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

Removal Procedure

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: Identifying Charge Air Cooler Inlet Pipe
    GM1769629Courtesy of GENERAL MOTORS CORP.
  1. Drain the cooling system. Refer to Cooling System Draining and Filling (GE 47716 Fill) or Cooling System Draining and Filling (Static Fill LNF) .
  2. Remove the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement .
  3. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  4. Remove the charge air cooler pipe bolts at the turbocharger.
  5. Remove the charge air cooler pipe from the turbocharger.
    6. Fig 2: Identifying Turbocharger Heat Shield & Bolts
    GM1750397Courtesy of GENERAL MOTORS CORP.
  6. Remove the turbocharger heat shield bolts (1) and shield.
  7. Remove the catalytic converter. Refer to Catalytic Converter Replacement (LNF) .
  8. Remove the heated oxygen sensor. Refer to Heated Oxygen Sensor 1 Replacement .
    9. Fig 3: Identifying Turbocharger Exhaust Pipe Heat Shield & Bolts
    GM2030269Courtesy of GENERAL MOTORS CORP.
  9. Remove the turbocharger exhaust pipe heat shield bolts (1).
  10. Remove the turbocharger exhaust pipe heat shield (2).
    11. Fig 4: Identifying Turbocharger Exhaust Pipe Heat Shield Nuts
    GM2030323Courtesy of GENERAL MOTORS CORP.
  11. Remove the turbocharger exhaust pipe nuts (1).
  12. Remove the turbocharger exhaust pipe (2).
    13. Fig 5: Identifying Turbocharger Bracket & Bolts
    GM2029560Courtesy of GENERAL MOTORS CORP.
  13. Remove the turbocharger bracket bolt (1).
  14. Remove the turbocharger bracket bolt (2) and bracket (3).
  15. Remove the turbocharger brace bolts (4).
  16. Remove the turbocharger brace nut (5) and brace (6).
  17. Lower the vehicle.
    18. Fig 6: Locating turbocharger wastegate solenoid valve Harness & Connector
    GM1750410Courtesy of GENERAL MOTORS CORP.
  18. Disconnect the engine wiring harness electrical connector from the turbocharger wastegate solenoid valve.
    19. Fig 7: View Of Turbocharger Vacuum Hose
    GM1750413Courtesy of GENERAL MOTORS CORP.
  19. Reposition the vacuum hose clamp (5) at the turbocharger.
  20. Remove the vacuum hose from the turbocharger.
    21. Fig 8: Turbocharger Coolant Feed Pipe Clip
    GM1750409Courtesy of GENERAL MOTORS CORP.
  21. Remove the engine wiring harness clip (1) from the turbocharger coolant feed pipe.
    22. Fig 9: Turbocharger Coolant Feed Pipe Bolt
    GM1750401Courtesy of GENERAL MOTORS CORP.
  22. Remove the turbocharger coolant feed pipe bolt (1) at the turbocharger.
  23. Remove and discard the turbocharger coolant feed pipe gasket.
  24. Remove the turbocharger coolant feed pipe bolt (3) from the cylinder head.
  25. Reposition the turbocharger coolant feed pipe out of the way.
    26. Fig 10: Identifying Positive Crankcase Ventilation (PCV) Pipe
    GM2030152Courtesy of GENERAL MOTORS CORP.
  26. Remove the positive crankcase ventilation (PCV) pipe (1) from the turbocharger. Reposition the PCV pipe (with fitting) out of the way.
    27. Fig 11: Identifying Turbocharger Coolant Return Pipe
    GM2030231Courtesy of GENERAL MOTORS CORP.
  27. Remove the turbocharger coolant return pipe bolts and pipe (1).
  28. Remove and discard the turbocharger coolant return pipe gaskets.
    29. Fig 12: Identifying Turbocharger Oil Feed Pipe & Fittings
    GM2030255Courtesy 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.
  29. Remove the turbocharger oil feed pipe bolts and pipe (1).
  30. Remove and discard the turbocharger oil feed pipe gaskets.
    31. Fig 13: View Of Turbocharger Nuts
    GM1750407Courtesy of GENERAL MOTORS CORP.
  31. Remove the turbocharger nuts (2).
  32. Remove the turbocharger from the exhaust manifold studs while also removing the turbocharger oil return hose from the engine block.
  33. Remove and discard the turbocharger gasket (1) and oil return hose O-ring seal (3).
    34. Fig 14: Identifying Turbocharger Oil Return Hose
    GM1750408Courtesy of GENERAL MOTORS CORP.
  34. If replacing the turbocharger, perform the following steps otherwise proceed to the step 7 in the Installation Procedure.
  35. Remove the turbocharger oil return hose bolts (2) and hose from the turbocharger.
  36. Remove and discard the turbocharger oil return hose gasket (1).
    37. Fig 15: Vacuum Hose Clamps & Boost Sensor Retainer
    GM1750487Courtesy of GENERAL MOTORS CORP.
  37. Reposition the vacuum hose clamps (1, 2, and 3) at the turbocharger wastegate solenoid valve.
  38. Remove the vacuum hoses from the turbocharger wastegate solenoid valve.
  39. Gently push back the turbocharger wastegate solenoid valve retainer (4) and remove the turbocharger wastegate solenoid valve from the bracket.
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