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.
- 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).
- 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)
.
- 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.
- Tighten the turbocharger coolant feed pipe hollow screw with ratchet wrench
and extension (1) to 30 Y (22 lb ft)
.
Note:
Mind the turbocharger oil return pipe.
Caution:
Refer to Fastener Caution.
Caution:
Refer to Torque-to-Yield Fastener Caution.
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.
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.
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:
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:
1. Select the mirror by moving the selector switch to L for the driver side or
R for the passenger s ...
Replacing Safety Belt System Parts after a Crash
Warning: A crash can damage the safety belt system in the vehicle.
A damaged safety belt system may not properly protect the person using it, resulting
in serious injury or even death in a crash. To help make sure the safety belt
systems are working properly after a crash, have them insp ...
Fuel System Description
Fuel System Overview
The fuel system is an electronic returnless on-demand design. A returnless
fuel system reduces the internal temperature of the fuel tank by not returning
hot fuel from the engine to the fuel tank. Reducing the internal temperature
of the fuel tank results in lo ...
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