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

    Object Number: 1769646 Size: SH
  1. Install a new turbocharger oil return pipe gasket (1).
  2. Install the turbocharger oil return pipe (2) onto the turbocharger.

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

  3. Install the turbocharger oil return pipe bolts (3) and tighten to 10 N·m (89 lb in).

    4. Object Number: 1769653 Size: SH
  4. Attach the positive crankcase ventilation (PCV) hose and fitting with O-ring from the camshaft cover to the turbocharger.
  5. Install the PCV hose fitting bolt and tighten to 10 N·m (89 lb in).
  6. Lubricate the O-ring on the turbocharger oil return pipe with clean engine oil.
  7. Install a new turbocharger gasket (3).
  8. Install the turbocharger (2) and the oil return pipe.
  9. Install the turbocharger nuts (1).
    10. 9.1. Tighten the turbocharger nuts to 30 N·m (22 lb ft).
    9.2. 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 and tighten to 58 N·m (43 lb ft).
  12. Install the turbocharger brace.
  13. Install the turbocharger brace nuts and tighten to 50 N·m (37 lb ft).
  14. Install the turbocharger brace bolt and tighten to 50 N·m (37 lb ft).
  15. Install the turbocharger brace bracket and bolt to the turbocharger brace if necessary. Tighten the turbocharger brace bracket bolt to 22 N·m (16 lb ft).

    16. 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. 18.1. Tighten the turbocharger coolant feed pipe bolts to 20 N·m (15 lb ft).
    18.2. 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 and tighten to 25 N·m (18 lb ft).

    22. Object Number: 2046139 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.

    Note: The engine block end of the oil feed pipe fitting has an anti-rotation feature. Ensure that the fitting is fully seated against the block when installing the bolt.

  22. Install the turbocharger oil feed pipe on the engine block side.
  23. Install the turbocharger oil feed pipe gasket on the engine block side.
  24. Install the bolt and tighten to 20 N·m (15 lb ft).

    25. Object Number: 2046140 Size: SH
  25. Install the turbocharger coolant return pipe.
  26. Install the turbocharger coolant return pipe gaskets.
  27. Install the turbocharger coolant return pipe bolts and tighten to 20 N·m (15 lb ft).

    28. Object Number: 2046139 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.

  28. Install the turbocharger oil feed pipe onto the turbocharger.
  29. Install the turbocharger oil feed pipe gasket for the turbocharger side.
  30. Install the turbocharger oil feed pipe bolt and tighten to 20 N·m (15 lb ft).

    31. Object Number: 2046138 Size: SH
  31. Install the turbocharger exhaust pipe seal.
  32. Install the turbocharger exhaust pipe.
  33. Install the turbocharger exhaust pipe bolt and tighten to 22 N·m (16 lb ft).
  34. Install the turbocharger exhaust pipe nuts and tighten to 50 N·m (37 lb ft).

    35. Object Number: 2046250 Size: SH
  35. Install the turbocharger exhaust pipe heat shield.
  36. Install the turbocharger exhaust pipe heat shield bolts and tighten to 10 N·m (89 lb in).

    37. Object Number: 2046137 Size: SH
  37. Install the turbocharger heat shield.
  38. Install the turbocharger heat shield bolts and tighten to 10 N·m (89 lb in).