Exhaust Manifold Replacement — 2.0L Diesel Engines (Opel Insignia A)

Removal

1. Open the hood.

2. Remove the turbocharger.

3. Remove the oil dipstick tube.

Attention.

• To prevent burns, do not service the exhaust system while it is hot. Wait until it cools down.
• Always wear safety glasses and gloves when removing exhaust system components to prevent rust and chips from getting into your eyes and to protect your hands from sharp edges of worn components.

4. Remove and discard the nine exhaust manifold nuts (1).



5. Remove the nine heat shield washers (2) from the exhaust manifold.

6. Remove the exhaust manifold (3).

7. Remove the exhaust manifold gasket (4).

Installation

1. Check the tightness of the exhaust manifold studs.

2. Check the condition of the exhaust manifold stud threads.

3. Clean the contact surface. Remove all traces of the old gasket.

4. Install a new exhaust manifold gasket (4).



5. Install the exhaust manifold (3).



6. Install nine heat shield washers (2) on the exhaust manifold.

7. Install nine new exhaust manifold nuts (1) and tighten in the sequence shown to 20 Nm.

Note: Do not reuse exhaust manifold nuts.

8. Repeat the tightening procedure to ensure that the fastening is secure.

9. Install the oil dipstick tube.

10. Install the turbocharger.

11. Close the hood.