Cylinder head cover (Opel Insignia A)

Contents: Removal ⬇ Installation ⬇

Note: The procedures are based on the left cylinder head cover. The operations for the right cylinder head cover are similar.

Removal

1. Remove the catalytic converter from the turbocharger.

2. Remove the upper intake manifold.

3. Remove the secondary air outlet pipe.

4. Disconnect the positive crankcase ventilation pipe (1) from the oil dipstick pipe and the cylinder head cover (8).

5. Disconnect the wiring harness connectors and unscrew the fasteners, then remove the engine wiring harness (2). Tightening torque during installation: 20 Nm.

6. Loosen the bolt (3) securing the secondary air supply check valve. Tightening torque during installation: 65 Nm.

7. Loosen the three mounting bolts (4) and remove the secondary air supply check valve (5). Tightening torque during installation: 10 Nm.

Note: When installing the secondary air check valve, use a new gasket.

8. Loosen the two mounting bolts (6) and remove the engine lifting eye (7). Tightening torque during installation: 65 Nm.

9. Loosen the bolts (1) and remove the ignition coils (2).

9. Loosen the bolts (1) and remove the ignition coils (2).

10. Loosen the 13 mounting bolts (1) and remove the left cylinder head cover (2).

11. Remove and dispose of the cylinder head cover bushings with bolts.

Installation

1. Install EN 46101 guides onto the spark plug tubes of the left cylinder head.

2. Install new cylinder head cover bushings before installing the bolts.

3. Clean the contact surfaces on the cylinder head with a clean, lint-free cloth.

4. Place a bead of sealant 4 mm in diameter and 8 mm in length on the joint line of the front engine cover (1).

5. Install the cylinder head cover (2).

6. Tighten the 13 bolts (1) of the cylinder head cover.

7. Tighten the 13 cylinder head cover bolts in the specified sequence in two passes to a torque of 10 Nm.