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Installation Procedure

WARNING: This page is about a different car, the 2010 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Vacuum Hose Clamps & Boost Sensor Retainer
    GM1750487Courtesy of GENERAL MOTORS CORP.
  1. If replacing the turbocharger, perform the following steps otherwise proceed to step 7.
  2. Install the turbocharger wastegate solenoid valve to the bracket until the retainer (4) clips into place.
  3. Install the vacuum hoses to the turbocharger wastegate solenoid valve.
  4. Position the vacuum hose clamps (1, 2, and 3) at the turbocharger wastegate solenoid valve.
    5. Fig 2: Turbocharger Oil Return Hose
    GM1750408Courtesy of GENERAL MOTORS CORP.
  5. Position a NEW turbocharger oil return hose gasket (1) on the turbocharger oil return hose.
    6. CAUTION: Refer to Fastener Caution .
  6. Install the turbocharger oil return hose and bolts (2) and tighten to 10 N.m (89 lb in).
    7. Fig 3: Identifying Turbocharger Coolant Return Pipe
    GM2030231Courtesy of GENERAL MOTORS CORP.
  7. Install NEW gaskets onto the turbocharger coolant return pipe fittings.
  8. Install the turbocharger coolant return pipe (1) and bolts and tighten to 35 N.m (26 lb ft).
  9. Install the thermostat outlet housing and pipe. Refer to Engine Coolant Thermostat Housing Replacement (LNF) .
    10. Fig 4: Turbocharger
    GM1750407Courtesy of GENERAL MOTORS CORP.
  10. Install a NEW turbocharger gasket (1) onto the exhaust manifold studs.
  11. Lubricate and install a NEW turbocharger oil return hose O-ring seal (3).
  12. Install the turbocharger oil return hose to the engine block while also installing the turbocharger to the exhaust manifold studs.
  13. Install the turbocharger nuts (2) and tighten to 35 N.m (26 lb ft).
    14. Fig 5: Identifying Turbocharger Oil Feed Pipe & Fittings
    GM2030255Courtesy of GENERAL MOTORS CORP.
  14. Install NEW gaskets onto the turbocharger oil feed pipe fittings.
  15. Install the turbocharger oil feed pipe (1) and bolts and tighten the bolts to 32 N.m (24 lb ft).
    16. Fig 6: Identifying Positive Crankcase Ventilation (PCV) Pipe
    GM2030152Courtesy of GENERAL MOTORS CORP.
  16. Position the PCV pipe (with fitting) and install the PCV fitting to the turbocharger.
    17. Fig 7: Turbocharger Coolant Feed Pipe Bolt
    GM1750401Courtesy of GENERAL MOTORS CORP.
  17. Position the turbocharger coolant feed pipe to the turbocharger.
  18. Install NEW gaskets onto the turbocharger coolant feed pipe fitting.
  19. Install the turbocharger coolant feed pipe bolt (1) at the turbocharger and tighten the bolt to 35 N.m (26 lb ft).
  20. Install the turbocharger coolant feed pipe bolt (3) to the cylinder head and tighten the bolt to 10 N.m (89 lb in.
    21. Fig 8: Turbocharger Coolant Feed Pipe Clip
    GM1750409Courtesy of GENERAL MOTORS CORP.
  21. Install the engine wiring harness clip (1) to the turbocharger coolant feed pipe.
    22. Fig 9: Charge Air Bypass Valve Solenoid Tube
    GM1750413Courtesy of GENERAL MOTORS CORP.
  22. Install the vacuum hose to the turbocharger.
  23. Position the vacuum hose clamp (5) at the turbocharger.
    24. Fig 10: Turbocharger Boost Sensor
    GM1750410Courtesy of GENERAL MOTORS CORP.
  24. Connect the engine wiring harness electrical connector to the turbocharger wastegate solenoid valve.
    25. Fig 11: Identifying Turbocharger Bracket & Bolts
    GM2029560Courtesy of GENERAL MOTORS CORP.
  25. Install the turbocharger brace (6) and brace nut (5) and tighten to 50 N.m (37 lb ft).
  26. Install the turbocharger brace bolts (4) and tighten the nut to 50 N.m (37 lb ft).
  27. Install the turbocharger bracket (3) and bracket bolt (2) and tighten the nut to 25 N.m (18 lb ft).
  28. Install the turbocharger bracket bolt (1) and tighten to 25 N.m (18 lb ft).
    29. Fig 12: Identifying Turbocharger Exhaust Pipe Heat Shield Nuts
    GM2030323Courtesy of GENERAL MOTORS CORP.
  29. Install the turbocharger exhaust pipe (2).
  30. Install the turbocharger exhaust pipe nuts (1) and tighten to 50 N.m (37 lb ft).
    31. Fig 13: Identifying Turbocharger Exhaust Pipe Heat Shield & Bolts
    GM2030269Courtesy of GENERAL MOTORS CORP.
  31. Install the turbocharger exhaust pipe heat shield (2).
  32. Install the turbocharger exhaust pipe heat shield bolts (1) and tighten the nut to 10 N.m (89 lb in).
  33. Install the transmission shiftier bracket with the cables to the transmission.
  34. Install the brake vacuum booster vacuum hose to the booster. Refer to Power Brake Booster Vacuum Check Valve and Hose Replacement (2.0L) .
  35. Install the A/C rear condenser tube. Refer to Condenser Tube Replacement (LNF) .
  36. Install the A/C evaporator hose assembly. Refer to Air Conditioning Evaporator Hose Assembly Replacement .
  37. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
  38. Install the heated oxygen sensor. Refer to Heated Oxygen Sensor Replacement - Sensor 1 .
  39. Install the catalytic converter. Refer to Catalytic Converter Replacement (LNF) .
    40. Fig 14: Identifying Turbocharger Heat Shield & Bolts
    GM1750397Courtesy of GENERAL MOTORS CORP.
  40. Lower the vehicle.
  41. Install the turbocharger heat shield and bolts (1) and tighten the bolts to 10 N.m (89 lb in).
    42. Fig 15: Charge Air Cooler Inlet Pipe
    GM1769629Courtesy of GENERAL MOTORS CORP.
  42. Install the charge air cooler pipe and gasket to the turbocharger.
  43. Install the charge air cooler pipe bolts at the turbocharger and tighten the bolts to 22 N.m (16 lb ft).
  44. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  45. Install the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement .
  46. Fill the cooling system. Refer to . Cooling System Draining and Filling (Static Fill LNF) .
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