How to Replace Turbocharger, Exhaust Manifold and Gaskets 2011-2015 Chevrolet Cruze

Introduction

This tutorial provides a comprehensive guide on how to replace the turbocharger, exhaust manifold, and gaskets on a 2011-2015 Chevrolet Cruze. This process is crucial for maintaining the performance of your vehicle, as a well-functioning turbocharger enhances engine efficiency. Following these steps will help you successfully complete the replacement.

Step 1: Remove the Intake Pipe

• Use a 7mm socket to loosen the worm clamps on the intake pipe.
• Twist the pipe back and forth to remove it.
• Disconnect the hose by pushing in on the tabs and sliding it off.
• Remove a lower hose using needle nose pliers to squeeze the clamp and slide it off.

Step 2: Disconnect Additional Hoses and Electrical Connections

• Disconnect the connector by pressing down on the lock and sliding it off.
• Loosen the worm clamp on the lower hose with a 7mm socket and remove the hose.
• Use an 11mm socket to loosen another clamp, and pry it out if necessary.
• Remove the heat shield using a trim tool and a 7mm socket for the bolts.

Step 3: Remove the Oil Return Line and Turbocharger

• Use an E10 socket to remove the lower oil return line bolt.
• Locate and remove another bolt with the same socket, using a universal joint if needed.
• Use a T45 socket to remove the banjo bolt from the hose.
• Loosen and remove additional bolts from the manifold with a 10mm socket (four on top and four underneath).
• Slide the turbo forward and remove any obstructing brackets or bolts.

Step 4: Replace Turbocharger Components

• Remove the old coolant feed and return pipes with a 17mm wrench.
• Take off the seals using a pick and clean the area before installing the new turbo.
• Install the new seals on the new turbo’s coolant pipes and torque them to 15 foot-pounds.

Step 5: Install New Gaskets and Turbocharger

• Clean the area where the old gasket was located using brake parts cleaner and a scraper.
• Remove old studs and replace them with new ones using two nuts if necessary.
• Install the new gaskets in the appropriate locations.
• Slide the new turbo into position carefully, ensuring all seals are in place.

Step 6: Reattach Components

• Reinstall the manifold nuts while torquing them to 71 inch-pounds in a specific sequence (start from the middle and work outward).
• Reconnect all hoses, ensuring clamps are secure.
• Connect the electrical connector to the turbo.

Step 7: Final Assembly and Testing

• Reattach the intake hose and secure it with the worm clamp.
• Reinstall the heat shield and any other panels.
• Top off the coolant reservoir and start the vehicle.
• Run the engine for about 10 minutes while monitoring the coolant temperature.

Conclusion

By following these steps, you can successfully replace the turbocharger and related components in your Chevrolet Cruze. Remember to check for any leaks after the installation and adjust the coolant level as necessary. If you’re unsure about any part of the process, consult a professional mechanic for assistance.