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Chevrolet Sonic Repair Manual: Turbocharger Installation

Chevrolet Sonic Repair Manual / Powertrain / Engine / Intake and Forced Induction / Forced Induction / 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.

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

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

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

    7. Caution:

    Refer to Fastener Caution.

    Caution:

    Refer to Torque-to-Yield Fastener Caution.

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

    .

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

  9. 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)

    .

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

    .

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

    .



    14. 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.

  14. 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.


    15. 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.

  15. 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:

Rear Brake Hose Replacement (Axle to Caliper)
Removal Procedure Warning: Refer to Brake Dust Warning. Warning: Refer to Brake Fluid Irritant Warning. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Install ...

Radiator Mounting Stud Repair
Repair Procedure Note: If the radiator is leaky, replace it. Refer to Radiator Replacement. Pressure test the cooling system. Refer to Cooling System Leak Testing. Grind the fracture surface (1) with a proper tool. Drill a hole in the cente ...

Timing Belt Center Front Cover Replacement
Timing Belt Center Front Cover Replacement Callout Component Name Preliminary Procedure Remove the timing belt upper front cover. Refer to Timing Belt Upper Front Cover Replacement. Remove the engine mount bracket. Refer ...

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