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

Removal Procedure
  1. Raise the vehicle by its full height. Refer to Lifting and Jacking the Vehicle.
  2. Drain the cooling system. Refer to Cooling System Draining and Filling.
  3. Remove the engine sight shield. Refer to Engine Sight Shield Replacement.
  4. Remove the turbocharger heat shield. Refer to Turbocharger Heat Shield Replacement.
  5. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.
  6. Release the charge air cooler inlet air tube. Refer to Charge Air Cooler Inlet Air Hose Replacement.
  7. Release the turbocharger coolant feed pipe. Refer to Turbocharger Coolant Feed Pipe Replacement.
  8. Release the turbocharger coolant return pipe. Refer to Turbocharger Coolant Return Pipe Replacement.
  9. Release the turbocharger oil feed pipe. Refer to XXX.
  10. Release the catalytic converter. Refer to Catalytic Converter Replacement.

    11. Object Number: 2019546 Size: SH
  11. Disconnect the electrical connector (1) from turbocharger.

    12. Object Number: 2019547 Size: SH
  12. Release the vacuum pipe (1) from charger air bypass valve (2).
  13. Release the positive crankcase ventilation hose. Refer to XXX.
  14. Raise the vehicle by its full height.
  15. Remove the exhaust front pipe. Refer to Exhaust Front Pipe Replacement.
  16. Remove the turbocharger brace. Refer to XXX.
  17. Remove the turbocharger oil return hose. Refer to XXX.

    18. Object Number: 2019548 Size: SH
  18. Remove the 4 fasteners (1) from turbocharger (2).

Installation Procedure
  1. Install the turbocharger and tighten to 30 N·m (22 lb ft) , then to 35 N·m (26 lb ft).
  2. Install the turbocharger oil return hose. Refer to XXX.
  3. Install the turbocharger brace. Refer to XXX.
  4. Raise the vehicle by its full low.
  5. Connect the positive crankcase ventilation hose. Refer to XXX.

    6. Object Number: 2019549 Size: SH
  6. Connect the vacuum pipe (1) from charger air bypass valve (2).

    7. Object Number: 2019550 Size: SH
  7. Connect the electrical connector (1) from turbocharger.
  8. Connect the catalytic converter. Refer to Catalytic Converter Replacement.
  9. Connect the turbocharger oil feed pipe. Refer to XXX.
  10. Connect the turbocharger coolant return pipe. Refer to Turbocharger Coolant Feed Pipe Replacement.
  11. Connect the charge air cooler inlet air tube. Refer to Charge Air Cooler Inlet Air Hose Replacement.
  12. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.
  13. Install the turbocharger heat shield. Refer to Turbocharger Heat Shield Replacement.
  14. Install the engine sight shield. Refer to Engine Sight Shield Replacement.
  15. Fill the cooling system. Refer to Cooling System Draining and Filling.
  16. Raise the vehicle by its full lower. Refer to Lifting and Jacking the Vehicle.