GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Optra - Mexico 🢒 Engine 🢒 Engine Controls and Fuel - 2.0L (Diesel) 🢒 Charge Air Cooler Inlet Pipe and Outlet Pipe Replacement

Removal Procedure

    Warning: Refer to Battery Disconnect Warning in the Preface section.


    Object Number: 1820502 Size: SH
  1. Disconnect the negative battery cable.
  2. Remove the engine cover. Refer to Engine Cover Replacement.

    3. Object Number: 1820433 Size: SH
  3. Disconnect the mass air flow (MAP) sensor connector.
  4. Remove the air cleaner assembly bolts.
  5. Remove the turbocharger inlet duct bolt and clamp.
  6. Remove the air cleaner assembly and turbocharger duct.
  7. Remove the charge air cooler inlet pipe bolts.
  8. Remove the charge air cooler inlet pipe.

    9. Object Number: 1822506 Size: SH
  9. Disconnect the PCV hose and clamp from the turbocharger inlet elbow.
  10. Remove the turbocharger inlet elbow.
  11. Remove the turbocharger outlet duct.
  12. Remove the charge air cooler inlet/outlet clamps and electric throttle control (ETC) side clamp.
  13. Remove the charge air cooler inlet/outlet hoses.

Installation Procedure


    Object Number: 1822506 Size: SH
  1. Install the charge air cooler inlet/outlet hoses.
  2. Install the turbocharger inlet elbow and outlet duct.

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


    Object Number: 1820433 Size: SH
  3. Install the charge air cooler inlet pipe.

    4. Tighten
    Tighten the charge air cooler inlet pipe bolts to 8 N·m (70.8 lb in).

  4. Install the air cleaner assembly and the turbocharger inlet duct.

    5. Tighten

        • Tighten the air cleaner assembly bolts to 6 N·m (53  lb in)
        • Tighten the turbocharger inlet duct bolt to 3 N·m (26.6  lb in).