
rail(s) for signs of wear or damage to their
chain contact faces, renewing any which are
badly marked.
Refitting
Camshaft chain and sprockets
25
If any new components are being fitted,
transfer any alignment marks you have made
from the original components to aid refitting.
Ensure the crankshaft is still at the TDC
position.
26 If not already fitted, refit the balance shaft
timing chain and sprockets as described in
paragraphs 42 to 49.
27 Slide the crankshaft drive sprocket (and
spring washer, where fitted) onto the Woodruff
8.27 Refit the timing chain crankshaft
sprocket, noting FRONT is marked on the
outer face
key on the crankshaft. Note: FRONT is
marked on the outer face of the sprocket (see
illustration).
28 Refit the intake camshaft sprocket complete
with timing chain down through the top of the
cylinder head. The copper coloured link should
line up with the INT mark on the intake sprocket
(a cable tie can be used to keep the chain in
position - see illustration 8.0b). Attach the
sprocket to the camshaft using a new securing
bolt, tightening it hand-tight at this stage.
29 Insert the timing chain tension rail up
through the engine casing into position for the
tensioner. (Do not refit the lower securing bolt
until the timing chain is in position.)
30 Insert the exhaust camshaft sprocket into
the timing chain, making sure the silver link on
the timing chain lines up with the EXH mark on
the sprocket (a cable tie can be used to keep
the chain in position - see illustration 8.0a).
Attach the sprocket to the camshaft using a
new securing bolt, tightening it hand-tight at
this stage. Note: One or both of the camshafts
may have moved slightly, due to valve spring
pressure. It may be necessary to turn the
camshafts slightly to locate the sprockets
in the correct position, use an open-ended
spanner on the camshaft if required (see
illustration). Do not tum the camshafts too
8.30 Turning the camshaft slightly using
an open-ended spanner to locate the
sprocket in the correct position