Sequence of execution
1. Prepare the car for work (see "Preparing the car for maintenance and repair").
Note: To make work on the Zafira easier, you need to remove the ventilation grille and the top panel of the engine shield (see "Zafira Front Windscreen Wiper Drive - Checking and Replacing").
2. Drain the oil (see "Lubrication system - changing the oil and oil filter") and coolant (see "Coolant - Replacement").
3. Remove the air supply pipe (see "Throttle assembly - removal, gasket replacement and installation").
4. Disconnect the brake booster vacuum pipe from the receiver (see "Intake manifold and pipeline of 1.4 and 1.6 DOHC engines - replacement of gaskets").
5. Move the exhaust manifold away from the cylinder head (see "Exhaust manifold - gasket replacement"),
6. Disconnect the fuel line from the fuel rail (see "Injectors - checking and replacement").
7. Disconnect the wiring harness connectors from the coolant temperature sensor (see "Coolant Temperature Sensor - Checking and Replacing"), from the purge valve of the adsorber (see "Evaporative Canister Purge Valve - Checking and Replacing"), from the camshaft position sensor (see "Camshaft Position Sensor - Replacement"), from oxygen concentration sensors (see "Oxygen Concentration Sensors - Replacement"), from the absolute pressure sensor in the intake manifold (see "Absolute pressure sensor in the intake manifold of 1.4 and 1.6 DOHC engines - replacement"), from the exhaust gas recirculation valve (see "Exhaust Gas Recirculation Valve - Replacement") and from the throttle assembly (see "Throttle assembly - removal, gasket replacement and installation"),
8. On vehicles with a cable-operated throttle valve, disconnect the cable from the throttle assembly (see "Throttle assembly - removal, gasket replacement and installation").
9. Disconnect the upper wiring harness holder (crankcase ventilation hose removed).
10. Disconnect the wiring harness connector from the crankshaft position sensor (see "Crankshaft Sensor - Replacement"),
11. Disconnect the wiring harness connector from the ignition module (see "Ignition module - checking and replacement"),
12. Using the TORX E12 key, unscrew the bolt securing the ECU ground wire.
13. Remove the ECU (see "Electronic control unit for 1.4 and 1.6 DOHC engines — replacement").
14. Using the TORX E12 key, unscrew the bolt securing the negative engine wire.
15. Using a TORX T35 key, unscrew the three bolts securing the ECU bracket and remove it.
16. Move aside the upper wiring harness of the cylinder head (see "Injectors - checking and replacement").
17. Disconnect the hoses from the thermostat (see "Thermostat - Checking and Replacing").
18. Remove the rear cover of the timing belt drive (see "Camshaft Seals - Replacement").
19. Loosen the clamp on the cylinder head pipe hose and remove the hose from the cylinder head pipe.
20. Remove the upper generator mounting bracket (see "Generator - replacement").
21. Disconnect the hose supplying liquid to the air conditioning system heater radiator (see "Intake manifold and pipeline of 1.4 and 1.6 DOHC engines - replacement of gaskets").
22. Using a TORX E12 key, evenly unscrew the ten cylinder head mounting bolts in half-turns in the specified order.
23. Once again, we make sure that all necessary elements are disconnected from the cylinder head.
24. Remove the cylinder head assembly with the intake manifold.
25. Remove the cylinder head gasket.
Recommendation: When replacing the cylinder head gasket, we strongly recommend that you perform a cylinder head inspection (see "Cylinder head - check").
26. Clean the mating surface of the cylinder block and pistons from oil deposits, and remove carbon deposits from the piston bottoms using a metal brush.
27. Install the new cylinder head gasket, aligning the holes with the cylinder head guides. The OBEN/TOP inscription should be facing up.
28. Install the remaining parts in the reverse order, tighten the bolts to the prescribed torque (see "Reference data") in the order specified.
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