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Installation Procedure

WARNING: This page is about a different variant/trim than selected.
    Fig 1: Turbocharger Mounting Studs
    GM2791208Courtesy of GENERAL MOTORS COMPANY
    NOTE:
    • If the turbocharger is being replaced, the new turbocharger will not include mounting studs. New mounting studs and nuts must be used.
    • If the turbocharger is being reused, only replace the nuts.
  1. Replace the three way catalytic converter to turbocharger studs and nuts if necessary.
    1. Install the turbocharger into a wise. Use softmetal braces.
    2. Install the 4 NEW three way catalytic converter to turbocharger studs and tighten the studs to 25 N.m (18 lb ft).
    2. Fig 2: Turbocharger, Gasket & Mounting Nuts
    GM2743382Courtesy of GENERAL MOTORS COMPANY
  2. Install a NEW turbocharger gasket (3).
  3. Install the turbocharger (1).
    4. CAUTION:

    Refer to Fastener Caution .

  4. Install the 4 NEW turbocharger nuts (2) and tighten to 30 N.m (22 lb ft).
  5. Install the turbocharger brace. Refer to Turbocharger Brace Replacement .
    6. Fig 3: Fuel Pipe Heat Shield & Retainers
    GM2743383Courtesy of GENERAL MOTORS COMPANY
  6. Install the brake and fuel pipe heat shield (1).
  7. Install the brake and fuel pipe heat shield fasteners (2).
  8. Install the heater inlet hose to the heater inlet. Refer to Heater Inlet Hose Replacement (2.0L LHU) .
  9. Install the heater outlet hose to the heater outlet. Refer to Heater Outlet Hose Replacement (2.0L LHU) .
  10. Install the steering gear heat shield. Refer to Steering Gear Heat Shield Replacement .
    11. Fig 4: Positive Crankcase Ventilation Hose/Pipe/Tube, Seal Ring & Mounting Components
    GM2743381Courtesy of GENERAL MOTORS COMPANY
  11. Install a NEW positive crankcase ventilation hose seal ring (1).
  12. Install the positive crankcase ventilation hose (2).
  13. Install the positive crankcase ventilation hose bolt (3) and tighten to 10 N.m (89 lb in).
    14. Fig 5: ECM Wiring Harness Plug, Vacuum Hose & Clamp
    GM2743380Courtesy of GENERAL MOTORS COMPANY
  14. Connect the ECM wiring harness plug (3) to the turbocharger.
  15. Install the vacuum hose (2) to the turbocharger air bypass valve and tighten the clamp (1).
  16. Install the turbocharger coolant return pipe. Refer to Turbocharger Coolant Return Pipe Replacement .
  17. Install the turbocharger coolant feed pipe. Refer to Turbocharger Coolant Feed Pipe Replacement .
  18. Install the turbocharger oil feed pipe. Refer to Turbocharger Oil Feed Pipe Replacement .
  19. Install the turbocharger oil return pipe. Refer to Turbocharger Oil Return Pipe Replacement .
  20. Install the three way catalytic converter. Refer to Three-Way Catalytic Converter Replacement (2.0L LHU) .
  21. Install the catalytic converter. Refer to Catalytic Converter Replacement (2.0L LHU) .
  22. Lower and unsupport the vehicle. Refer to Lifting and Jacking the Vehicle .
  23. Install the turbocharger heat shield. Refer to Turbocharger Heat Shield Replacement .
  24. Install the charge air cooler inlet hose - turbocharger side. Refer to Charge Air Cooler Inlet Hose Replacement (Turbocharger) .
  25. Install the air cleaner outlet rear duct. Refer to Air Cleaner Outlet Rear Duct Replacement .
  26. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  27. Install the engine sight shield. Refer to Engine Sight Shield Replacement .
  28. Fill the cooling system. Refer to Cooling System Draining and Filling (2.0L LHU) .
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