GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Opel 🢒 2009 🢒 Insignia HB (Global Epsilon) 🢒 Engine 🢒 Engine Mechanical - 2.0L 🢒 Intake Manifold Replacement

Removal Procedure
  1. Remove engine appearance cover replacement. Refer to LINK.
  2. Remove the evaporative emission canister purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement.
  3. Release the power brake booster vacuum pipe. Refer to LINK.
  4. Remove the manifold absolute pressure sensor. Refer to Manifold Absolute Pressure Sensor Replacement.
  5. Remove the turbocharger control solenoid valve. Refer to LINK.
  6. Remove the oil level indicator and tube. Refer to Oil Level Indicator and Tube Replacement.
  7. Release the charge air cooler outlet air hose. Refer to LINK.
  8. Remove the intake manifold brace. Refer to LINK.
  9. Remove the fuel feed pipe. Refer to Fuel Feed Pipe Replacement.

    10. Object Number: 2019537 Size: SH
  10. Remove the electrical cable holder fastener (1).

    11. Object Number: 2019538 Size: SH

    Warning: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury.

    After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.

  11. Remove the 3 fasteners (1) from the fuel damper (2).

    12. Object Number: 2019539 Size: SH
  12. Remove the 7 fasteners (1) from the intake manifold (2).

Installation Procedure

    Object Number: 2019540 Size: SH
  1. Install the intake manifold (1) and tighten to X N·m (X lb ft) (2).

    2. Object Number: 2019541 Size: SH
  2. Install the fuel damper (1) and tighten to X N·m (X lb ft) (2).

    3. Object Number: 2019545 Size: SH
  3. Install the electrical holder (1).
  4. Install the fuel feed pipe. Refer to Fuel Feed Pipe Replacement.
  5. Install the intake manifold brace. Refer to LINK.
  6. Install the charge air cooler outlet air hose. Refer to LINK.
  7. Install the oil level indicator and tube. Refer to Oil Level Indicator and Tube Replacement.
  8. Install the turbocharger control solenoid valve. Refer to LINK.
  9. Install the manifold absolute pressure sensor. Refer to Manifold Absolute Pressure Sensor Replacement.
  10. Install the power brake booster vacuum pipe. Refer to LINK.
  11. Install the evaporative emission canister purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement.
  12. Install engine appearance cover replacement. Refer to LINK.