krautsalat

I thought of doing this a while ago and now its a reality. So far I have:
Complete LSJ donor car
zzp heat exchanger(ordered today)
zzp modular pulley system w/2.9(ordered today)
42lb injectors
pig tails
all hoses and bolts
aem uego wideband(ordered today)
autometer boost/vacuum guage(ordered today)
extra coolant tank
stage 2 belt(ordered today)
zzp triple guage pillar(ordered today)
rolls of wire
1 step colder plugs
All gaskets

Prob more.

I need:
Tune which is going to be ordered when all parts arrive that way its ready.
????

I plan on doing this on a weekend. I'll mount the heat exchanger and wire the guages before hand so there ready to plug in.

Other then that I don't know what else I would need..if anyone knows anything else let me know.

Jn2

iTrader: (1)

You need a angle grinder to cut off a small part of the block by the timing chain tensionor Allen plug...

krautsalat

haha yup. good thing I have one then.

rockstarbass1

is there a pic of that in one of the build threads???

Gene Culley

iTrader: (1)

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 ž 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.

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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.

Jn2

iTrader: (1)

gene you keep that saved somewhere dont you :p

Gene Culley

iTrader: (1)

I do, lol.

krautsalat

and I have saved it at least 3 times in the past 3 weeks.

UPDATE:
Picked up the m62, IM, all brackets/bolts, idler, tensioner, TB ( well a whole LSJ actually) on saturday and cleaned everything up...man everything was dirty. cleaned up good though. Only thing I will need is a h/e pump as the one that was on it the outlet tube was broken right off.

other then that I now have everything and have alot of stuff on its way in the mail. Still need to find a coolant tank though and intake(either stock or aftermarket) then order my tune.
quick pic of some stuff when I first tore it off the motor

krautsalat

Update: ordered my tune/dealer kit last night, also ordered a new h/e pump from ottp today. All in all I have all my stuff with the rest in the mail right now. anticipating the build date for two weeks from now.

krautsalat

UPDATE: big order from ZZP is being delivered tomorrow. Also Gene sent me out a nice goodie box haha thanks man. Ordered both the BKR7E copper cores and BKR7EIX Iridiums to se which ones I like better. Pics to start soon!! Painted my s/c last night and doing the IM manifold as we speak as well. Pics to come shortly.

Gene Culley

iTrader: (1)

Oh so this is Cole, lol. I totally reconditioned my intake manifold and it looked brand new. Well, I actually reconditioned everything that was used. Sounds like you're making progress. Keep us updated.

krautsalat

haha I thought you knew my screen name. ya mine isn't too bad. it was dirty on the outside but the inside was like new when i took it off the motor.

Gene Culley

iTrader: (1)

No, I didn't realize it was you, lol. Post some pics of your painting work on the supercharger and intake!

krautsalat

UPDATE:
Order from ZZP arrived and I have snapped some crappy pics of paint work and new parts
SC with the stock pulley still on it haha

IM

Autometer mech boost gauge

ZZP 2.9 pulley w/hub

SC Oil and ZZP Heat exchanger

triple pillar

09CobaltLT

sub'd

DoMiStIc_RuSh_06

iTrader: (1)

So are you gonna be a dealer for trifecta? If so, pm me.

krautsalat

pm'd and yes

redcobalt07

iTrader: (18)

good luck, its a bitch

Gene Culley

iTrader: (1)

Nice paint job. The intake looks exactly how mine was painted. I really took my time with it. There were probably 10 coats of paint on it. I primed it as well. I will admit the whole installation thing was a bitch, but I'm pretty picky about things. Mine looks like it came from the factory with it, and not a hack job, so I'm happy with it. Keep up the good work.

krautsalat

Ya I only scuffed any contaminates off with a scotch pad then painted first coat and cured it with a industrial heat gun then applied a few more coats since the pics were taken. Looks pretty good...just glad the hoses hide the endplate nipples as they have light corossion on them.

krautsalat

got my software and tune from trifecta friday. cable is shipped out that day as well. sparkplugs should be here tomorrow as well as the rest of my goodies should be here this week. going to go shopping for a universal coolant tank tomorrow and get the wideband bung welded in as well. pulley and hub get put on tuesday i think. I should be good to start the install hopefully by the end of the week!! Its too bad i just put brand new tires on...got a feeling they won't last past the summer.

DoMiStIc_RuSh_06

iTrader: (1)

Sweet I'll be in contact with you soon once I get this issue fixed.

krautsalat

Sounds good man...just let me know when and we'll get you that tune

krautsalat

UPDATE: Picked up my sparkplugs...good thing they ordered 4 packs cause apparently they only come with 1 in a pack. Also ordered a universal coolant resevoir from NAPA to make my homeade option b. Might get someone to weld an aluminum bung in my endplate and go dual pass while I am at it.

Also I am looking for a downpipe....either stock lsj or other

Whitty

i'll prob be looking for a tune this summer as well. i'll pm u when i know for sure GL with teh build! I lived in windsor for a year and never saw / met u weird!