GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2008 🢒 Cobalt 🢒 Engine 🢒 Engine Mechanical - 2.0L 🢒 Turbocharger Installation

    Object Number: 1956807 Size: SH
  1. Install a new turbocharger oil return pipe gasket.
  2. Install the turbocharger oil return pipe into the engine block.

    3. Object Number: 1956811 Size: SH
  3. Attach the positive crankcase ventilation (PCV) hose and fitting with O-ring from the camshaft cover to the turbocharger.

    4. Notice: Refer to Fastener Notice in the Preface section.

  4. Install the PCV hose fitting bolt.

    5. Tighten
    Tighten the PCV hose fitting bolt to 10 N·m (89 lb in).

  5. Lubricate the O-ring on the turbocharger oil return pipe with clean engine oil.
  6. Install the turbocharger oil return pipe bolts.

    7. Tighten
    Tighten the turbocharger oil return pipe bolts to 10 N·m (89 lb in).

  7. Install a new turbocharger gasket.
  8. Install the turbocharger.
  9. Install the turbocharger nuts.

    10. Tighten

    • Tighten the turbocharger nuts to 30 N·m (22 lb ft).
    • Tighten the turbocharger nuts a second time to 35 N·m (26 lb ft).

    Object Number: 2045496 Size: SH
  10. Install the turbocharger brace bracket.
  11. Install the turbocharger brace bracket bolt.

    12. Tighten
    Tighten the turbocharger brace bolt to 58 N·m (43 lb ft).

  12. Install the turbocharger brace.
  13. Install the turbocharger brace nuts.

    14. Tighten
    Tighten the turbocharger brace nuts to 50 N·m (37 lb ft).

  14. Install the turbocharger brace bolt.

    15. Tighten
    Tighten the turbocharger brace bolt to 50 N·m (37 lb ft).

  15. Install the turbocharger brace bracket and bolt to the turbocharger brace if necessary.

    16. Tighten
    Tighten the turbocharger brace bracket bolt to 22 N·m (16 lb ft).


    Object Number: 1769641 Size: SH
  16. Install the turbocharger coolant feed pipe.
  17. Install the turbocharger coolant feed pipe gaskets.
  18. Install the turbocharger coolant feed pipe bolts.

    19. Tighten

        • Tighten the turbocharger coolant feed pipe bolts to 20 N·m (15 lb ft).
        • Tighten the turbocharger coolant feed pipe mounting bolt to 10 N·m (89 lb in).
  19. Connect the positive crankcase ventilation (PCV) and hose assembly.

    20. Object Number: 2045495 Size: SH
  20. Install the turbocharger air cooler outlet pipe.
  21. Install the turbocharger air cooler outlet pipe bolts.

    22. Tighten
    Tighten the turbocharger air cooler outlet pipe bolts to 25 N·m (18 lb ft).


    Object Number: 2046140 Size: SH
  22. Install the turbocharger coolant return pipe.
  23. Install the turbocharger coolant return pipe gaskets.
  24. Install the turbocharger coolant return pipe bolts.

    25. Tighten
    Tighten the turbocharger coolant return pipe bolts to 20 N·m (15 lb ft).


    Object Number: 2046139 Size: SH

    Notice: Do not twist the turbocharger oil feed pipe. Twisting of the feed pipe will result in the collapse and deformation of the plastic pipe, restricting oil flow and causing turbocharger damage. During turbocharger replacement, gently push the oil feed pipe towards the front of the engine to clear the turbocharger. Assistance may be required to keep the pipes clear of the turbocharger during removal or installation.

  25. Install the turbocharger oil feed pipe.
  26. Install the turbocharger oil feed pipe gaskets.
  27. Install the turbocharger oil feed pipe bolts.

    28. Tighten
    Tighten the turbocharger oil feed pipe bolts to 20 N·m (15 lb ft).


    Object Number: 2046138 Size: SH
  28. Install the turbocharger exhaust pipe seal.
  29. Install the turbocharger exhaust pipe.
  30. Install the turbocharger exhaust pipe bolt.

    31. Tighten
    Tighten the turbocharger exhaust pipe bolt to 22 N·m (16 lb ft).

  31. Install the turbocharger exhaust pipe nuts.

    32. Tighten
    Tighten the turbocharger exhaust pipe nuts to 50 N·m (37 lb ft).


    Object Number: 2046250 Size: SH
  32. Install the turbocharger exhaust pipe heat shield.
  33. Install the turbocharger exhaust pipe heat shield bolts.

    34. Tighten
    Tighten the turbocharger exhaust pipe heat shield bolts to 10 N·m (89 lb in).


    Object Number: 2046137 Size: SH
  34. Install the turbocharger heat shield.
  35. Install the turbocharger heat shield bolts.

    36. Tighten
    Tighten the turbocharger heat shield bolts to 10 N·m (89 lb in).