Replacing the turbocharger. Engines LBS/A20DTH, LBX/A20DTJ, LCD/A20DTC (Opel Insignia A)

Removal

1. Open the hood.

2. Remove the rear air cleaner outlet duct.

3. The turbocharger pressure oil line has been removed.

4. Remove the turbocharger return oil hose.

5. Disconnect the electrical connector of the damper actuator.

6. Loosen the nut (1) and remove the catalytic converter clamp (2).



7. Raise and secure the vehicle.

8. Loosen the two bolts (3) of the air intake hose.



9. Remove the air inlet hose (2) and set it aside.

10. Remove the gasket (1) of the air intake hose.

11. Remove the hose of the electromagnetic valve controlling the turbocharger flap vacuum drive (4).



12. Unscrew the two exhaust manifold nuts (2).



13. Lower the vehicle.

14. Unscrew the nut (1) of the exhaust manifold.

15. Remove the turbocharger (4).

16. Remove the turbocharger gasket (3).

17. Clean all contact surfaces from gasket residue.

Installation

1. Install a new turbocharger gasket.

2. Install the turbocharger.

3. Hand tighten the three new exhaust manifold nuts to align the turbocharger with the catalytic converter.

4. Install the catalytic converter clamp (2) and tighten the nut (1) to 20 Nm.



5. Tighten the three exhaust manifold nuts in two stages in the following sequence:

• First stage: nut No.2 with a torque of 15 Nm, nut No.1 with a torque of 15 Nm, nut No.3 with a torque of 15 Nm.
• Second stage: nut No.2 with a torque of 28 Nm, nut No.1 with a torque of 28 Nm, nut No.3 with a torque of 28 Nm.

Note: Following the tightening sequence is necessary to prevent damage to the gasket between the turbocharger and the exhaust manifold.

6. Raise the car.

7. Install the hose (4) of the electromagnetic valve for controlling the turbocharger flap vacuum drive.



8. Install a new air intake hose gasket (1).



9. Install the air inlet hose (2) and tighten the two bolts (3) to 25 Nm.

10. Connect the electrical connector of the damper drive.

11. Install the turbocharger oil return hose.

12. Install the turbocharger pressure oil line.

13. Install the rear air filter outlet duct.

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14. Close the hood.