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:

When to Add Engine Oil
1.8L Shown, 1.4L Similar If the oil is below the minimum mark on the dipstick, add 1 L (1 qt) of the recommended oil and then recheck the level. See “Selecting the Right Engine Oil” in this section for an explanation of what kind of oil to use. For engine oil crankcase capacity, see Cap ...

Radiator Cleaning
Warning: NEVER spray water on a hot heat exchanger. The resulting steam could cause personal injury. Caution: The heat exchanger fins are necessary for good heat transfer. Do not brush the fins. This may cause damage to the fins, reducing heat transfer. Note: Blow compressed ...

Intake Manifold Cleaning and Inspection
Clean the intake manifold mating surfaces. Inspect the intake manifold (2) for damage. Inspect the intake manifold for cracks near metallic inserts. Inspect the crankcase ventilation passages in the intake manifold face for blockage. Warning: Wear safety glasses in or ...

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