Undo Support Bracket Bolts, Release Retaining Clips; Cylinder Head Gasket Thickness Identification Hole - Opel Zafira B MPV 2006 Owners Workshop Manual

time to gradually impose the pressure of the
valve springs on the bearing caps. Repeat this
sequence until all bearing caps are in contact
with the cylinder head then go around and
tighten the camshaft bearing cap bolts to the
specified torque.
Caution: If the bearing cap bolts are
carelessly tightened, the bearing caps
might break. If any bearing cap breaks
then the complete cylinder head assembly
must be renewed; the bearing caps are
matched to the head and are not available
separately.
19 Fit a new camshaft oil seal as described in
Section 9.
20 Refit the braking system vacuum pump as
described in Chapter 9.
21 Refit the camshaft cover as described in
Section 5.
22 Refit the camshaft sprocket as described
in Section 8. Rotate the camshaft until the
mark on the camshaft sprocket is aligned with
the pointer on the camshaft cover (see Sec-
tion 3) . .
23 Turn the crankshaft clockwise by 90° to
bring No 1 and 4 pistons to approximately the
TDC position.
24 Refit the timing belt as described in
Section 7.
25
If any new components have been fitted,
check, and if necessary adjust, the valve
clearances as described in Section 10.
Note: New cylinder head bolts will be required
on refitting.
Removal
1
Disconnect the battery negative terminal
(refer to Disconnecting the battery in the
Reference Chapter).
2 Drain the cooling system as described in
Chapter 18.
3 Remove the timing belt as described in
Section 7.
4 Disconnect the wiring harness connectors
from the following components with reference
to the Chapters indicated:
a) Coolant temperature sensor (Chapter 3).
b) Fuel pressure sensor (Chapter 48).
c) Fuel pressure regulating valve (Chapter 48).
d) Throttle housing (Chapter 48).
e) Fuel injectors (Chapter 48).
f) Air conditioning compressor (Chapter 3).
g) EGR valve (Chapter 4C).
h) Charge (boost) pressure sensor (Chap-
ter 48).
O
High-pressure fuel pump (Chapter 48).
j) Camshaft sensor (Chapter 48).
5 Undo the wiring harness support bracket
bolts, release the retaining clips and move the
harness to one side (see illustration).
6 Remove the intake and exhaust manifolds
as described in Chapter 48.
1.9 litre SOHC diesel engine in-car repair procedures 2C•11
7 Remove the camshaft cover as described in
Section 5.
8 Remove the braking system vacuum pump
as described in Chapter 9.
9 Make a final check to ensure that all
relevant hoses, pipes and wires have been
disconnected.
10 Working in the reverse of the tightening
sequence (see illustration 12.28).
progressively slacken the cylinder head bolts
by half a turn at a time, until all bolts can be
unscrewed by hand. Note that an M14 Rl8E
socket bit will be required to unscrew the
bolts. Remove the cylinder head bolts and
recover the washers.
11 Engage the help of an assistant and lift the
cylinder head from the cylinder block. Take
care as it is a bulky and heavy assembly.
Caution: Do not lay the head on its lower
mating surface; support the head on
wooden blocks, ensuring each block only
contacts the head mating surface.
12
Remove the gasket and keep it for
identification purposes (see paragraph 19).
13 If the cylinder head is to be dismantled for
overhaul, then refer to Part E of this Chapter.
Preparation for refitting
14 The mating faces of the cylinder head and
cylinder block/crankcase must be perfectly
clean before refitting the head. Use a hard
plastic or wood scraper to remove all traces
of gasket and carbon; also clean the piston
crowns. Take particular care, as the surfaces
are damaged easily. Also, make sure that the
carbon is not allowed to enter the oil and
water passages - this ls particularly important
for the lubrication system, as carbon could
block the oil supply to any of the engine's
components. Using adhesive tape and
paper, seal the water, oil and bolt holes in the
cylinder block/crankcase. To prevent carbon
entering the gap between the pistons and
bores, smear a little grease in the gap. After
cleaning each piston, use a small brush to
remove all traces of grease and carbon from
the gap, then wipe away the remainder with
a clean rag. Clean all the pistons in the same
way.
15 Check the mating surfaces of the cylinder
block/crankcase and the cylinder head for
nicks, deep scratches and other damage. If
slight, they may be removed carefully with a
file, but if excessive, machining may be the
only alternative to renewal.
16 Ensure that the cylinder head bolt holes
in the crankcase are clean and free of oil.
Syringe or soak up any oil left in the bolt holes.
This is most important in order that the correct
bolt tightening torque can be applied and
to prevent the possibility of the block being
cracked by hydraulic pressure when the bolts
are tightened.
17 The cylinder head bolts must be discarded
and renewed, regardless of their apparent
condition.
18 If warpage of the cylinder head gasket
surface is suspected, use a straight-edge to
12.5 Undo the support bracket bolts
(arrowed), release the retaining clips and
move the wiring harness to one side
check it for distortion. Refer to Part E of this
Chapter if necessary.
19 On this engine, the cylinder head-to-
piston clearance is controlled by fitting
different thickness head gaskets. The gasket
thickness can be determined by looking at the
holes stamped on the edge of the gasket (see
illustration).
Number of holes
No holes
One hole
Gasket thickness
0.77 to 0.87 mm
0.87 to 0.97 mm
Two holes 0.97 to 1.07 mm
The correct thickness of gasket required is
selected by measuring the piston protrusions
as follows.
20 Mount a dial test indicator securely on the
block so that its pointer can be easily pivoted
between the piston crown and block mating
surface. Turn the crankshaft to bring No 1
piston roughly to the TDC position. Move the
dial test indicator probe over and in contact
with No 1 piston. Turn the crankshaft back-
and-forth slightly until the highest reading is
shown on the gauge, indicating that the piston
is at TDC.
21
Zero the dial test indicator on the gasket
surface of the cylinder block then carefully
move the indicator over No 1 piston. Measure
its protrusion at the highest point between the
valve cut-outs, and then again at its highest
point between the valve cut-outs at 90° to the
first measurement (see illustration). Repeat
this procedure with No 4 piston.
22 Rotate the crankshaft half a turn (180°)
to bring No 2 and 3 pistons to TDC. Ensure
the crankshaft is accurately positioned
12.19 Cylinder head gasket thickness
identification hole (arrowed)