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Home >> Chevrolet >> 2006 >> Cobalt LTZ >> Repair and Diagnosis >> External Pages >> Different car >> Section 790 (Engine Mechanical - 2.0L) >> Repair Instructions - Off Vehicle >> Turbocharger Installation

Turbocharger Installation

WARNING: This page is about a different car, the 2008 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Turbocharger Oil Return Pipe & Gasket
    GM1956807Courtesy of GENERAL MOTORS CORP.
  1. Install a new turbocharger oil return pipe gasket.
  2. Install the turbocharger oil return pipe into the engine block.
    3. Fig 2: View Of Turbocharger & Gasket
    GM1956811Courtesy of GENERAL MOTORS CORP.
  3. Attach the positive crankcase ventilation (PCV) hose and fitting with O-ring from the camshaft cover to the turbocharger.
    4. NOTE: Refer to Fastener Notice .
  4. Install the PCV hose fitting bolt.

    Tighten:  Tighten the PCV hose fitting bolt to 10 N.m (89 lb in).

  5. Lubricate the O-ring on the turbocharger oil return pipe with clean engine oil.
  6. Install the turbocharger oil return pipe bolts.

    Tighten:  Tighten the turbocharger oil return pipe bolts to 10 N.m (89 lb in).

  7. Install a new turbocharger gasket.
  8. Install the turbocharger.
  9. Install the turbocharger nuts.

    Tighten

    • Tighten the turbocharger nuts to 30 N.m (22 lb ft).
    • Tighten the turbocharger nuts a second time to 35 N.m (26 lb ft).
    10. Fig 3: View Of Turbocharger Brace Bracket & Bolts
    GM2045496Courtesy of GENERAL MOTORS CORP.
  10. Install the turbocharger brace bracket.
  11. Install the turbocharger brace bracket bolt.

    Tighten:  Tighten the turbocharger brace bolt to 58 N.m (43 lb ft).

  12. Install the turbocharger brace.
  13. Install the turbocharger brace nuts.

    Tighten:  Tighten the turbocharger brace nuts to 50 N.m (37 lb ft).

  14. Install the turbocharger brace bolt.

    Tighten:  Tighten the turbocharger brace bolt to 50 N.m (37 lb ft).

  15. Install the turbocharger brace bracket and bolt to the turbocharger brace if necessary.

    Tighten:  Tighten the turbocharger brace bracket bolt to 22 N.m (16 lb ft).

    16. Fig 4: Identifying Turbocharger Coolant Feed Pipe
    GM1769641Courtesy of GENERAL MOTORS CORP.
  16. Install the turbocharger coolant feed pipe.
  17. Install the turbocharger coolant feed pipe gaskets.
  18. Install the turbocharger coolant feed pipe bolts.

    Tighten: 

    • Tighten the turbocharger coolant feed pipe bolts to 20 N.m (15 lb ft).
    • Tighten the turbocharger coolant feed pipe mounting bolt to 10 N.m (89 lb in).

  19. Connect the positive crankcase ventilation (PCV) and hose assembly.
    20. Fig 5: View Of Turbocharger Coolant Outlet Pipe
    GM2045495Courtesy of GENERAL MOTORS CORP.
  20. Install the turbocharger air cooler outlet pipe.
  21. Install the turbocharger air cooler outlet pipe bolts.

    Tighten:  Tighten the turbocharger air cooler outlet pipe bolts to 25 N.m (18 lb ft).

    22. Fig 6: View Of Turbocharger Coolant Return Pipe
    GM2046140Courtesy of GENERAL MOTORS CORP.
  22. Install the turbocharger coolant return pipe.
  23. Install the turbocharger coolant return pipe gaskets.
  24. Install the turbocharger coolant return pipe bolts.

    Tighten:  Tighten the turbocharger coolant return pipe bolts to 20 N.m (15 lb ft).

    25. Fig 7: Identifying Turbocharger Oil Feed Pipe
    GM2046139Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not twist the turbocharger oil feed pipe. Twisting of the feed pipe will result in the collapse and deformation of the plastic pipe, restricting oil flow and causing turbocharger damage. During turbocharger replacement, gently push the oil feed pipe towards the front of the engine to clear the turbocharger. Assistance may be required to keep the pipes clear of the turbocharger during removal or installation.
  25. Install the turbocharger oil feed pipe.
  26. Install the turbocharger oil feed pipe gaskets.
  27. Install the turbocharger oil feed pipe bolts.

    Tighten:  Tighten the turbocharger oil feed pipe bolts to 20 N.m (15 lb ft).

    28. Fig 8: Identifying Turbocharger Exhaust Pipe & Seal
    GM2046138Courtesy of GENERAL MOTORS CORP.
  28. Install the turbocharger exhaust pipe seal.
  29. Install the turbocharger exhaust pipe.
  30. Install the turbocharger exhaust pipe bolt.

    Tighten:  Tighten the turbocharger exhaust pipe bolt to 22 N.m (16 lb ft).

  31. Install the turbocharger exhaust pipe nuts.

    Tighten:  Tighten the turbocharger exhaust pipe nuts to 50 N.m (37 lb ft).

    32. Fig 9: Identifying Turbocharger Heat Shield & Bolts
    GM2046250Courtesy of GENERAL MOTORS CORP.
  32. Install the turbocharger exhaust pipe heat shield.
  33. Install the turbocharger exhaust pipe heat shield bolts.

    Tighten:  Tighten the turbocharger exhaust pipe heat shield bolts to 10 N.m (89 lb in).

    34. Fig 10: Identifying Turbocharger Heat Shield
    GM2046137Courtesy of GENERAL MOTORS CORP.
  34. Install the turbocharger heat shield.
  35. Install the turbocharger heat shield bolts.

    Tighten:  Tighten the turbocharger heat shield bolts to 10 N.m (89 lb in).

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