Exhaust manifold — gasket replacement (Opel Zafira A)

The need to replace the gasket is usually indicated by the appearance of a specific sound from the engine (see "Exhaust system - technical condition check") and the appearance of traces of black soot around the perimeter of the exhaust manifold gasket.

Sequence of execution

Note: The operation is shown using the example of replacing a 1.6 DOHC engine. Differences in performing the operation on other engines are indicated in the text.

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

2. Remove the decorative engine cover (see "Engine trim panel - removal and installation").

3. On cars produced after 2000, unscrew the oxygen concentration control sensor (see "Oxygen Concentration Sensors - Replacement").

4. Using a TORX E10 key, unscrew the three bolts securing the exhaust manifold heat shield.



5. Remove the heat shield.



6. Using a 10 mm socket wrench, unscrew the nine nuts securing the exhaust manifold (for clarity, the mounting nuts are shown on the removed head).





7. Remove the mounting eye from the exhaust manifold studs.



8. Carefully move the exhaust manifold along the studs and move it away from the cylinder head.



9. Remove the exhaust manifold gasket.



10. Install the parts in the reverse order. Tighten the exhaust manifold mounting nuts to 12 Nm in the order specified (the mounting nuts are shown on the removed head).