GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Cobalt 🢒 Engine 🢒 Engine Cooling 🢒 Turbocharger Coolant Return Pipe Replacement

Removal Procedure

    Object Number: 2073336 Size: SH
  1. Drain the cooling system. Refer to Cooling System Draining and Filling.
  2. Remove the catalytic converter. Refer to Catalytic Converter Replacement.
  3. Remove the O2 sensor. Refer to Heated Oxygen Sensor Replacement - Sensor 1.
  4. Remove the charge air cooler. Refer to Charge Air Cooler Inlet Pipe Replacement.
  5. Remove the AC EVAP hose assembly. Refer to Air Conditioning Evaporator Hose Assembly Replacement.
  6. Remove the rear condenser tube. Refer to Condenser Tube Replacement.
  7. Disconnect the brake booster vacuum hose and reposition.
  8. Disconnect the shifter bracker from the transmission and reposition. Leave the cables attached.
  9. Remove the turbo exhaust pipe heat shield bolts (1) and shield (2).

    10. Object Number: 2073344 Size: SH
  10. Remove the turbo heat shield bolts (1) and the turbo heat shield (2).

    11. Object Number: 2073354 Size: SH
  11. Remove the turbo brace bolts (1) the turbo brace nut (2) and the turbo brace (3),

    12. Object Number: 2073358 Size: SH
  12. Remove the turbo exhaust pipe nuts (1) and elbow (2).

    13. Object Number: 2073361 Size: SH
  13. Remove the banjo bolts (1) and the turbocharger coolant return pipe (2).

Installation Procedure

    Object Number: 2073361 Size: SH
  1. Install NEW gaskets to the banjo fittings (1) on the turbocharger coolant return pipe (2).

    2. Caution: Refer to Fastener Caution in the Preface section.

  2. Install the turbocharger coolant return pipe banjo bolts (1) and tighten to 35 N·m (26 lb ft).

    3. Object Number: 2073358 Size: SH
  3. Install a NEW turbo exhaust pipe gasket (3).
  4. Install the turbo exhaust pipe elbow (2) and nuts (1) and tighten to 50 N·m (37 lb ft).

    5. Object Number: 2073354 Size: SH
  5. Install the turbo brace (3) the turbo brace bolts (1) and the turbo brace nut (2) and tighten to 58 N·m (43 lb ft).

    6. Object Number: 2073344 Size: SH
  6. Install the turbo heat shield (2) and the turbo heat shield bolts (1) and tighten to 9 N·m (80 lb in).

    7. Object Number: 2073336 Size: SH
  7. Install the turbo exhaust pipe heat shield (2) and the heat shield bolts (1).
  8. Connect the shifter bracker to the transmission and reposition. Leave the cables attached.
  9. Connect the brake booster vacuum hose.
  10. Install the rear condenser tube. Refer to Condenser Tube Replacement.
  11. Install the AC EVAP hose assembly. Refer to Air Conditioning Evaporator Hose Assembly Replacement.
  12. Install the charge air cooler. Refer to Charge Air Cooler Inlet Pipe Replacement.
  13. Install the O2 sensor. Refer to Heated Oxygen Sensor Replacement - Sensor 1.
  14. Install the catalytic converter. Refer to Catalytic Converter Replacement.
  15. Fill the cooling system. Refer to Cooling System Draining and Filling.