GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Cobalt 🢒 Engine 🢒 Engine Mechanical - 2.2L or 2.4L 🢒 Turbocharger Replacement

Removal Procedure

    Object Number: 1769629 Size: SH
  1. Drain the cooling system. Refer to Cooling System Draining and Filling.
  2. Remove the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement.
  3. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.
  4. Remove the charge air cooler pipe bolts at the turbocharger.
  5. Remove the charge air cooler pipe from the turbocharger.
  6. Remove the air conditioning (A/C) evaporator hose assembly. Refer to Air Conditioning Evaporator Hose Assembly Replacement.
  7. Remove the A/C rear condenser tube. Refer to Condenser Tube Replacement.
  8. Remove the brake vacuum booster vacuum hose from the booster. Refer to Vacuum Brake Booster Check Valve and/or Hose Replacement.
  9. Unbolt the transmission shiftier bracket from the transmission and leave cables attached and position aside.

    10. Object Number: 1750397 Size: SH
  10. Remove the turbocharger heat shield bolts (1) and shield.
  11. Remove the catalytic converter. Refer to Catalytic Converter Replacement.
  12. Remove the heated oxygen sensor. Refer to Heated Oxygen Sensor 1 Replacement.

    13. Object Number: 2030269 Size: SH
  13. Remove the turbocharger exhaust pipe heat shield bolts (1).
  14. Remove the turbocharger exhaust pipe heat shield (2).

    15. Object Number: 2030323 Size: SH
  15. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
  16. Remove the turbocharger exhaust pipe nuts (1).
  17. Remove the turbocharger exhaust pipe (2).

    18. Object Number: 2029560 Size: SH
  18. Remove the turbocharger bracket bolt (1).
  19. Remove the turbocharger bracket bolt (2) and bracket (3).
  20. Remove the turbocharger brace bolts (4).
  21. Remove the turbocharger brace nut (5) and brace (6).
  22. Lower the vehicle.

    23. Object Number: 1750410 Size: SH
  23. Disconnect the engine wiring harness electrical connector from the turbocharger wastegate solenoid valve.

    24. Object Number: 1750413 Size: SH
  24. Reposition the vacuum hose clamp (5) at the turbocharger.
  25. Remove the vacuum hose from the turbocharger.

    26. Object Number: 1750409 Size: SH
  26. Remove the engine wiring harness clip (1) from the turbocharger coolant feed pipe.

    27. Object Number: 1750401 Size: SH
  27. Remove the turbocharger coolant feed pipe bolt (1) at the turbocharger.
  28. Remove and discard the turbocharger coolant feed pipe gasket.
  29. Remove the turbocharger coolant feed pipe bolt (3) from the cylinder head.
  30. Reposition the turbocharger coolant feed pipe out of the way.

    31. Object Number: 2030152 Size: SH
  31. Remove the positive crankcase ventilation (PCV) pipe (1) from the turbocharger. Reposition the PCV pipe (with fitting) out of the way. Refer to Metal Collar Quick Connect Fitting Service.
  32. Remove the thermostat outlet housing and pipe. Refer to Engine Coolant Thermostat Housing Replacement.

    33. Object Number: 2030255 Size: SH

    Caution: 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.

  33. Remove the turbocharger oil feed pipe bolts and pipe (1).
  34. Remove and discard the turbocharger oil feed pipe gaskets.

    35. Object Number: 2030231 Size: SH
  35. Remove the turbocharger coolant return pipe bolts and pipe (1).
  36. Remove and discard the turbocharger coolant return pipe gaskets.

    37. Object Number: 1750407 Size: SH
  37. Remove the turbocharger nuts (2).
  38. Remove the turbocharger from the exhaust manifold studs while also removing the turbocharger oil return hose from the engine block.
  39. Remove and discard the turbocharger gasket (1) and oil return hose O-ring seal (3).

    40. Object Number: 1750408 Size: SH
  40. If replacing the turbocharger, perform the following steps otherwise proceed to the step 7 in the Installation Procedure.
  41. Remove the turbocharger oil return hose bolts (2) and hose from the turbocharger.
  42. Remove and discard the turbocharger oil return hose gasket (1).

    43. Object Number: 1750487 Size: SH
  43. Reposition the vacuum hose clamps (1, 2, and 3) at the turbocharger wastegate solenoid valve.
  44. Remove the vacuum hoses from the turbocharger wastegate solenoid valve.
  45. Gently push back the turbocharger wastegate solenoid valve retainer (4) and remove the turbocharger wastegate solenoid valve from the bracket.

Installation Procedure

    Object Number: 1750487 Size: SH
  1. If replacing the turbocharger, perform the following steps otherwise proceed to step 7.
  2. Install the turbocharger wastegate solenoid valve to the bracket until the retainer (4) clips into place.
  3. Install the vacuum hoses to the turbocharger wastegate solenoid valve.
  4. Position the vacuum hose clamps (1, 2, and 3) at the turbocharger wastegate solenoid valve.

    5. Object Number: 1750408 Size: SH
  5. Position a NEW turbocharger oil return hose gasket (1) on the turbocharger oil return hose.

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

  6. Install the turbocharger oil return hose and bolts (2) and tighten to 10 N·m (89 lb in).

    7. Object Number: 2030231 Size: SH
  7. Install NEW gaskets onto the turbocharger coolant return pipe fittings.
  8. Install the turbocharger coolant return pipe (1) and bolts and tighten to 35 N·m (26 lb ft).
  9. Install the thermostat outlet housing and pipe. Refer to Engine Coolant Thermostat Housing Replacement.

    10. Object Number: 1750407 Size: SH
  10. Install a NEW turbocharger gasket (1) onto the exhaust manifold studs.
  11. Lubricate and install a NEW turbocharger oil return hose O-ring seal (3).
  12. Install the turbocharger oil return hose to the engine block while also installing the turbocharger to the exhaust manifold studs.
  13. Install the turbocharger nuts (2) and tighten to 35 N·m (26 lb ft).

    14. Object Number: 2030255 Size: SH
  14. Install NEW gaskets onto the turbocharger oil feed pipe fittings.
  15. Install the turbocharger oil feed pipe (1) and bolts and tighten the bolts to 32 N·m (24 lb ft).

    16. Object Number: 2030152 Size: SH
  16. Position the PCV pipe (with fitting) and install the PCV fitting to the turbocharger.

    17. Object Number: 1750401 Size: SH
  17. Position the turbocharger coolant feed pipe to the turbocharger.
  18. Install NEW gaskets onto the turbocharger coolant feed pipe fitting.
  19. Install the turbocharger coolant feed pipe bolt (1) at the turbocharger and tighten the bolt to 35 N·m (26 lb ft).
  20. Install the turbocharger coolant feed pipe bolt (3) to the cylinder head and tighten the bolt to 10 N·m (89 lb in.

    21. Object Number: 1750409 Size: SH
  21. Install the engine wiring harness clip (1) to the turbocharger coolant feed pipe.

    22. Object Number: 1750413 Size: SH
  22. Install the vacuum hose to the turbocharger.
  23. Position the vacuum hose clamp (5) at the turbocharger.

    24. Object Number: 1750410 Size: SH
  24. Connect the engine wiring harness electrical connector to the turbocharger wastegate solenoid valve.

    25. Object Number: 2029560 Size: SH
  25. Install the turbocharger brace (6) and brace nut (5) and tighten to 50 N·m (37 lb ft).
  26. Install the turbocharger brace bolts (4) and tighten the nut to 50 N·m (37 lb ft).
  27. Install the turbocharger bracket (3) and bracket bolt (2) and tighten the nut to 25 N·m (18 lb ft).
  28. Install the turbocharger bracket bolt (1) and tighten to 25 N·m (18 lb ft).

    29. Object Number: 2030323 Size: SH
  29. Install the turbocharger exhaust pipe (2).
  30. Install the turbocharger exhaust pipe nuts (1) and tighten to 50 N·m (37 lb ft).

    31. Object Number: 2030269 Size: SH
  31. Install the turbocharger exhaust pipe heat shield (2).
  32. Install the turbocharger exhaust pipe heat shield bolts (1) and tighten the nut to 10 N·m (89 lb in).
  33. Install the transmission shiftier bracket with the cables to the transmission.
  34. Install the brake vacuum booster vacuum hose to the booster. Refer to Vacuum Brake Booster Check Valve and/or Hose Replacement.
  35. Install the A/C rear condenser tube. Refer to Condenser Tube Replacement.
  36. Install the A/C evaporator hose assembly. Refer to Air Conditioning Evaporator Hose Assembly Replacement.
  37. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle.
  38. Install the heated oxygen sensor. Refer to Heated Oxygen Sensor 1 Replacement.
  39. Install the catalytic converter. Refer to Catalytic Converter Replacement.

    40. Object Number: 1750397 Size: SH
  40. Lower the vehicle.
  41. Install the turbocharger heat shield and bolts (1) and tighten the bolts to 10 N·m (89 lb in).

    42. Object Number: 1769629 Size: SH
  42. Install the charge air cooler pipe and gasket to the turbocharger.
  43. Install the charge air cooler pipe bolts at the turbocharger and tighten the bolts to 22 N·m (16 lb ft).
  44. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.
  45. Install the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement.
  46. Fill the cooling system. Refer to Cooling System Draining and Filling.