Chevrolet Sonic manuals

Chevrolet Sonic Repair Manual: Turbocharger Installation

Special Tool

EN-49942 Holding Wrench

For equivalent regional tools, refer to Special Tools.

  1. Clean the sealing surfaces.
  2. Replace the connect fittings on the turbocharger coolant feed pipe and the turbocharger coolant return pipe. Refer to Turbocharger Disassemble and Turbocharger Assemble.


  3. Note:

    Mind the turbocharger oil return pipe.

  4. Install the turbocharger assembly (1) and a NEW turbocharger gasket (2).

  5. Connect the turbocharger oil return pipe to the engine while installing the turbocharger.
  6. Install the turbocharger coolant feed pipe hollow screw along with 2 NEW seal rings (1) and (2).

  7. Install the 8 NEW turbocharger nuts (1).

  8. Caution:

    Refer to Fastener Caution.

    Caution:

    Refer to Torque-to-Yield Fastener Caution.

  9. Tighten the 8 turbocharger nuts in a sequence as shown to  8 Y (71 lb in)

    .

  10. Repeat the tightening procedure to ensure a proper fastening of the turbocharger nuts.

  11. Connect the turbocharger coolant return hose (6) to the oil cooler coolant inlet pipe and install the turbocharger coolant return pipe bolt (7) to the oil cooler. Tighten the turbocharger coolant return pipe bolt to  8 Y (71 lb in)

    .

  12. Install the turbocharger oil feed pipe (2) along with a NEW rubber seal ring.
  13. Install the turbocharger oil feed pipe hollow screw (4) in compound with 2 NEW seal rings (1) and (3).
  14. Install the turbocharger oil feed pipe bolt (5) to the oil cooler and tighten to  10 Y (89 lb in)

    .

  15. Tighten the turbocharger oil feed pipe hollow screw to  30 Y (22 lb ft)

    .



  16. Note:

    The EN-49942 holding wrench  (2) should be installed to turbocharger coolant feed pipe as shown. The holding wrench should be installed to avoid twisting of the turbocharger coolant feed pipe during the fastening procedure.

  17. Install the EN-49942 holding wrench  (2) to the turbocharger coolant feed pipe. Guide a ratchet wrench (1) along with an extension through EN-49942 holding wrench to the turbocharger coolant feed pipe hollow screw.


  18. Note:

    EN-49942 holding wrench  (2) should be installed to turbocharger coolant feed pipe as shown. The holding wrench should be installed to avoid twist of the turbocharger coolant feed pipe while the fastening procedure.

  19. Tighten the turbocharger coolant feed pipe hollow screw with ratchet wrench and extension (1) to  30 Y (22 lb ft)

    .

Turbocharger Disassemble
Special Tool EN-49940 Remover Quick Connector For equivalent regional tools, refer to Special Tools. Remove the 2 turbocharger oil return pipe bolts (2). Remove the turbo ...

Turbocharger Oil Feed Pipe Replacement
Removal Procedure Open the hood. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection. Remove the exhaust manifold heat shield. Refer ...

Other materials:

Roof Outer Panel Replacement (5HB)
Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning. Disable the SIR system. Refer to SIR Disabling and Enabling. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. Remove all ...

Liftgate Strut Replacement
Liftgate Strut Replacement Callout Component Name 1 Liftgate Strut Warning: When a lift gate hold open device is being removed or installed, provide alternate support to avoid the possibility of damage ...

Oil Pressure Relief Valve Replacement
Removal Procedure Remove the oil pan. Refer to Oil Pan Replacement. Remove the oil pressure relief valve closure bolt (1). Remove the oil pressure relief valve assembly (2). Separate the piston (3) and the spring (4). Warning: Bod ...

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