Gen 2 Cruze DIY Intercooler Install Guide! - 2016.5 to 2019 Chevy Cruze

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Install Guide on Facebook page:
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The long awaited DIY Budget Intercooler video is finally here for the Gen 2 Community! This essentially applies to all 2nd Gen Chevrolet Cruzes from 2016, 2017, 2018, 2019.


This is a Guide on Intercooler Install for the Cruze. First thing that should be noted, you should watch through 100% of this guide before attempting, and watch all videos/sites linked here.


Total cost: ~$310


Some notes:
This will provide a generalized guidance on exactly what I used on my car. However, you are not just limited to the color of piping I used, you are able to find many different colors on eBay! Just ensure the pipes are similar bends. This is definitely an all day project. So allocate yourself plenty of time to do this.

Piping/Couplers:
1x 12 Piece Universal 2.5in Piping Kit: https://www.ebay.com/itm/114491786001
1x 2.5in CX Racing Large 90 deg Elbow: https://www.ebay.com/itm/180725178916
1x 2.25in to 2.5in 90 deg Elbow Coupler: https://www.ebay.com/itm/305072214283
1x 2.5in to 1.75in Reducer Coupler: https://www.ebay.com/itm/374638439633
1x 48mm-56mm stainless steel coupler clamp
1x 60mm-68mm stainless steel coupler clamp

Intercooler/Sensor:
1x Rev9 Universal 2.5in 28x9x2.5 intercooler: https://www.ebay.com/itm/272623237477
1x AcDelco Boost Sensor 55573249: https://www.ebay.com/itm/125970061318
1x 2 Pack 6061 Aluminum 1/4x1x12 Flat Bar: https://www.ebay.com/itm/334409179758

Tools/ Hardware/ Extras:
1x 29/64 Drill Bit : https://www.ebay.com/itm/203089997985...
1x Intercooler Pipe Bead Roller tool
4x M8x1.00 20mm Bolts
4x M8 Lock washers
4x M8 washers
1x M7x1.00 25mm Bolt
2x M8 Riv Nuts +tool Or Self tappers
Misc Drill Bits rated for high strength steel

Basics: This will cover the basics on terminology used thru out the rest of this guide. The intercooler pipe kit includes 6x large 90 deg pipes, 4x small 90 deg pipes, 2x straight pipe, 4x 90 couplers, 8x straight couplers, 24x 2.5in clamps. Then the CX Racing extra large 90 deg pipe is your extra large pipe. Everything will be in as chronological order as possible. This also will assume you will use your 2.5in clamps on all silicone couplers.

Piping used for Turbo to Intercooler Side:
First off the turbo to intercooler side. You will be reusing the plastic coupler that pre-exists on the stock intercooler setup. This isnt really that restrictive, but you can port this if you wish. This just removes with a single hose clamp. If your choose to, you can get better clamps to clamp the coupler directly to the turbo. But this is how I did it since I saw zero issues with using it. This is what the 1.75 to 2.5 coupler will be used to clamp to the turbo.

For this side in order, from turbo to intercooler I used; turbo silencer to 1.75 to 2.5 coupler to Small 90 pipe to straight coupler to small 90 pipe to straight coupler to straight pipe cut to appropriate length & re-beaded to 90 coupler cut down to Intercooler

Piping used for Intercooler to Throttle Body Side:
As for this side. Nothing gets reused. This is also the easier of two sides.

For this side in order, from intercooler to the throttle body I used; 90 coupler cut down to straight pipe cut to appropriate length & re-beaded to 90 degree coupler to large 90 pipe to straight coupler to large 90 pipe to straight coupler to extra large cxracing 90 pipe to 2.5in to 2.25 90 coupler to throttle body

Intercooler Sensor install:
I did a video on this already:    • Boost Sensor Install - Intercooler In...  

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Websites:

www.ChevyCruze.org

https://www.ebay.com/itm/394807355120

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