HHR 2006-2008

Turbocharger

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Removal & Installation



2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the charge air cooler inlet pipe.
  6.  
  7. Remove the charge air cooler pipe bolts at the turbocharger.
  8.  
  9. Remove the charge air cooler pipe from the turbocharger.
  10.  
  11. Remove the turbocharger heat shield bolts and shield.
  12.  
  13. Remove the catalytic converter
  14.  
  15. Remove the catalytic converter bracket bolt, nut, and bracket.
  16.  
  17. Lower the vehicle
  18.  
  19. Remove the turbocharger brace nut and brace.
  20.  
  21. Disconnect the engine wiring harness electrical connector from the turbocharger wastegate solenoid valve.
  22.  
  23. Reposition the vacuum hose clamp at the turbocharger.
  24.  
  25. Remove the vacuum hose from the turbocharger.
  26.  
  27. Remove the engine wiring harness clip from the turbocharger coolant feed pipe.
  28.  
  29. Remove the turbocharger coolant feed pipe bolt at the turbocharger.
  30.  
  31. Remove and discard the turbocharger coolant feed pipe gasket.
  32.  
  33. Remove the turbocharger coolant feed pipe bolt from the cylinder head.
  34.  
  35. Reposition the turbocharger coolant feed pipe out of the way.
  36.  
  37. Remove the Positive Crankcase Ventilation (PCV) fitting bolt from the turbocharger. Reposition the PCV pipe (with fitting) out of the way.
  38.  
  39. Remove the turbocharger coolant return pipe bolts and pipe.
  40.  
  41. Remove and discard the turbocharger coolant return pipe gaskets.
    WARNING
    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.

  42.  
  43. Remove the turbocharger oil feed pipe bolts and pipe.
  44.  
  45. Remove and discard the turbocharger oil feed pipe gaskets.
  46.  
  47. Remove the turbocharger nuts.
  48.  
  49. Remove the turbocharger from the exhaust manifold studs while also removing the turbocharger oil return hose from the engine block.
  50.  
  51. Remove and discard the turbocharger gasket and oil return hose O-ring seal.

    Click image to see an enlarged view

    Fig. Turbocharger 2.0L engine

  52.  

To install:

  1. Install a new turbocharger gasket onto the exhaust manifold studs.
  2.  
  3. Lubricate and install a new turbocharger oil return hose O-ring seal.
  4.  
  5. Install the turbocharger oil return hose to the engine block while also installing the turbocharger to the exhaust manifold studs.
  6.  
  7. Install the turbocharger nuts and tighten to 26 ft. lbs. (35 Nm).
  8.  
  9. Install new gaskets onto the turbocharger oil feed pipe fittings.
  10.  
  11. Install the turbocharger oil feed pipe and bolts. Tighten the bolts to 24 ft. lbs. (32 Nm).
  12.  
  13. Install new gaskets onto the turbocharger coolant return pipe fittings.
  14.  
  15. Install the turbocharger coolant return pipe and bolts. Tighten the bolts to 26ft. lbs. (35 Nm).
  16.  
  17. Install a new o-ring seal to the PCV fitting.
  18.  
  19. Position the PCV pipe (with fitting) and install the PCV fitting bolt to the turbocharger. Tighten the bolt to 89 inch. lbs. (10 Nm).
  20.  
  21. Position the turbocharger coolant feed pipe to the turbocharger.
  22.  
  23. Install NEW gaskets onto the turbocharger coolant feed pipe fitting.
  24.  
  25. Install the turbocharger coolant feed pipe bolt at the turbocharger. Tighten the bolt to 26 ft. lbs. (35 Nm).
  26.  
  27. Install the turbocharger coolant feed pipe bolt to the cylinder head. Tighten the bolt to 89 inch. lbs. (10 Nm).
  28.  
  29. Install the engine wiring harness clip to the turbocharger coolant feed pipe.
  30.  
  31. Install the vacuum hose to the turbocharger.
  32.  
  33. Position the vacuum hose clamp at the turbocharger.
  34.  
  35. Connect the engine wiring harness electrical connector to the turbocharger wastegate solenoid valve.
  36.  
  37. Install the turbocharger brace bolt and nut. Tighten the nut to 43 ft. lbs. (58 Nm).
  38.  
  39. Raise and suitably support the vehicle.
  40.  
  41. Position the catalytic converter bracket to the engine.
  42.  
  43. Install the catalytic converter bracket bolt, and nut until snug.
  44.  
  45. Install the catalytic converter
  46.  
  47. Tighten the catalytic converter bracket bolt and nut.
  48.  
  49. Tighten the bolt and nut to 43 ft. lbs. (58 Nm).
  50.  
  51. Lower the vehicle.
  52.  
  53. Install the turbocharger heat shield and bolts. Tighten the bolts to 89 inch. lbs. (10 Nm).
  54.  
  55. Install the charge air cooler pipe and gasket to the turbocharger.
  56.  
  57. Install the charge air cooler pipe bolts at the turbocharger. Tighten the bolts to 16 ft. lbs. (22 Nm).
  58.  
  59. Install the charge air cooler inlet pipe.
  60.  
  61. Fill and bleed the cooling system.
  62.  

 
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