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

Removal

1. Remove the high pressure fuel pump.

2. Remove the EGR cooler valve.

3. Disconnect the intake air sensor connector (1) and the glow plug connector (2).



4. Disconnect the cooling system connector.



5. Loosen the screw (1) of the cable bracket.

6. Disconnect the exhaust gas injection pipe, electrical connector (2), clamp (3); remove the hose and unscrew the two bolts (4).

7. Remove the quick-release connector (5) of the cooling system.

8. Remove the oil seal from the cylinder block, loosen the upper hose connection (6), remove the clamp (7). Unscrew the two bolts (8) and move the oil seal to the side.

9. Disconnect the connector (1) of the exhaust gas recirculation drive.





10. Remove the stud (1) holding the high-pressure fuel pump in place. To remove the stud, lock two M8 nuts.



11. Loosen the bolt (1) on the side of the rigging eye.



12. Loosen the mounting nuts (2) and remove the intake manifold.

Installation

1. Install the intake manifold (2) with new seals. Tighten the mounting nuts to 25 Nm.





2. Install the bolt (1) of the rigging eye.

3. Insert the pin (1).



4. Insert the connector (1) of the exhaust gas recirculation drive.



5. Install the exhaust gas injection pipe and screw in the two bolts (4). Install the electrical connector (2), clamp (3) and connect the hose.



6. Install the oil seal on the cylinder block, connect the upper hose connector (6), install the clamps (7) and two bolts (8).



7. Install the quick-release connector (5) of the cooling system.

8. Install the cable bracket (1).

9. Connect the connector (1) of the intake air sensor and the connectors (2) of the glow plug.



10. Install the exhaust gas recirculation cooler valve.

11. Install the high pressure fuel pump.

12. Connect the exhaust hose and start the engine. Check for leaks. Connect the diagnostic tool and clear the fault codes from the vehicle's memory.