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

Removal Procedure

    Object Number: 1769629 Size: SH
  1. Drain the cooling system. Refer to Cooling System Draining and Filling .
  2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
  3. Remove the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement .
  4. Remove the charge air cooler pipe bolts at the turbocharger.
  5. Remove the charge air cooler pipe from the turbocharger.

    6. Object Number: 1750397 Size: SH
  6. Remove the turbocharger heat shield bolts (1) and shield.
  7. Remove the heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor Replacement - Sensor 1 .

    8. Object Number: 2073530 Size: SH
  8. Remove the turbocharger exhaust pipe elbow heat shield bolts (1).
  9. Remove the turbocharger exhaust pipe elbow heat shield (2).
  10. Remove the catalytic converter. Refer to Catalytic Converter Replacement .

    11. Object Number: 2073547 Size: SH
  11. Remove the turbocharger exhaust elbow support bracket bolt (1).

    12. Object Number: 2073641 Size: SH
  12. Remove the turbocharger exhaust elbow to turbocharger retaining nuts.
  13. Remove the turbocharger exhaust elbow.

    14. Object Number: 2073661 Size: SH
  14. Remove the turbocharger bracket upper retaining nut (1)

    15. Object Number: 2073674 Size: SH
  15. Loosen the turbocharger bracket lower retaining nut (1) and bolt (2).

    16. Object Number: 2073720 Size: SH
  16. Remove the stud (1) from the turbocharger.
  17. Reposition the turbocharger bracket.
  18. Lower the vehicle.

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

    20. Object Number: 2003903 Size: SH
  20. Reposition the vacuum hose clamp (1) at the turbocharger.
  21. Remove the vacuum hose from the turbocharger.

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

    23. Object Number: 1750401 Size: SH
  23. Remove the turbocharger coolant feed pipe bolt (1) at the turbocharger.
  24. Remove and discard the turbocharger coolant feed pipe gasket.
  25. Remove the turbocharger coolant feed pipe bolt (3) from the cylinder head.
  26. Reposition the turbocharger coolant feed pipe out of the way.

    27. Object Number: 1750398 Size: SH
  27. Remove the turbocharger coolant return pipe bolts and pipe.
  28. Remove and discard the turbocharger coolant return pipe gaskets.

    29. Object Number: 2073828 Size: SH
  29. Remove the turbocharger oil feed pipe bolt (1) at the turbocharger and position aside.
  30. Remove and discard the turbocharger oil feed pipe gaskets.

    31. Object Number: 2073844 Size: SH
  31. Disconnect the positive crankcase ventilation (PCV) pipe (1) from the turbocharger. Refer to Metal Collar Quick Connect Fitting Service .
  32. Raise the vehicle.

    33. Object Number: 1750407 Size: SH
  33. Remove the turbocharger nuts (2).
  34. Lower the vehicle.
  35. Remove the turbocharger from the exhaust manifold studs while also removing the turbocharger oil return hose from the engine block.
  36. Remove and discard the turbocharger gasket (1) and oil return hose O-ring seal (3).

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

    40. Object Number: 1750487 Size: SH
  40. Reposition the vacuum hose clamps (1, 2, and 3) at the turbocharger wastegate solenoid valve.
  41. Remove the vacuum hoses from the turbocharger wastegate solenoid valve.
  42. 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: 1750407 Size: SH
  7. Raise the vehicle.
  8. Install a NEW turbocharger gasket (1) onto the exhaust manifold studs.
  9. Lubricate and install a NEW turbocharger oil return hose O-ring seal (3).
  10. Install the turbocharger oil return hose to the engine block while also installing the turbocharger to the exhaust manifold studs.
  11. Install the turbocharger nuts (2) and tighten to 35 N·m (26 lb ft) .
  12. Lower the vehicle.

    13. Object Number: 2073844 Size: SH
  13. Connect the positive crankcase ventilation (PCV) pipe (1) to the turbocharger.

    14. Object Number: 2073828 Size: SH
  14. Install NEW gaskets onto the turbocharger oil feed pipe fittings.
  15. Install the turbocharger oil feed pipe and bolt (1) and tighten to 40 N·m (30 lb ft) .

    16. Object Number: 1750398 Size: SH
  16. Install NEW gaskets onto the turbocharger coolant return pipe fittings.
  17. Install the turbocharger coolant return pipe and bolts and tighten to 40 N·m (30 lb ft) .

    18. Object Number: 1750401 Size: SH
  18. Position the turbocharger coolant feed pipe to the turbocharger.
  19. Install NEW gaskets onto the turbocharger coolant feed pipe fitting.
  20. Install the turbocharger coolant feed pipe bolt (1) at the turbocharger and tighten to 40 N·m (30 lb ft) .
  21. Install the turbocharger coolant feed pipe bolt (3) to the cylinder head and tighten to 10 N·m (89 lb in) .

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

    23. Object Number: 2003903 Size: SH
  23. Install the vacuum hose to the turbocharger.
  24. Position the vacuum hose clamp (1) at the turbocharger.

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

    26. Object Number: 2073720 Size: SH
  26. Install a NEW stud (1) to the turbocharger.

    27. Object Number: 2073674 Size: SH
  27. Tighten the turbocharger bracket lower retaining nut (1) and bolt (2).
    28. • Tighten the nut to 50 N·m (37 lb ft) .
    • Tighten the bolt to 58 N·m (43 lb ft) .

    Object Number: 2073661 Size: SH
  28. Install the turbocharger bracket upper retaining nut (1) and tighten to 46 N·m (34 lb ft)

    29. Object Number: 2073641 Size: SH
  29. Install the turbocharger exhaust elbow.
  30. Install the turbocharger exhaust elbow to turbocharger retaining nuts and tighten to 50 N·m (37 lb ft) .

    31. Object Number: 2073547 Size: SH
  31. Install the turbocharger exhaust elbow support bracket bolt (1) and tighten to 25 N·m (18 lb ft) .

    32. Object Number: 2073530 Size: SH
  32. Install the turbocharger exhaust pipe elbow heat shield (2).
  33. Install the turbocharger exhaust pipe elbow heat shield bolts (1) and tighten to 10 N·m (89 lb in) .

    34. Object Number: 1750397 Size: SH
  34. Lower the vehicle.
  35. Install the HO2S. Refer to Heated Oxygen Sensor Replacement - Sensor 1 .
  36. Install the turbocharger heat shield and bolts (1) and tighten to 10 N·m (89 lb in) .

    37. Object Number: 1769629 Size: SH
  37. Install the charge air cooler pipe and gasket to the turbocharger.
  38. Install the charge air cooler pipe bolts at the turbocharger and tighten to 22 N·m (16 lb ft) .
  39. Install the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement .
  40. Install the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement .
  41. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
  42. Fill the cooling system. Refer to Cooling System Draining and Filling .