1.9 Litre Sohc Diesel Engine In-Car Repair Procedures - Opel Zafira B MPV 2006 Owners Workshop Manual

hapter 2 Part C:
1.9 litre SOHC diesel engine
in-car repair procedures
Contents
Section number
Camshaft and followers - removal, inspection and refitting ....... 11
Camshaft cover - removal and refitting . . . . . . . . . . . . . . . . . . . . . . 5
Camshaft oil seal - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Compression and leakdown tests - description and interpretation. . 2
Crankshaft oil seals - renewal . . . . . . . . . . . . . . . . . . . . . ........ 16
Crankshaft pulley/vibration damper - removal and refitting . . . . . . . 6
Cylinder head - removal and refitting ......................... 12
Engine oil and filter renewal . . . . . . . . . . . . . . . . . . . . . See Chapter 1 B
Engine oil level check ........................ See Weekly checks
Engine/transmission mountings - inspection and renewal . . . . . .
18
Flywheel/driveplate - removal, inspection and refitting ........... 17
Degrees of difficulty
Section number
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Oil filter housing - removal and refitting ....................... 15
Oil pump - removal, overhaul and refitting. . . . . . . . . . . . . . . . . . . . . 14
Sump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Timing belt - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Timing belt sprockets, tensioner and idler pulley - removal and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Top dead centre (TDC) for No 1 piston - locating . . . . . . . . . . . . . . . 3
Valve clearances - checking and adjustment . . . . . . . . . . . . . . . . . . 10
Valve timing - checking and adjustment . . . . . . . . . . . . . . . . . . . . . 4
Easy, suitable for
novice with little
experience
~
I
Fairly easy, suitable~
I
Fairiy difficult,
~
I
Difficult, suitable
~
I
Very difficult,
~
~
for beginner with
~
suitable for competent~
for experienced DIY ~ suitable for expert ~
~
some experience
~
DIY mechanic
~
mechanic
~
OIY or professional
~
Specifications
General
Engine type .............................................. .
Manufacturer's engine code. . . . ............................ .
Bore ................................................... .
Stroke........... . ..................................... .
Capacity ................................................ .
Compression ratio ........................................ .
Firing order .............................................. .
Direction of crankshaft rotation . . . . . . . . . . . . . . . . ............. .
Compression pressures
Maximum difference between any two cylinders ................ .
Valve clearances
Four-cylinder, in-line, water-cooled. Single overhead camshaft,
belt-driven
219DT and 21 9DTL
82.0 mm
90.4 mm
1910 cc
18.0:1
1-3-4-2 (No 1 cylinder at timing belt end of engine)
Clockwise (viewed from timing belt end of engine)
1.5 bar
Engine cold (intake and exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 to 0.40 mm
Lubrication system
Minimum oil pressure at 100°C .............................. .
Oil pump type ............................................ .
1.0 bar at idle speed
Rotor-type, driven by crankshaft pulley/vibration damper from
crankshaft