GM Intercooler vs ZZP
12-02-2010, 12:33 PM
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GM Intercooler vs ZZP
So after doing this to my GM Intercooler: (Thumbnails, click to enlarge)
Twice:
I went ahead and bought this from ZZP:
Now I haven't installed it yet because I am waiting to blow up my 3rd intercooler and try and get a warranty reimbursement, but if that doesn't happen in a thousand miles or so, I'll put it on anyways. So far I had one go at 4k miles, one at 8k, and now I am at 12k (bought the car 3 months ago ha).
But I thought I would post up these pics because looking at the pics on ZZP's website I didn't think their intercooler was very big compared to the stocker... It DEFINITELY is. The picture with the juice can helps you realize just how much bigger than the stocker it is... When I swap the intercooler I'll get some side-by-side pics. But I am VERY happy with the quality so far (pending fitment) so
ZZP! 
The only downside, the ZZP intercooler is probably 2x as heavy based on what I remember the stockers weighing... On the other hand, maybe it'll help with traction!
And before anyone tries to call me out on some dumb ****, no, I haven't stressed my intercooler or curbed it in any way. What you are looking at is the result of 27 PSI the first time, 25 PSI the second time, and I am down to 24 PSI now pending a third blowup. Plastic end tanks were a POS idea.
Twice:
I went ahead and bought this from ZZP:
Now I haven't installed it yet because I am waiting to blow up my 3rd intercooler and try and get a warranty reimbursement, but if that doesn't happen in a thousand miles or so, I'll put it on anyways. So far I had one go at 4k miles, one at 8k, and now I am at 12k (bought the car 3 months ago ha).
But I thought I would post up these pics because looking at the pics on ZZP's website I didn't think their intercooler was very big compared to the stocker... It DEFINITELY is. The picture with the juice can helps you realize just how much bigger than the stocker it is... When I swap the intercooler I'll get some side-by-side pics. But I am VERY happy with the quality so far (pending fitment) so
ZZP! The only downside, the ZZP intercooler is probably 2x as heavy based on what I remember the stockers weighing... On the other hand, maybe it'll help with traction!And before anyone tries to call me out on some dumb ****, no, I haven't stressed my intercooler or curbed it in any way. What you are looking at is the result of 27 PSI the first time, 25 PSI the second time, and I am down to 24 PSI now pending a third blowup. Plastic end tanks were a POS idea.
12-02-2010, 12:54 PM
#3
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Disclaimer: I am not saying that you have installed the piping incorrectly, I'm just giving you my experience.
From my experience, the end tanks breaking is a result of incorrect installation of the hot and coldside piping. I broke my first intercooler by hitting a raccoon. The GM bodyshop installed a new one and I cracked the end tank a week later on stock tune. They installed another IC and I cracked the end tank on that one 2 days later on stock tune. They tried to blame it on me. The third IC was put on. I requested the mechanic history and found that the same guy installed them all. I looked at the piping and he was clamping the coldside tubing all the way up at the endtank, instead of directly in front of the barb on the endtank tube. When I would close the throttle plate after WOT, the pressure would balloon the coldside pipe around the barb, then the clamp would slip and blow the IC forward, cracking the tank. Once I moved the clamp to directly in front of the barb on the endtank tube, I haven't had any issue since. That was about a year ago.
Whether because of loose clamping or incorrect position of clamping, I would say that the factory IC is only cracked by human error, not by a measly 30 psi of air pressure.
From my experience, the end tanks breaking is a result of incorrect installation of the hot and coldside piping. I broke my first intercooler by hitting a raccoon. The GM bodyshop installed a new one and I cracked the end tank a week later on stock tune. They installed another IC and I cracked the end tank on that one 2 days later on stock tune. They tried to blame it on me. The third IC was put on. I requested the mechanic history and found that the same guy installed them all. I looked at the piping and he was clamping the coldside tubing all the way up at the endtank, instead of directly in front of the barb on the endtank tube. When I would close the throttle plate after WOT, the pressure would balloon the coldside pipe around the barb, then the clamp would slip and blow the IC forward, cracking the tank. Once I moved the clamp to directly in front of the barb on the endtank tube, I haven't had any issue since. That was about a year ago.
Whether because of loose clamping or incorrect position of clamping, I would say that the factory IC is only cracked by human error, not by a measly 30 psi of air pressure.
12-02-2010, 01:01 PM
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Disclaimer: I am not saying that you have installed the piping incorrectly, I'm just giving you my experience.
From my experience, the end tanks breaking is a result of incorrect installation of the hot and coldside piping. I broke my first intercooler by hitting a raccoon. The GM bodyshop installed a new one and I cracked the end tank a week later on stock tune. They installed another IC and I cracked the end tank on that one 2 days later on stock tune. They tried to blame it on me. The third IC was put on. I requested the mechanic history and found that the same guy installed them all. I looked at the piping and he was clamping the coldside tubing all the way up at the endtank, instead of directly in front of the barb on the endtank tube. When I would close the throttle plate after WOT, the pressure would balloon the coldside pipe around the barb, then the clamp would slip and blow the IC forward, cracking the tank. Once I moved the clamp to directly in front of the barb on the endtank tube, I haven't had any issue since. That was about a year ago.
Whether because of loose clamping or incorrect position of clamping, I would say that the factory IC is only cracked by human error, not by a measly 30 psi of air pressure.
From my experience, the end tanks breaking is a result of incorrect installation of the hot and coldside piping. I broke my first intercooler by hitting a raccoon. The GM bodyshop installed a new one and I cracked the end tank a week later on stock tune. They installed another IC and I cracked the end tank on that one 2 days later on stock tune. They tried to blame it on me. The third IC was put on. I requested the mechanic history and found that the same guy installed them all. I looked at the piping and he was clamping the coldside tubing all the way up at the endtank, instead of directly in front of the barb on the endtank tube. When I would close the throttle plate after WOT, the pressure would balloon the coldside pipe around the barb, then the clamp would slip and blow the IC forward, cracking the tank. Once I moved the clamp to directly in front of the barb on the endtank tube, I haven't had any issue since. That was about a year ago.
Whether because of loose clamping or incorrect position of clamping, I would say that the factory IC is only cracked by human error, not by a measly 30 psi of air pressure.
That's definitely some good information for others having this problem, however.
12-04-2010, 07:42 PM
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Okay, here are some pics from the install.
Comparison of the two intercoolers. Ignore my feet I work on cars not take pictures
So the ZZP is quite a bit bigger... Nice piece. Everything fit nice and the installation took me 1/2 hour since I've done a few intercoolers already. One of the L shaped brackets (drivers side) had one hole about 1/8 inch off and I had to widen it a little or the IC would rub on a little lip on the crash bar. When this happened, the hole didn't line up. Overall, very easy install. My first GM intercooler took me about an hour to install, and I don't think the hole being off would happen to everybody. I'd say about an hour to install it for a first timer, +/- 10 minutes.
Only part I don't like - reduced ground clearance by about .5-.75 inch. I'm stock height and careful when parking, I can live with this.
Overall, huge to ZZP, I think it's a great product.
SSlobalt -- PM me anytime.
Comparison of the two intercoolers. Ignore my feet I work on cars not take pictures
So the ZZP is quite a bit bigger... Nice piece. Everything fit nice and the installation took me 1/2 hour since I've done a few intercoolers already. One of the L shaped brackets (drivers side) had one hole about 1/8 inch off and I had to widen it a little or the IC would rub on a little lip on the crash bar. When this happened, the hole didn't line up. Overall, very easy install. My first GM intercooler took me about an hour to install, and I don't think the hole being off would happen to everybody. I'd say about an hour to install it for a first timer, +/- 10 minutes.
Only part I don't like - reduced ground clearance by about .5-.75 inch. I'm stock height and careful when parking, I can live with this.
Overall, huge
to ZZP, I think it's a great product.SSlobalt -- PM me anytime.
12-05-2010, 04:15 PM
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" What you are looking at is the result of 27 PSI the first time, 25 PSI the second time, and I am down to 24 PSI now pending a third blowup"
I don't *get* the problem with the stocker..sorry. I'm at 20lbs with no issues at all. Looks like high boost could be the culprit. Have you looked into vibrations caused by motor mounts..etc?
Anyway, hope this *fix* solves the problem. You're gonna have clearance *issues* for sure...
12-05-2010, 10:13 PM
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Got to datalog some runs today... IATs dropped from 25-35 degrees above ambient with the stocker to 8-15 degrees above ambient with the ZZP piece. Nice improvement. No loss of pressure, and the turbo doesn't seem to spool any faster or slower.
Last edited by IFRYRCE; 12-05-2010 at 10:20 PM.
12-05-2010, 11:27 PM
#11
Changing out the intercooler is definitely one of my mods for next year. I broke the bracket off the plastic end tank (zip tied now) and on the track I noticed my top speed on the straight drop by 4-5 mph after 7 laps. I'm sure a beefier intercooler will help with that as well. I'm not thrilled by reading about the extra weight... Does anyone know how the ZZP's weight compares with Hahn's IC? I know the latter is much more expensive. I'm sure the extra weight is a price you pay for the bigger size though.
I do think charge piping is higher on my list than the IC though...
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Black 2010 SS/TC – G85 |Debadged | GMS1 | Hahn 3” DP and Catback | AEM intake | GM racing pedals | Summer: Stock Contis on OZ Ultraleggera rims | Winter: Blizzak LM60s on black powder coated stock TC rims|DEPO 4th gen projectors w/ 6K HIDs | smoked LED tails | 20% 3M tint |Pioneer Avic Z110bt head unit, Alpine PDX-5 amp, Focal speakers all around | Escort 9500iX
http://www.cardomain.com/ride/3835837
I do think charge piping is higher on my list than the IC though...
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Black 2010 SS/TC – G85 |Debadged | GMS1 | Hahn 3” DP and Catback | AEM intake | GM racing pedals | Summer: Stock Contis on OZ Ultraleggera rims | Winter: Blizzak LM60s on black powder coated stock TC rims|DEPO 4th gen projectors w/ 6K HIDs | smoked LED tails | 20% 3M tint |Pioneer Avic Z110bt head unit, Alpine PDX-5 amp, Focal speakers all around | Escort 9500iX
http://www.cardomain.com/ride/3835837
12-06-2010, 07:41 PM
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I just don't like the fact it hangs down, that's the only reason why I can't bring myself to buying a ZZP. If I ever bottomed out on my car, I'd car if it ruined my intercooler.
12-06-2010, 08:32 PM
#14
Disclaimer: I am not saying that you have installed the piping incorrectly, I'm just giving you my experience.
From my experience, the end tanks breaking is a result of incorrect installation of the hot and coldside piping. I broke my first intercooler by hitting a raccoon. The GM bodyshop installed a new one and I cracked the end tank a week later on stock tune. They installed another IC and I cracked the end tank on that one 2 days later on stock tune. They tried to blame it on me. The third IC was put on. I requested the mechanic history and found that the same guy installed them all. I looked at the piping and he was clamping the coldside tubing all the way up at the endtank, instead of directly in front of the barb on the endtank tube. When I would close the throttle plate after WOT, the pressure would balloon the coldside pipe around the barb, then the clamp would slip and blow the IC forward, cracking the tank. Once I moved the clamp to directly in front of the barb on the endtank tube, I haven't had any issue since. That was about a year ago.
Whether because of loose clamping or incorrect position of clamping, I would say that the factory IC is only cracked by human error, not by a measly 30 psi of air pressure.
From my experience, the end tanks breaking is a result of incorrect installation of the hot and coldside piping. I broke my first intercooler by hitting a raccoon. The GM bodyshop installed a new one and I cracked the end tank a week later on stock tune. They installed another IC and I cracked the end tank on that one 2 days later on stock tune. They tried to blame it on me. The third IC was put on. I requested the mechanic history and found that the same guy installed them all. I looked at the piping and he was clamping the coldside tubing all the way up at the endtank, instead of directly in front of the barb on the endtank tube. When I would close the throttle plate after WOT, the pressure would balloon the coldside pipe around the barb, then the clamp would slip and blow the IC forward, cracking the tank. Once I moved the clamp to directly in front of the barb on the endtank tube, I haven't had any issue since. That was about a year ago.
Whether because of loose clamping or incorrect position of clamping, I would say that the factory IC is only cracked by human error, not by a measly 30 psi of air pressure.
12-06-2010, 08:39 PM
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i never had problems with the factory intercooler. I've ran some high boost tunes too and tracked the car, the intercooler as far as I'm concerned has been very very good to me.
12-08-2010, 12:41 PM
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I cracked cold side both times. Hot side never had a problem. Odd, isn't it? I mean, hot side has more pressure...
12-08-2010, 02:18 PM
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When you changed out the hot side it may have been tweaked enough to stress the other side. Most people having problems with stock IC have done something to the charge pipes one way or another.
12-08-2010, 02:20 PM
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12-08-2010, 10:35 PM
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Nice purchase, I can't wait to pick mine up
When people say it hangs down so much they can't buy it, it's no like it hangs down 5 inches I believe it was 1/2" or something like that
Which isn't much at all espeacially when most are at stock height
When people say it hangs down so much they can't buy it, it's no like it hangs down 5 inches I believe it was 1/2" or something like that
Which isn't much at all espeacially when most are at stock height
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