Intake manifold and pipeline of 1.4 and 1.6 DOHC engines — replacement of gaskets (Opel Zafira A)

The gaskets must be replaced if air is sucked into the engine cylinders, as well as when removing the intake receiver and pipeline.

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. Disconnect the wiring harness connector 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").

Material copied from this portal: OPELBOOK

3. Disconnect the wiring harness block and the coolant supply hoses, crankcase gases and fuel vapors from the adsorber from the throttle assembly (see "Throttle assembly - removal, gasket replacement and installation").

4. Disconnect the pipeline from the fuel rail (see "Injectors - checking and replacement").

5. Using a 13 mm socket wrench, unscrew the bolt securing the lower receiver bracket.



6. Remove the upper generator bracket (see "Generator - replacement").



7. Press the retainer and disconnect the brake booster tube from the receiver.



8. Using the TORX E10 key, unscrew the two bolts securing the wire holder bracket on the left side of the intake manifold.



9. Using a TORX T30 key, unscrew the three bolts securing the right side of the receiver...



...and two bolts securing the left side of the receiver to the pipeline.





10. Remove the receiver assembly with the throttle assembly.



11. Remove the receiver gasket.



Further operations are required to replace the intake manifold gasket.

12. Drain the coolant (see "Coolant - Replacement").

Comment.

The intake manifold gasket can be replaced as a whole or in parts. The gasket has notches along which the gasket can be divided.

It should be remembered that damage to only the long part of the gasket will lead to air being sucked into the cylinders. The procedure for replacing the entire gasket is described below. When replacing a part of the gasket, perform only the operations necessary in this case.

13. Using pliers, loosen the clamp on the coolant supply hose to the heater radiator and slide it along the hose.



14. Disconnect the hose from the intake manifold.



15. Disconnect the wiring harness connector from the exhaust gas recirculation valve (see "Exhaust Gas Recirculation Valve - Replacement").

16. Remove the wiring harness from the casing on the fuel rail (see "Injectors - checking and replacement").

17. Unscrew the nine nuts securing the intake manifold to the cylinder head (shown on a removed cylinder head).



18. Move the pipeline along the studs from the cylinder head and remove it together with the fuel rail and the exhaust gas recirculation valve.





19. Using the TORX E12 key, unscrew the two bolts securing the cooling system flange to the cylinder head.



20. Move the flange to the side without disconnecting the hose from it.



21. Remove the intake manifold gasket.



22. Install the parts in the reverse order. Tighten the nuts securing the intake manifold to the cylinder head to a torque of 20 Nm in the order specified.