Removal and installation the intake manifold — 2.0L petrol engines (Opel Insignia A)

Removal

1. Remove the decorative engine cover.

2. Remove the fuel vapor recovery system purge solenoid valve.

3. Disconnect the brake booster vacuum line.

4. Remove the manifold absolute pressure sensor.

5. Remove the turbocharger control solenoid valve.

6. Remove the oil dipstick with the pipe.

7. Loosen the air outlet hose.

8. Remove the intake manifold bracket.

9. Remove the fuel pressure line.

Before servicing fuel system components, relieve pressure to reduce the risk of fire and injury. After relieving system pressure, a small amount of fuel may leak when servicing fuel lines or connections. To reduce the risk of injury, cover the regulator and fuel line connections with a rag before disconnecting to prevent fuel from leaking. Place the rag in a designated container after disconnecting.

10. Remove the metal fuel line.

11. Unscrew the seven bolts (1) securing the intake manifold (2).



12. Remove the intake manifold (2).

Installation

1. Install the intake manifold and tighten the mounting bolts in the specified sequence to a torque of 25 Nm.



2. Install the metal pressure fuel line.



3. Install the intake manifold bracket.

4. Install the intercooler air bleed hose.

5. Install the oil dipstick with the pipe.

6. Install the turbocharger control solenoid valve.

7. Install the manifold absolute pressure sensor.

8. Install the servo vacuum hose.

9. Install the solenoid valve for purging the carbon filter of the fuel vapor recovery system.

10. Install the engine cover.