GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Opel 🢒 2009 🢒 GT 🢒 Engine 🢒 Engine Controls and Fuel - 2.0L 🢒 Charge Air Cooler Outlet Pipe Replacement

Removal Procedure

    Object Number: 1826861 Size: SH
  1. Disconnect the engine wiring harness electrical connector (2) from the intake air pressure and temperature sensor.

    2. Object Number: 1750413 Size: SH
  2. Reposition the charge air bypass valve solenoid vacuum hose clamp (3) at the charge air cooler outlet pipe.
  3. Remove the vacuum hose from the charge air cooler outlet pipe.

    4. Object Number: 1829472 Size: SH
  4. Remove the charge air cooler outlet pipe bolt (1) at the rear bracket.

    5. Object Number: 1829691 Size: SH
  5. Remove the charge air cooler rear bracket nut (4) and bracket (1).

    6. Object Number: 1717120 Size: SH
  6. Loosen the charge air cooler hose clamp (2) at the throttle body charge air cooler outlet hose.
  7. Remove the charge air cooler outlet pipe from the throttle body charge air cooler hose (1).
  8. If needed, remove the throttle body charge air cooler hose (1) from the throttle body.

    9. Object Number: 1829472 Size: SH
  9. Remove the charge air cooler outlet pipe bolt (3) at the front bracket.
  10. Loosen the charge air cooler clamp (2) at the charge air cooler outlet pipe.
  11. Remove the charge air cooler outlet pipe.
  12. Remove any oil film from inside the pipes and hoses.

Installation Procedure

    Object Number: 1829472 Size: SH
  1. Install the charge air cooler outlet pipe to the charge air cooler and the charge air cooler hose.

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

  2. Install the charge air cooler outlet pipe bolt (3) at the front bracket and tighten to 7 N·m (62 lb in).

    3. Object Number: 1829691 Size: SH
  3. Install the charge air cooler rear bracket (1) and nut (4). Tighten the nut to 9 N·m (80 lb in).

    4. Object Number: 1829472 Size: SH
  4. Install the charge air cooler outlet pipe bolt (1) at the rear bracket and tighten to 7 N·m (62 lb in).
  5. Tighten the charge air cooler clamp (2) at the charge air cooler outlet pipe and tighten to 5 N·m (44 lb in).

    6. Object Number: 1717120 Size: SH
  6. If removed, install the throttle body charge air cooler hose (1) onto the throttle body and tighten to 5 N·m (44 lb in).
  7. Install the charge air cooler outlet pipe to the throttle body charge air cooler hose.
  8. Tighten the throttle body charge air cooler hose clamp (2) at the charge air cooler outlet pipe to 5 N·m (44 lb in).

    9. Object Number: 1750413 Size: SH
  9. Install the vacuum hose to the charge air cooler outlet pipe.
  10. Position the charge air bypass valve solenoid vacuum hose clamp (3) at the charge air cooler outlet pipe.

    11. Object Number: 1826861 Size: SH
  11. Connect the engine wiring harness electrical connector (2) to the intake air pressure and temperature sensor.