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:

Instrument Panel, Leather, Vinyl, Other Plastic Surfaces, Low Gloss Paint Surfaces and Natural Open Pore Wood Surfaces
Use a soft microfiber cloth dampened with water to remove dust and loose dirt. For a more thorough cleaning, use a soft microfiber cloth dampened with a mild soap solution. Caution Soaking or saturating leather, especially perforated leather, as well as other interior surfaces, may cause per ...

Mirror Adjustment
Exterior Mirrors Manual Outside Mirrors Move the control up, down, or side to side to adjust the mirror. See Manual Mirrors. Power Outside Mirrors For vehicles with power outside mirrors: Select the mirror by moving the selector switch to L for the driver s ...

Air Conditioning System Seal Replacement
Removal Procedure Disassemble the A/C refrigerant components. Refer to the appropriate repair procedure. Note: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. Cap or tape the A/C refrigerant components. ...

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