Timing Belt; Move Leak-Off Hose Assembly Rearward, Then Lift Camshaft Cover; Fit The Seal To The Camshaft Cover Groove; Crankshaft Pulley/Vibration Damper Retaining Bolts - Opel Zafira B MPV 2006 Owners Workshop Manual

2C•6 1.9 litre SOHC diesel engine in-car repair procedures
5.6 Move the leak-off hose assembly
rearward, then lift the camshaft cover from
the cylinder head
are clean and dry then fit the seal to the cover
groove (see illustration).
8 Move the leak-off hose assembly to the rear
and carefully lower the cover Into position.
Screw in the retaining bolts and lightly tighten
them. Once all bolts are hand-tight, go around
and tighten them all to the specified torque
setting.
9 Reconnect the leak-off hose fittings to
the injectors by pushing in the locking clip,
attaching the fitting, then releasing the locking
clip. Ensure that each fitting is securely
connected and retained by the clip.
10 · Reconnect the breather hoses to the cover.
11 Refit and tighten the bolts securing the
vacuum lines.
12 Refit the plastic cover to the top of the
engine, tighten the two retaining bolts and
resecure the hose.
7 .2 Undo the bolt (arrowed) and remove
the auxiliary drivebelt idler pulley from the
engine bracket
7.3b ... and the three upper bolts
(arrowed) ...
5.7 Fit the seal to the camshaft cover
groove
Removal
1 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.
2 Remove the auxiliary drivebelt as
described in Chapter 1 B. Prior to removal,
mark the direction of rotation on the belt
to ensure the belt is refitted the same way
around.
3 Undo the four bolts securing the pulley to
the crankshaft sprocket and remove the pulley
from the sprocket (see illustration).
7.3a Undo the two lower bolts
(arrowed) ...
7.3c ... and remove the engine bracket
from the engine
6.3 Crankshaft pulley/vibration damper
retaining bolts (arrowed)
Refitting
4 Locate the crankshaft pulley on the
sprocket, ensuring that the hole on the rear
face of the pulley engages with the lug on the
sprocket.
5 Refit the four retaining bolts and tighten
them progressively to the specified torque.
6 Refit the auxiliary drivebelt as described
in Chapter 1 B using the mark made prior to
removal to ensure the belt is fitted the correct
way around.
7 Refit the roadwheel, then lower the car to
the ground and tighten the wheel bolts to the
specified torque.
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Note: The timing belt must be removed and
refitted with the engine cold.
Removal
1 Position No 1 cylinder at TDC on its com-
pression stroke as described in Section 3.
2 Undo the retaining bolt and remove the
auxiliary drivebelt idler pulley from the engine
bracket (see illustration).
3 Undo the two lower bolts, and the three
upper bolts, and remove the engine bracket
from the engine (see illustrations).
4 Undo the nut and bolt and remove the
crankshaft positioning tool (EN-46788) from
the crankshaft sprocket.
5 Slacken the timing belt tensioner retaining
bolt and allow the tensioner to retract, relieving
the tension on the timing belt.
6 Slide the timing belt from its sprockets and
remove it from the engine. If the belt is to be
re-used, use white paint or similar to mark the
direction of rotation on the belt. Do not rotate
the crankshaft or camshafts until the timing
belt has been refitted.
7 Check the timing belt carefully for any signs
of uneven wear, splitting or oil contamination,
and renew it if there is the slightest doubt
about its condition. If the engine is undergoing
an overhaul and is approaching the specified
interval for belt renewal (see Chapter 1 B)
renew the belt as a matter of course,