Replacing the turbocharger (Opel Insignia A)

Removal

Caution: If the turbocharger has failed, it is necessary to carefully remove the gasket residue and excess oil from the intercooler system before installing a new turbocharger. Neglecting to remove the gasket residue can cause serious damage to the turbocharger and engine after starting. The presence of oil in the turbocharger air ducts can lead to increased engine speed at start-up, which can lead to serious engine damage.

1. Raise the vehicle to maximum height.

2. Drain the coolant.

3. Remove the decorative engine cover.

4. Loosen the mounting bolts and remove the turbocharger heat shield (1).



5. Remove the air filter outlet pipe.

6. Remove the turbocharger intercooler intake duct.



7. Disconnect the turbocharger cooling supply pipe.





8. Disconnect the turbocharger cooling return pipe.



9. Disconnect the turbocharger pressure oil line.



10. Disconnect the catalytic converter.



11. Disconnect the electrical connector (1) from the turbocharger.





Material copied from the portal (opelbook)

12. Disconnect the vacuum line (1) from the boost relief valve (2).



13. Disconnect the positive crankcase ventilation hose.

14. Raise the vehicle to maximum height.

15. Remove the front exhaust pipe.

16. Remove the turbocharger bracket.



17. Remove the turbocharger return oil hose.



18. Unscrew the four nuts (1) and remove the turbocharger (2).

Installation

1. Install the turbocharger and tighten the mounting nuts first to 30 Nm, then to 35 Nm.

2. Install the turbocharger oil return hose.

3. Install the turbocharger bracket.

4. Raise the vehicle to maximum height.

5. Connect the forced crankcase ventilation hose.

6. Connect the vacuum line (1) to the boost relief valve (2).



7. Connect the electrical connector (1) to the turbocharger.



8. Connect the catalytic converter



9. Connect the turbocharger pressure oil line.

10. Connect the turbocharger cooling return pipe.

11. Connect the turbocharger intercooler inlet pipe.

12. Install the air filter outlet pipe.

13. Install the turbocharger heat shield.

14. Install the decorative engine cover.

15. Fill the engine cooling system.

16. Replace the oil filter and fill the engine with engine oil.