Daewoo Chevrolet Forums and Owners Club

The intake manifold is not readily available for the 0.8L engines. The ordered ones may not have that build quality as the factory fitted one does. So, I decided not to cut the manifold as suggested by 'Spikey 2009' although it seems to be a permanent solution. Anyone who wants to play safe in this Intake Manifold Coolant Leak repair can follow my way of repairing. Here is the detailed repair procedure-

1) Get a new Intake Manifold gasket. Here is the one that I bought.

[attachment=1115]


2) Remove the Battery and drain the Coolant.

3) Open the whole Intake Manifold: This is the first important part. Please refer to the service manual for detailed removal instructions of various components.
a) Make space by removing Canister, Canister Solenoid, Air Filter assembly, MAP Sensor assembly, Ignition Coil and all necessary connecting wires.
b) Remove the Starter Motor for essential working space and good field of view. Don't worry, it is easy and safe. Remove the bolts from top, jack-up the car, lie underneath and remove the remaining bolts.
c) Relieve the fuel system pressure and remove the fuel line to the fuel rail and disconnect the injector connections.
d) Remove the bolts of the Intake Manifold assembly including the EGR assembly and carefully take out the Intake Manifold.

This my car's Intake Manifold. As you can see there is little left of the gasket in the Coolant block part.

[attachment=1116]

[attachment=1117]


4) Remove the remaining parts of the gasket and clean the gasket groove and the Coolant block part to dry. Optionally you can also clean the inside of the intake and injector surfaces.

5) Install the new Gasket carefully. Apply a gel based epoxy sealant that is heat resistant on top of the gasket in the squared Coolant block part. This will keep the gasket intact for a very very long time.

6) When the sealant is set, install the Intake Manifold back and the other components following above steps in reverse order to complete the repair.

This is how my car's Intake Manifold Coolant leak was repaired. Hope anyone having this problem will find my technique as a systematic and standard approach. A great thanks to all who responded to my post.

OK – this is good effort really and solves one of the most prominent problems in Matiz.

But you removed a lot of things unnecessarily as to reach this far.

Also I don't think it’s a good idea to us epoxy as it will permanently seal the manifold and will be very hard to remove from the block, in case you had to take the manifold out again for any sort of reason. It would have been better if you used RTV silicone baste, which would have sealed the manifold for leaking and will be easy to remove later. This TRV silicone stuff is now being used in replace of standard gaskets and can withstand temperatures up to 1500 degrees. Fancy that.

Now I am happy you got it sorted anyway.

(02-07-2010 07:45 AM)sidy_porche Wrote: [ -> ]The intake manifold is not readily available for the 0.8L engines. The ordered ones may not have that build quality as the factory fitted one does. So, I decided not to cut the manifold as suggested by 'Spikey 2009' although it seems to be a permanent solution. Anyone who wants to play safe in this Intake Manifold Coolant Leak repair can follow my way of repairing. Here is the detailed repair procedure-

1) Get a new Intake Manifold gasket. Here is the one that I bought.




2) Remove the Battery and drain the Coolant.

3) Open the whole Intake Manifold: This is the first important part. Please refer to the service manual for detailed removal instructions of various components.
a) Make space by removing Canister, Canister Solenoid, Air Filter assembly, MAP Sensor assembly, Ignition Coil and all necessary connecting wires.
b) Remove the Starter Motor for essential working space and good field of view. Don't worry, it is easy and safe. Remove the bolts from top, jack-up the car, lie underneath and remove the remaining bolts.
c) Relieve the fuel system pressure and remove the fuel line to the fuel rail and disconnect the injector connections.
d) Remove the bolts of the Intake Manifold assembly including the EGR assembly and carefully take out the Intake Manifold.

This my car's Intake Manifold. As you can see there is little left of the gasket in the Coolant block part.






4) Remove the remaining parts of the gasket and clean the gasket groove and the Coolant block part to dry. Optionally you can also clean the inside of the intake and injector surfaces.

5) Install the new Gasket carefully. Apply a gel based epoxy sealant that is heat resistant on top of the gasket in the squared Coolant block part. This will keep the gasket intact for a very very long time.

6) When the sealant is set, install the Intake Manifold back and the other components following above steps in reverse order to complete the repair.

This is how my car's Intake Manifold Coolant leak was repaired. Hope anyone having this problem will find my technique as a systematic and standard approach. A great thanks to all who responded to my post.