GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Opel 🢒 2009 🢒 Insignia Wagon (Global Epsilon) 🢒 Engine 🢒 Engine Mechanical - 2.8L, 3.0L, 3.2L, or 3.6L 🢒 Turbocharger Replacement

Removal Procedure
  1. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement.
  2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.
  3. Remove the upper intake manifold. Refer to Upper Intake Manifold Replacement.
  4. Remove the catalytic converter. Refer to Catalytic Converter Replacement.

    5. Note: Do NOT remove the exhaust manifold - right side.

  5. Remove the exhaust manifold brace - right side. Refer to Exhaust Manifold Replacement - Right Side.
  6. Remove the charge air cooler outlet air tube. Refer to Charge Air Cooler Outlet Air Tube Replacement.
  7. Remove the generator. Refer to Generator Replacement.
  8. Remove the positive crankcase ventilation tube from the oil level indicator tube.
  9. Remove the secondary air injection inlet pipe. Refer to LINK 184188.
  10. Remove the secondary air injection outlet pipe. Refer to Secondary Air Injection Pump Pipe Replacement.
  11. Remove the oil level indicator and tube. Refer to Oil Level Indicator Tube Replacement.

    12. Object Number: 2020071 Size: SH
  12. Remove the turbocharger coolant feed pipe (1).

    13. Object Number: 2020072 Size: SH
  13. Remove the 4 exhaust front manifold heat shield fasteners (1).
  14. Remove the exhaust front manifold heat shield (2).

    15. Object Number: 2020073 Size: SH
  15. Remove the 3 exhaust manifold brace fasteners (1).

    16. Object Number: 2020074 Size: SH
  16. Remove the exhaust turbocharger inlet pipe fasteners (1).
  17. Remove the exhaust turbocharger inlet pipe (2).
  18. Remove the charge air cooler inlet hose. Refer to Charge Air Cooler Inlet Hose Replacement.

    19. Object Number: 2026533 Size: SH
  19. Remove the 2 turbocharger oil feed pipe fittings (2,6) and gaskets (1,3).
  20. Remove the turbocharger oil feed pipe fastener (4).
  21. Remove the turbocharger oil feed pipe (5).

    22. Object Number: 2026567 Size: SH
  22. Remove the 2 turbocharger oil return pipe fasteners (5).
  23. Remove the turbocharger oil return pipe fastener (3).
  24. Remove the turbocharger oil return pipe (4).
  25. Remove the turbocharger oil return pipe gasket (1).
  26. Remove the turbocharger oil return pipe seal (2).

    27. Object Number: 2026568 Size: SH
  27. Remove the positive crankcase ventilation tube (1).
  28. Remove the turbocharger fastener (2).
  29. Remove the turbocharger (3).

Installation Procedure

    Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 2026568 Size: SH
  1. Install the turbocharger (3).
  2. Install the turbocharger fastener (2) and tighten to 65 N·m (48 lb ft).
  3. Install the positive crankcase ventilation tube (1).

    4. Object Number: 2026567 Size: SH
  4. Install the NEW turbocharger oil return pipe seal (2).
  5. Install the NEW turbocharger oil return pipe gasket (1).
  6. Install the turbocharger oil return pipe (4).
  7. Install the 2 turbocharger oil return pipe fasteners (5) and tighten to 14 N·m (11 lb ft).
  8. Install the turbocharger oil return pipe fasteners (3) and tighten to 65 N·m (48 lb ft).

    9. Object Number: 2026533 Size: SH
  9. Install the turbocharger oil feed pipe (5).
  10. Install the NEW turbocharger oil feed pipe fastener gaskets (1,3).
  11. Install the turbocharger oil feed pipe fastener (4).
  12. Install the 2 turbocharger oil feed pipe fittings (2, 6) and tighten the banjo screws to 30 N·m (22 lb ft).
  13. Install the charge air cooler inlet hose. Refer to Charge Air Cooler Inlet Hose Replacement.

    14. Object Number: 2020074 Size: SH
  14. Install a NEW exhaust turbocharger inlet pipe gasket.
  15. Install the exhaust turbocharger inlet pipe (2).
  16. Install the exhaust turbocharger inlet pipe fasteners (1) and tighten to 30 N·m (22 lb ft).

    17. Object Number: 2020073 Size: SH
  17. Install the 3 exhaust manifold brace fasteners (1) and tighten to 30 N·m (22 lb ft).

    18. Object Number: 2020072 Size: SH
  18. Install the exhaust front manifold heat shield (2). 19.
  19. Install the 4 exhaust front manifold heat shield fasteners (1) and tighten to 10 N·m (89 lb in).

    20. Object Number: 2020071 Size: SH
  20. Install the turbocharger coolant feed pipe (1) and tighten M12 to 30 N·m (22 lb ft) and M14 to 35 N·m (26 lb ft).
  21. Install the oil level indicator and tube. Refer to Oil Level Indicator Tube Replacement.
  22. Install the secondary air injection outlet pipe. Refer to Secondary Air Injection Pump Pipe Replacement.
  23. Install the secondary air injection inlet pipe. Refer to LINK 184188.
  24. Install the positive crankcase ventilation tube to the oil level indicator tube.
  25. Install the generator. Refer to Generator Replacement.
  26. Install the charge air cooler outlet air tube. Refer to Charge Air Cooler Outlet Air Tube Replacement.
  27. Install the exhaust manifold brace - right side. Refer to Exhaust Manifold Replacement - Right Side.
  28. Install the catalytic converter. Refer to Catalytic Converter Replacement.
  29. Install the upper intake manifold. Refer to Upper Intake Manifold Replacement.
  30. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.
  31. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement.