2.2L LAP/L61 S/C Technical Build Thread

Discussion in 'Car Builds' started by cobalt123, Aug 1, 2009.

  1. cobalt123

    cobalt123 Platinum Member

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    PLEASE NOTE THAT SOME INFORMATION IS QUOTED TO PRESERVE THE ORIGINAL POSTERS CREDIT ITS POSTED HERE AS A MEANS TO CONDENSE A MASSIVE AMOUNT OF INFORMATION

    2.2 SC Thread
    2.2 FI Thread
    Sedan Pic thread
    Build Book Left out
    http://www.cobaltss.net/forums/showthread.php?t=70397&highlight=install+header]Header
    http://www.cobaltss.net/forums/showthread.php?t=92797&highlight=install+header]Header
    http://www.cobaltss.net/forums/showthread.php?t=158475&highlight=install+header]Header

    First off I have alot of the parts already. to get the thing running, im planning on basicc stage 2 setup, smoothflow 3.0 pulley w/stg 2 hub and 42 lb/hr injectors. Cooling mods include cobra HE w/ LSJ HE, Devils own meth (i know i dont need it now, but i plan to drop to 2.8) im peiceing my own option b together, im getting a resevoir from a Saturn L200 as the hose ports are facing the correct direction as it will be mounted on the left of the engine bay. Dual pass endplate. I bought a trans cooler but its tiny, so i think im going to sell it and get a bigger one.


    Car Stats-Current
    2006 Chevrolet Cobalt 2.2L L61-NON-SAI
    Black Sedan


    Suspension and Brakeing

    Dropzone Lowering Springs
    TTR Rear Sway Bar
    SS/TC Front Sway Bar
    FE5 Struts/Shocks-need to ordernote: paid for, received bought to install rear FE5 shocks
    16in Konig Traction Rims Wrapped in Yokohama rubber
    rotors(slotted only), SS brake lines, and wilwood dot4 brake fluid

    Used Parts-Bold Parts I Have


    Cobra Heat Exchanger (Used from a 03 Mustang Cobra)

    Cobra Heat Exchanger Brackets (custom or bwoodyperformance.com)
    Eaton M62 Supercharger- 300.00 shipped, 32,000 miles
    GM Stage 2 Injectors (42lbs)- 30.00 shipped, 5,000 miles(42lb/hr)
    Stock LSJ Tensioner
    Stock LSJ Downpipe
    Stock LSJ Idler Pulley- used 15 shipped
    Stock LSJ Throttle Body
    Stock LSJ Serpentine Belt-20 shipped, used
    Stock LSJ Intake Manifold- 250 shipped, used
    Stock LSJ Exhaust Manifold 20.00 shipped, used ~ 15,000miles
    Stock LSJ Alternator Bracket
    Stock LSJ Supercharger Pulley-
    Stock LSJ Heat Exchanger
    Stock LSJ Intercooler Pump

    GM Parts- Bold Parts I Have

    11900248 – LSJ TB To SC Bolts (4)
    12575463 – LSJ TB Gasket
    12584342 – LSJ Supercharger Gasket
    12594387 – LSJ IC Pump Insulator
    12597855 – LSJ Intake Manifold Gasket
    12597993 – LSJ Stage 2 Serpentine Belt
    12614973 – LSJ 1 Bar Map Sensor
    15247280 – LSJ Upper Radiator Hose-cobalt addiction chrome URH
    9230949 – LSJ Exhaust Manifold Gasket
    11516342 – LSJ Intake Manifold Mount To Block Bolts (2)???
    11589214 – LSJ Supercharger to Intake Manifold Bolts (4)
    12345982 – Genuine GM Supercharger Oil (Qty 2) 4 oz ea)-not using
    12584369 – LSJ TB To Purge Solenoid Tube
    12585150 – LSJ IC Pump Rear Bracket To Intake Manifold Mount???
    12586367 – LSJ IC Pump Front Bracket To Rear Bracket
    12586632 – LSJ Lower Intake Manifold Mount
    15226536 – LAP | L61 | L65 Coolant Reservoir
    15075118 – LAP | L61 | L65 Coolant Reservoir Cap
    15231157 – LSJ Downpipe To Cat Back Gasket-using stock l61
    15235773 – LSJ Exhaust Manifold To Downpipe Gasket-using stock l61
    15253932 – LSJ Power Brake Booster Vacuum Hose
    22729469 – LSJ Windshield Washer Container
    22732432 – LSJ Wiper Cowl To Washer Container Hose
    88986255 – LSJ 8 Pin TB Connector (LAP | L61 Only 6)
    89046833 – IC Pump Connector
    90537953 – LSJ Exhaust Manifold Heat Shield
    15411879 – 2005 Cavalier Injector Wiring Harness. No cutting needed using GM Stage 2 Injectors-not needed

    New Parts- Bold Parts I Have

    ZZP Double Gauge Pod(I Have A Sedan)
    OTTP SS SC Pulley Bolts(I Have Two Sets)
    Aeroforce Interceptor Gauge-
    GlowShift Vacuum | Boost Gauge-eBay,$37.00,brand new
    AEM Wideband Air | Fuel Ratio Gauge
    OTTP 3.0 Polished Pulley (For Stage 2 Hub)
    NGK Copper Spark Plugs (Part# LFR6A-11)
    AEM Intake-eBay, 70.00, brand new(will tap for meth)
    Devils Own Base Meth Kit

    Possible Parts in Future

    GM Racing Ported head from gm P/N:88958619
    GM Racing Dual Valve Springs with Ti Retainers, Spring Seats & Valve Stem Seals

    GM Racing Stainless Steel Intake & Inconel Exhaust Valve Set .5mm Oversize

    Comp Cams Ecotec N/A Stage III Cams

    GM Racing Adjustable Cam Gear Set (DO i really need these? Can't timing be adjusted via the ECU?)

    Cometic 2.2L L61 Ecotec 87mm Head Gasket .040

    Eagle Forged H-Beam Connecting Rods(Do i need these I would prefer lightweight i beams)

    GM Racing Neutral Balance Shaft Set (Or just Delete?)

    Wiseco Forged Pistons 10:1CR .020 Overbore Where can I find 11:1? I want to still be able to run 93 Octane and With my e-Mange i could switch between two tunes the other would be self made E-100

    see:http://www.boltdepot.com/Fastener-Information/Printable-Tools/
    Head Stud Kit
    Standard Bolts Needed (Not GM)

    LSJ 1 Bar MAP To Intake Manifold
    M6 x 1.0 x 25 (Qty 1)


    LSJ Intake Manifold Mount Bracket To Intake Manifold
    M10 X 1.50 x 50 (Qty 1)


    LSJ Rear IC Pump Bracket To Intake Manifold Mount
    M8 X 1.25 X 25 – (Qty 2)


    LSJ Front IC Pump Bracket To Rear IC Pump Bracket
    M8 X 1.25 X 35 – (Qty 2)


    LSJ Idler Pulley To Block
    M10 X 1.50 x 75 (Qty 1)


    LSJ Idler Pulley To Alternator Bracket
    M8 x 1.25 x 25


    LSJ Intake Manifold To Block
    M6 x 1.0 X 75 (Qty 2)


    LSJ Alternator Bracket To Block
    M8 X 1.25 X 130 (Qty 3)


    LSJ SC Bypass Valve To SC
    M8 X 1.25 X 20 (Qty 2)


    LSJ Tensioner Lower To Alternator Bracket
    M8 x 1.25 x 35


    LSJ Tensioner Upper To Alternator Bracket
    M8 X 1.25 x 40… not standard bolt though. Has to be metric hex socket bolt.



    LSJ SC Reservoir Bracket To SC
    M6 x 1.0 x 15 (Qty 2)


    LSJ SC Reservoir To SC Reservoir Bracket
    M6 x 1.0 x 15 (Qty 2)


    Questions
    (1.) Spark Plugs- i want one step colder, what heat range is good for a 3.0 pullied 2.2?
    (2.) Please look over my list see and make any recommendations.:guns:
    (3.) Looking at swapping heads, LSJ head on my L61-researching compatibility

    http://www.youtube.com/watch?v=H7L13cTv0tI
    http://www.cobaltss.net/forums/showthread.php?t=215468&highlight=LSJ+Head+L61
    http://www.cobaltss.net/forums/showthread.php?t=27680&highlight=LSJ+Head+L61
    http://www.cobaltss.net/forums/showthread.php?t=217656&highlight=LSJ+Head+L61
    http://www.cobaltss.net/forums/showthread.php?t=206161&highlight=LSJ+Head+L61
    [/COLOR][​IMG]
    [​IMG]
    Wilwood's specially formulated
    Hi-Temp 570 Racing Brake Fluid has a minimum 570 F dry boiling point to withstand the severe heat requirements of automotive racing. Hi-Temp 570's low viscosity allows easy bleeding of your brake system, eliminating aeration of the brake fluid caused by foaming due to excessive pumping of the pedal.


    spark plug info

    http://www.gmperformancedivision.com/content/pulse/54/ECOTEC_2.0L_LSJ_Chap_1&2.pdf
    8 Pin

    Pin A (Dark Green): TP Sensor 1 Signal
    Pin B (Light Blue/Black): 5-Volt Ref 2
    Pin C (Black): Low Reference
    Pin D (Purple): TP Sensor 2 Signal
    Pin E (Yellow): TAC Motor control 1
    Pin F (Brown): TAC Motor control 2
    Pin G (Gray): 5-Volt Ref 1
    Pin H (Black/White): Low Reference

    6-Pin
    Pin A (Brown): TAC Motor control 2
    Pin B (Yellow): TAC Motor control 1
    Pin C (Tan): Low Reference
    Pin D (Dark Green): TP Sensor 1 Signal
    Pin E (Gray): 5-Volt Reference
    Pin F (Purple): TP Sensor 2 Signal

    8-Pin >>> 6 Pin

    A > D (Dark Green)
    B > E (Gray)
    C > C (Tan)
    D > F (Purple)
    E > B (Yellow)
    F > A (Brown)
    G > E (Gray)
    H > C (Tan)

    B/G both go to Pin E (Gray)
    C/H both go to Pin C (Tan)

    I think those colors are still the same (this was for my L61)
     
    Last edited: Jul 21, 2010
  2. cobalt123

    cobalt123 Platinum Member

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    [​IMG]

    use the part numbers on the left to order from boltdepot.com

    only ones not available are the 130 length ones

    In order to get the M8 x 1.25 x 130 and M8 x 1.25 x 125 go here:

    Home | Fastenal

    the part numbers on there website are as follows: these can change as time passes
    M8 x 1.25 x 125-SKU:11113083
    M8 x 1.25 x 130-SKU: 0127127


    Q&A i wanted to save

    Fuel Trims???

     
    Last edited: Jul 21, 2010
  3. cobalt123

    cobalt123 Platinum Member

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    ....
     
    Last edited: Jul 21, 2010
  4. cobalt123

    cobalt123 Platinum Member

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    ....
     
    Last edited: Jul 21, 2010
  5. cobalt123

    cobalt123 Platinum Member

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    selling the intercooler i also got the intake mani coming in soon,

    btw i have the lsj motor mount which now that i think of it is no good for 2.2 anyone want it

    thanks, i saw it earlier but i decided in favor of the other area cuz it didnt come this way factory noob error lol

    Oil Change
    Oil change
    Install How To:
    Hunterkiller
    Becks
    Tom's Build Info:
    Install info
    Ecotec Build Guige:
    Build Guide Link

    Note for Transmission Coolers:
    INSTALL TRANNY COOLER
    Note on installing SS/TC Front Strut Bar

    FE5 BAR INSTALL
    Dual Pass
    http://www.frozenboost.com/product_...=1015&osCsid=b4aca155b89f4eb25348cd3413f25b84
    DIY Dual Pass

    Attention Auto Trans Owners
    The reason it won't fit is because the automatic transmission makes the engine sit forward more than standard. therefore if you connect the DP it will pull the rest of the exhaust forward and will cause the DP to rub on the front sway bar. It has nothing to do with the header..

    Links
    http://www.siliconeintakes.com/index.php?cPath=17&osCsid=40f1db42a5c5f84c0e5c2dafb4310c6d
    http://www.extremepsi.com/store/customer/product.php?productid=17629&cat=1007&page=1
    http://en.wikipedia.org/wiki/AN_fitting

    Ecotec Links:
    FAQs
    Engine Breakdowns
    short history of ecotec

    [​IMG]
    [​IMG]

     
    Last edited: Jul 21, 2010
  6. cobalt123

    cobalt123 Platinum Member

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    thought so, well its not expensive, plus some one will want to buy it

    [​IMG]

    http://www.crateenginedepot.com/store/Cobalt-Sway-Bars-and-Components-C512.aspx

    http://www.crateenginedepot.com/store/Cobalt-FE5-Struts-and-Shock-Pkg-FE5-S-P2433C514.aspx

    [​IMG]--later sold spark plugs cuz they are not copper tops
    [​IMG]
     
    Last edited: Jul 21, 2010
  7. cobalt123

    cobalt123 Platinum Member

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    Actually I revised my list to talk about the MAP sensors, etc. Here it is... I hope you enjoy.

    This list is broken down to bare essentials for supercharging only and then adds the optional exhaust and optional wiper conversion lists. What type of injectors, pulley’s and other items you choose to change are strictly up to you. This is the list that I used and have modified it for a universal parts list.

    Supercharger Related Parts Only
    (Bare Essentials To SC Your 2.2 or 2.4)

    New GM Parts

    12575463 – LSJ TB Gasket
    11900248 – LSJ TB To SC Bolts (4)
    12584342 – LSJ Supercharger Gasket
    12594387 – LSJ IC Pump Insulator
    89046833 – IC Pump Connector
    12597855 – LSJ Intake Manifold Gasket
    12597993 – LSJ Stage 2 Serpentine Belt
    15247280 – LSJ Upper Radiator Hose
    15411879 – 2005 Cavalier Injector Wiring Harness
    15253932 – LSJ Power Brake Booster Vacuum Hose
    12584369 – LSJ TB To Purge Solenoid Tube
    12585150 – LSJ IC Pump Rear Bracket To Intake Manifold Mount
    12586367 – LSJ IC Pump Front Bracket To Rear Bracket
    12586632 – LSJ Lower Intake Manifold Mount
    11516342 – LSJ Intake Manifold Mount To Block Bolts (2)
    11589214 – LSJ Supercharger to Intake Manifold Bolts (4)
    12345982 – Genuine GM Supercharger Oil (Qty 2) 4 oz ea))

    Purchasing the LSJ power brake booster hose takes care of 2 issues. I cut off the ends of my 2.2 hose and used it as a PCV hose from the valve cover to the LSJ air intake hose. It gives you the correct hose from your power brake booster to SC and gives you a factory looking formed hose for your PCV hose.

    New Non- GM Parts

    ZZP Heat Exchanger
    GlowShift Vacuum | Boost Gauge
    AEM Wideband Air | Fuel Ratio Gauge
    OTTP 2.9 Polished Pulley (For Stage 2 Hub)
    M-8501-L54 Ford Racing Intercooler Pump
    NGK Copper Spark Plugs (Part# LFR6A-11) (Also one step colder)

    Copper plugs are better than Iridium plugs or any other plugs for supercharged applications. People have gaps anywhere from .035 to .040. They come .040 and that is what I am using.

    Used Parts

    Eaton M62 Supercharger
    GM Stage 2 Injectors (42lbs)
    Stock LSJ Air Intake
    Stock LSJ Tensioner
    Stock LSJ Idler Pulley
    Stock LSJ Throttle Body
    Stock LSJ Intake Manifold
    Stock LSJ Alternator Bracket

    Optional Parts

    ZZP Triple Gauge Pod
    Aeroforce Interceptor Gauge

    Injector Harness

    I used the 2005 Cavalier injector wiring harness because it came with the proper connectors for using the original GM 42.5 lb Stage 2 injectors. I did have to splice my MAP sensor connector in from my original harness as I started out with the stock MAP sensor.

    MAP Sensor

    You can choose to use 3 different MAP sensors for your conversion. Which MAP sensor you choose will also depend on the connector needed to be used.

    Stock MAP
    This MAP sensor fits into the LSJ intake manifold, but you must modify the opening in the sensor where it screws into the intake. How I modified the sensor is in my SC build thread. This is the least expensive option and is the least hassle option.

    LSJ 1 Bar MAP
    This is the MAP sensor that is used in the SC on the stock LSJ. We can take that sensor and use it in the LSJ intake manifold. You will need to modify a means to secure it and also seal it to the LSJ intake manifold. How I modified this sensor to fit my car is also in my SC build thread. I would honestly say this is the least optimal choice out of the 3 possibilities for me.

    LSJ 2.5 Bar MAP
    This is the real MAP sensor used on the stock LSJ in the intake manifold. It best fits the stock LSJ intake manifold (obviously). This MAP sensor also has a temp sensor, otherwise known as IAT2 (Intake Air Temperature 2). Our cars cannot read the temp without modification. How I did the 2.5 bar MAP sensor conversion to read IAT2’s is also in my SC build thread.

    Throttle Body Connector

    If you are using the LSJ throttle body the connector you’ll need to have is an 8 pin. Regardless of what connector you do have or if you have to purchase the 8 pin, you will need to wire them for the LSJ TB.

    2005 – 2006 2.2’s have an 8 pin connector. No new connector is needed.
    2007+ 2.2’s have a 6 pin connector and you will need the 8 pin connector.

    2006 – 2007 2.4’s have an 8 pin connector. No new connector is needed.
    2008+ 2.4’s have a 6 pin connector and you will need the 8 pin connector.

    If you need the 8 pin connector you’ll need the one below.

    88986255 – LSJ 8 Pin TB Connector

    Supercharger Cooling System

    New GM Parts

    22697069 – LSC SC Coolant Reservoir
    15076936 – LSJ SC Coolant Reservoir Cap
    15271970 – LSJ SC Coolant Reservoir Bracket
    22697111 – LSJ SC Coolant Reservoir Overflow Hose
    22699879 – LSJ SC Coolant Reservoir Inlet To Top Intake Manifold End Plate Hose
    22707607 – LSJ Bottom Intake Manifold End Plate To Intercooler Pump Outlet Hose

    Hose routing is with using ZZP heat exchanger only with 10 feet of ¾ heater hose. The house routing diagram I used is in my SC build thread.

    First hose went from LSJ SC coolant reservoir outlet to ZZP heat exchanger inlet.
    Second hose went from intercooler pump inlet to ZZP heat exchanger outlet.

    I chose the stock SC cooling system for now. If you choose to use option B or any other alternative then you will need different hoses and lengths of hose.

    I am running a 2.9 pulley with the ZZP heat exchanger only and my IAT2 temps are within +20 to +30 above ambient temp (which is optimal). Of course in traffic or during heavy WOT runs the temps are higher as expected (which is normal). This cooling method is very adequate.

    Standard Bolts Needed (Not GM)

    MAP To Intake Manifold
    M6 x 1.0 x 25 (Qty 1)

    LSJ Intake Manifold Mount Bracket To Intake Manifold
    M10 X 1.50 x 50 (Qty 1)

    LSJ Rear IC Pump Bracket To Intake Manifold Mount
    M8 X 1.25 X 25 – (Qty 2)

    LSJ Front IC Pump Bracket To Rear IC Pump Bracket
    M8 X 1.25 X 35 – (Qty 2)

    LSJ Idler Pulley To Alternator Bracket
    M8 x 1.25 x 25

    LSJ Intake Manifold To Block
    M6 x 1.0 X 75 (Qty 2)
    M6 x 1.0 x 25 (Qty 5)

    LSJ Alternator Bracket To Block
    M8 X 1.25 X 130 (Qty 3)

    LSJ SC Bypass Valve To SC
    M8 X 1.25 X 20 (Qty 2)

    LSJ Tensioner Lower To Alternator Bracket
    M8 x 1.25 x 35

    LSJ Tensioner Upper To Alternator Bracket
    M8 X 1.25 x 40… not standard bolt though. Has to be metric hex socket bolt.

    LSJ SC Reservoir Bracket To SC
    M6 x 1.0 x 15 (Qty 2)

    LSJ SC Reservoir To SC Reservoir Bracket
    M6 x 1.0 x 15 (Qty 2)

    End of bare essentials list to supercharge your 2.2 or 2.4. The rest of the list below is simply optional.

    ------------------------------------------------------------------------------------------------------------------------------------------

    Exhaust Parts (Optional)

    GM Parts

    90537953 – LSJ Exhaust Manifold Heat Shield
    15231157 – LSJ Downpipe To Cat Back Gasket
    15235773 – LSJ Exhaust Manifold To Downpipe Gasket

    Use your stock 2.2 or 2.4 exhaust manifold gasket, or buy new, as if you used the LSJ exhaust manifold gasket it wouldn’t fit properly and you would have an exhaust leak and/or noise.

    Used Parts

    Stock LSJ Downpipe
    Stock LSJ Exhaust Manifold

    The stock LSJ downpipe works on any manual shift car. It does not fit the automatic because of the way the automatic engine sits in the vehicle.

    The LSJ exhaust manifold and LSJ downpipe are much bigger to allow more exhaust to exit the engine. This is important as you are forcing more air into the engine with the supercharger so you need to provide adequate output as well. Feel free to purchase your aftermarket selection of header/dp combo.

    Windshield Wiper Conversion (Optional)

    GM Parts

    22729469 – LSJ Windshield Washer Container
    22732432 – LSJ Wiper Cowl To Washer Container Hose

    You’re moving the LSJ air intake to the left side of the vehicle and that is where the 2.2 and 2.4 windshield wiper container is. The container I listed includes a new pump, grommet, cap and hose to attach to wiper cowl hose. The wiper cowl to container hose I list is the original GM hose on the LSJ that goes from the left side of the wiper cowl (where ours is) and takes it to the right side where it meets up with the LSJ washer container that I list. As far as the connector for the pump, I cut the end of the connector off and added new wire to loom it from the left side of the car to the right side of the car to the new container location. I ran the loom across the top of the inside of the radiator support where there is already a loom running for something else. I ran it inside its own loom and wire tired to the existing loom. [​IMG]
    [​IMG]


    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
     
    Last edited: Jul 21, 2010
  8. cobalt123

    cobalt123 Platinum Member

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    thanks for the clarification

    How to Install Cobra Heat Exchanger-

     
    Last edited: Jul 21, 2010
  9. Jn2

    Jn2 Full Access Member

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    i c a pulley and nothing else...i have the pulley and the black thing the pulley bolts too, u would just need to get the strut thing....

    ---------- Post added at 11:18 PM ---------- Previous post was at 11:17 PM ----------

    [​IMG]

    the top part of #2...pretty much everything on #2 minus the actual strut
     
  10. cobalt123

    cobalt123 Platinum Member

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    10ft. x ¾” I.D. Hose
    10ft x ¼” I.D. Hose
    4ft. x ½” I.D. Hose
    1/4" is for option B if you have the stock HE or if your aftermarket one has a 1/4" bleeder nipple on it
    no clue why he's getting 1/2" though.

    correct
     
    Last edited: Jul 21, 2010

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