Chevrolet Sonic Repair Manual: Turbocharger Installation
Special Tool
EN-49942 Holding Wrench
For equivalent regional tools, refer to Special Tools.
- Clean the sealing surfaces.
- Replace the connect fittings on the turbocharger coolant feed pipe and the
turbocharger coolant return pipe. Refer to Turbocharger Disassemble and Turbocharger
Assemble.
Note:
Mind the turbocharger oil return pipe.
- Install the turbocharger assembly (1) and a NEW turbocharger gasket (2).
- Connect the turbocharger oil return pipe to the engine while installing
the turbocharger.
- Install the turbocharger coolant feed pipe hollow screw along with 2 NEW
seal rings (1) and (2).
- Install the 8 NEW turbocharger nuts (1).
Caution:
Refer to Fastener Caution.
Caution:
Refer to Torque-to-Yield Fastener Caution.
- Tighten the 8 turbocharger nuts in a sequence as shown to 8 Y (71 lb in)
.
- Repeat the tightening procedure to ensure a proper fastening of the turbocharger
nuts.
- 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)
.
- Install the turbocharger oil feed pipe (2) along with a NEW rubber seal
ring.
- Install the turbocharger oil feed pipe hollow screw (4) in compound with
2 NEW seal rings (1) and (3).
- Install the turbocharger oil feed pipe bolt (5) to the oil cooler and tighten
to 10 Y (89 lb in)
.
- Tighten the turbocharger oil feed pipe hollow screw to 30 Y (22 lb ft)
.
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.
- 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.
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.
- Tighten the turbocharger coolant feed pipe hollow screw with ratchet wrench
and extension (1) to 30 Y (22 lb ft)
.
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 ...
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:
Tire Sealant and Compressor Kit
Warning
Idling a vehicle in an enclosed area with poor ventilation is dangerous. Engine
exhaust may enter the vehicle. Engine exhaust contains carbon monoxide (CO) which
cannot be seen or smelled. It can cause unconsciousness and even death. Never run
the engine in an enclosed area that has n ...
Front Wheelhouse Liner Replacement (Rear)
!l
Front Wheelhouse Liner Replacement
Callout
Component Name
Preliminary Procedure
Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and
Installation.
1
Front Wheelhouse Rear Li ...
Body Control System Description and Operation
The body control system consists of the body control module (BCM), communications,
and various input and outputs. Some inputs, outputs and messages require other modules
to interact with the BCM. The BCM also has discrete input and output terminals to
control the vehicle's body functions. ...
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