Cylinder head cover for 1.4 and 1.6 DOHC engines — removal, gasket replacement and installation (Opel Zafira A)

The cylinder head cover gasket needs to be replaced if there are traces of oil leakage along the joint between the cover and the cylinder head. Very often, oil starts to accumulate in the spark plug wells. The gasket must be replaced after each cover removal.

Sequence of execution

1. Prepare the car for work (see "Preparing the car for maintenance and repair").

2. Remove the ignition module (see "Ignition module - checking and replacement").

3. Remove the oxygen concentration control sensor wiring harness from the holder on the cylinder head cover and move it to the side (see "Oxygen Concentration Sensors - Replacement").

4. Using pliers, squeeze the clamp and disconnect the crankcase ventilation hose.



5. In a similar manner, we disconnect the hose supplying crankcase gases to the throttle space...



...and a hose for supplying crankcase gases to the space in front of the throttle valve.





6. Remove the coolant supply hose to the throttle assembly from the holders on the cylinder head cover.



7. Using pliers, squeeze the clamp and disconnect the coolant supply hose to the throttle assembly; a small amount of coolant may spill out.



8. Using the TORX E10 key, unscrew the ten bolts securing the cylinder head cover.





9. Pull up and remove the cylinder head cover.



10. Remove the gasket from the grooves in the cylinder head cover.

Warning! Use only special sealant for vehicles equipped with oxygen sensors in the exhaust system. Using a regular sealant (with a high silicone content) may cause the sensors to fail.

11. Install the parts in the reverse order. Before installing the cover, apply a thin layer of sealant to the front camshaft bearing covers...





...and on the cutouts of the cylinder head opposite the rear ends of the camshafts.



12. Check and, if necessary, top up the coolant level to normal.