2.4 turbo build (for the haters! )
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Joined: 09-16-05
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From: UNDER YOUR BED
By each post that you make, you really do make yourself look more dumb each time. There are certain parts that do not need to be bought by a big name company. If your such a baller and buy the best parts start shopping at asm. Not ams, but if u want strictly quality parts. U can sell your entire car just to buy a set of coilovers
and a turbo is a CERTAIN PART you would probably want to invest a little more money into for a BRAND name. Especially considering if the turbo fails it can have catastrophic results. Its ok though, its not my car. Have fun when u get a blown bearing, premature shaft play, etc
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From: UNDER YOUR BED
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From: sidney mt
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From: long island
Hm that was actually interesting .. When ever im in gear and just let it coast down in rpms sometimes it will backfire like little bubbles of excess backpressure popping out..was going to redue exhaust (rn im running a str8 dump pipe from the wastegate.. Really short one tho its way to loud) so recuirculate the dump pipe and go from 2.5 to 3 str8 back.. ? But first and for most im going to check that exhaust side and see if those fins r bending in causing to much bp .. Thanks for the post..
Senior Member
Joined: 09-16-05
Posts: 13,306
Likes: 0
From: UNDER YOUR BED
Hm that was actually interesting .. When ever im in gear and just let it coast down in rpms sometimes it will backfire like little bubbles of excess backpressure popping out..was going to redue exhaust (rn im running a str8 dump pipe from the wastegate.. Really short one tho its way to loud) so recuirculate the dump pipe and go from 2.5 to 3 str8 back.. ? But first and for most im going to check that exhaust side and see if those fins r bending in causing to much bp .. Thanks for the post..
glad I could be of help to you
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From: long island
Thread Starter
Member
Joined: 09-05-11
Posts: 252
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From: long island
Ya man I ended up having just an exhaust leak (pain to notice it since that open dump pipe already sounds like exhaust leak lol ) but since I was in there I took a look in the turbo n fins seem fine..
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Joined: 05-16-07
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From: Riverside, CA
Not a Cobalt but I'm doing a similar build on my LE5 powered Sky. I was fortunate enough to get an entire LNF engine with turbo and exhaust manifold (and water and oil lines) that has a problem in the block for free. I also got my hands on a complete stock intercooler and charge pipe parts for free. So far I have spent $50 on my build and you can see the parts I have left to purchase run about $650.
Here is a list of parts (and prices) if you want to do this build yourself like I have. Now granted I have received a lot of my parts free of charge so keep in mind that unless you can do the same, getting the DDM kit is going to be MUCH cheaper. This really is for those with the 2.4 who are fortunate enough to be able to get a majority of the parts for free or nearly free. As you can see from this list of parts, it’s a lot more than just slapping on a turbo. All part numbers are GM part numbers unless otherwise specified. All GM part prices are MSRP and can be found for much less through online parts suppliers.
A couple other notes. I’m sure this list will change a bit as I do my build. I have not added parts here that you will reuse off your 2.4 such as manifold nuts or items that should be attached to pieces like the studs in the turbocharger. Also, I may have missed some things as this is a VERY big list but I’m almost certain I got everything. If I find something missing or I need to change something I will update this list. In addition, there are some items that are part of a previously listed section (such as intercooler) but that need to be custom fabricated so they are placed in their own section at the bottom of this list. Everything else are pretty much bolt on items. Finally, this does not include the cost of welding, cutting, forming of pipe ends or powder coating that I might do during the build.
Turbo Parts
12652494 – K04 Turbocharger $1,365.11
12609878 – Turbocharger to Catalytic Converter Gasket $17.37
12618586 – Turbocharger to Manifold Gasket $13.82
12589452 – Support Brace $20.82
12589408 – Heat Shield Turbo $32.58
12654315 – Oil Pipe Feed Line $100.56
11561946 – Bolt for Oil Line (2) $22.71 each
12611119 – Gasket for Oil Line (2) $7.40 each
12626611 – Water Feed Line $111.58
12618973 – Water Return Line $97.82
11561875 – Bolt for Water lines (3) $15.85 each
12626102 – Gasket for Water lines (3) $9.26 each
12602397 – Exhaust Manifold $482.74
12622668 – Manifold Gasket $11.30
12612286 – Heat Shield Manifold $35.55
12609268 – Catalytic Converter $877.57
15709703 – Nut for Cat to Turbo (4) $2.25 each
Oil Return Line - $89.99 (I have priced these out from ZZP but waiting on a quote from DDM.)
Total for Turbo Parts: $3,301.36
Water System Parts
12605853 – Thermostat Housing $128.51
90537471 – Thermostat Housing Gasket $23.28
12592401 – Outlet Pipe $49.58
90537379 – Outlet Pipe Seal (2) $15.17
Audi PN N90692901 – Audi A4 B8 2.0L Turbo Coolant T-fitting $12.00 at O'Riely*
1” to 3/4” barbed hose adaptor – $5.40 from Napa*
1’ section of 7/8” coolant line - $4.40 on eBay*
¾” to 3/8” barbed hose adaptor – apx $5.00 from Napa*
1’ section of ¾” coolant line - $3.52 on eBay*
¾-1” hose clamp (3) – apx $2.00*
½” hose clamp – apx $2.00*
*These parts are all to tie in the Water Feed line into the upper radiator hose. I found a couple 1’ to ½” adaptors but I don’t believe they are rated for engine coolant. Still looking for a better solution than this daisy chain of reducers.
Total for Water System Parts: $254.86
Intercooler Parts
25820725 – Intercooler $542.37
10386886 – Mount Bracket, Left $55.53
10386887 – Mount Bracket, Right $55.53
11609681 – Mount Bracket Bolt (2) $3.26 each
11589039 – Mount Bracket Bolt (4) $3.30 each
19129912 – Mount Bracket Insulator (2) $12.58 each
12595594 – Pipe Assembly $49.82
12615136 – 2 Bar MAP sensor $100.98
19129916 – Inlet Hose $123.86*
15286316 – Inlet Hose Clamp $9.88*
19129914 – Inlet Pipe (IC Hot pipe) $280.05*
20813754 – Upper Bracket $14.47*
15238800 – Lower Bracket $56.88*
15937524 – Air Baffle $30.15**
25791143 – Support Brace Right $23.33**
25791142 – Support Brace Left $23.33**
*These parts are optional if you decide to go with a different solution for your Intercooler piping on the hot side like I did by building the piping using eBay components. However, these stock pieces will work on this build.
**The 2.0L Turbo Sky uses a different Air Baffle and supports in the front bumper to direct air properly towards the Intercooler and radiator. Hardware from the parts on the 2.4 can be reused to attach these new pieces to the body.
Total for Intercooler Parts: $1,411.06
Fuel System Parts
60# Fuel injectors (4) – $159.00 (I have priced these out from ZZP but waiting on a quote from DDM.)
Total for Fuel System Parts: $159.00
Unique parts that must be fabricated or modified
Universal 2.5” intercooler 8 pc Piping Kit Aluminum - $90.00 on eBay. You need to make sure the kit you get includes piping with 90 degree, 45 degree, and 75 degree elbows. This kit has pipes that are all 18” long, couplers, and t-clamps. This kit is used to build the cold pipe coming off the intercooler. I will be using it for that and the hot side so both sides match. May need more sections of pipe or to cut and weld some of this pipe for final fitment. I will also be using some of this for the new intake. Note the cost on this may increase as the build progresses.
2.5” OD Slot Style MAF sensor aluminum bung - $23.95 on eBay. This will be welded into the cold pipe coming off the intercooler.
JDM Universal manual boost controller - $12.45 on eBay. Used for controlling the boost pressure of the K04 turbo. Still need to check other boost controller options at this point. Not sold on this one yet.
Aluminum ¼’ hose nipple - $14.95 off eBay. This is to connect the vent line from the head of the 2.4 to the new intake tube. This will be welded on the intake tube.
Tune – Free to $600. Really depends on what you have and what you want to do. I have talked to DDM about this and they said they can sell me the tune for this but still need to work out details. If you already own HPTuners, this is basically free but if not then it will all depend on the options you choose.
Total for Unique Parts: $141.35 - $741.35
Total Build Cost (MSRP): $5,267.63 - $5,867.63
I know that some of this stuff you can get for much cheaper than the listed prices. This isn’t about the LEAST expensive build, just about ALL the parts you need to do this build. Many folks think “Hey, I have the turbo…now just get an intercooler and I’m done.” This list should show that there is a lot more to a turbo kit than a turbo and intercooler.
Just have a few things to pick up still:
Piping for the IC...have the stock LNF parts but have to do something custom for the Cold side and figured might as well do the hot side too. Will be getting the intake parts, MAF bung and getting that welded together and powder coated.
Injectors and Oil Return line from DDM.
Misc. nuts and bolts from the dealer plus the air baffle. All total, under $100 in dealer parts.
Pieces to build the water feed line T fitting into the front radiator line.
Boost controller...still need to do some research on this.
MAP sensor.
And of course the tune.
I must say though I enjoyed reading this post and it brings up a lot of good points I'll keep an eye on in my build. Now to go search the for sale adds here for injectors and oil return lines. LOL
Here is a list of parts (and prices) if you want to do this build yourself like I have. Now granted I have received a lot of my parts free of charge so keep in mind that unless you can do the same, getting the DDM kit is going to be MUCH cheaper. This really is for those with the 2.4 who are fortunate enough to be able to get a majority of the parts for free or nearly free. As you can see from this list of parts, it’s a lot more than just slapping on a turbo. All part numbers are GM part numbers unless otherwise specified. All GM part prices are MSRP and can be found for much less through online parts suppliers.
A couple other notes. I’m sure this list will change a bit as I do my build. I have not added parts here that you will reuse off your 2.4 such as manifold nuts or items that should be attached to pieces like the studs in the turbocharger. Also, I may have missed some things as this is a VERY big list but I’m almost certain I got everything. If I find something missing or I need to change something I will update this list. In addition, there are some items that are part of a previously listed section (such as intercooler) but that need to be custom fabricated so they are placed in their own section at the bottom of this list. Everything else are pretty much bolt on items. Finally, this does not include the cost of welding, cutting, forming of pipe ends or powder coating that I might do during the build.
Turbo Parts
12652494 – K04 Turbocharger $1,365.11
12609878 – Turbocharger to Catalytic Converter Gasket $17.37
12618586 – Turbocharger to Manifold Gasket $13.82
12589452 – Support Brace $20.82
12589408 – Heat Shield Turbo $32.58
12654315 – Oil Pipe Feed Line $100.56
11561946 – Bolt for Oil Line (2) $22.71 each
12611119 – Gasket for Oil Line (2) $7.40 each
12626611 – Water Feed Line $111.58
12618973 – Water Return Line $97.82
11561875 – Bolt for Water lines (3) $15.85 each
12626102 – Gasket for Water lines (3) $9.26 each
12602397 – Exhaust Manifold $482.74
12622668 – Manifold Gasket $11.30
12612286 – Heat Shield Manifold $35.55
12609268 – Catalytic Converter $877.57
15709703 – Nut for Cat to Turbo (4) $2.25 each
Oil Return Line - $89.99 (I have priced these out from ZZP but waiting on a quote from DDM.)
Total for Turbo Parts: $3,301.36
Water System Parts
12605853 – Thermostat Housing $128.51
90537471 – Thermostat Housing Gasket $23.28
12592401 – Outlet Pipe $49.58
90537379 – Outlet Pipe Seal (2) $15.17
Audi PN N90692901 – Audi A4 B8 2.0L Turbo Coolant T-fitting $12.00 at O'Riely*
1” to 3/4” barbed hose adaptor – $5.40 from Napa*
1’ section of 7/8” coolant line - $4.40 on eBay*
¾” to 3/8” barbed hose adaptor – apx $5.00 from Napa*
1’ section of ¾” coolant line - $3.52 on eBay*
¾-1” hose clamp (3) – apx $2.00*
½” hose clamp – apx $2.00*
*These parts are all to tie in the Water Feed line into the upper radiator hose. I found a couple 1’ to ½” adaptors but I don’t believe they are rated for engine coolant. Still looking for a better solution than this daisy chain of reducers.
Total for Water System Parts: $254.86
Intercooler Parts
25820725 – Intercooler $542.37
10386886 – Mount Bracket, Left $55.53
10386887 – Mount Bracket, Right $55.53
11609681 – Mount Bracket Bolt (2) $3.26 each
11589039 – Mount Bracket Bolt (4) $3.30 each
19129912 – Mount Bracket Insulator (2) $12.58 each
12595594 – Pipe Assembly $49.82
12615136 – 2 Bar MAP sensor $100.98
19129916 – Inlet Hose $123.86*
15286316 – Inlet Hose Clamp $9.88*
19129914 – Inlet Pipe (IC Hot pipe) $280.05*
20813754 – Upper Bracket $14.47*
15238800 – Lower Bracket $56.88*
15937524 – Air Baffle $30.15**
25791143 – Support Brace Right $23.33**
25791142 – Support Brace Left $23.33**
*These parts are optional if you decide to go with a different solution for your Intercooler piping on the hot side like I did by building the piping using eBay components. However, these stock pieces will work on this build.
**The 2.0L Turbo Sky uses a different Air Baffle and supports in the front bumper to direct air properly towards the Intercooler and radiator. Hardware from the parts on the 2.4 can be reused to attach these new pieces to the body.
Total for Intercooler Parts: $1,411.06
Fuel System Parts
60# Fuel injectors (4) – $159.00 (I have priced these out from ZZP but waiting on a quote from DDM.)
Total for Fuel System Parts: $159.00
Unique parts that must be fabricated or modified
Universal 2.5” intercooler 8 pc Piping Kit Aluminum - $90.00 on eBay. You need to make sure the kit you get includes piping with 90 degree, 45 degree, and 75 degree elbows. This kit has pipes that are all 18” long, couplers, and t-clamps. This kit is used to build the cold pipe coming off the intercooler. I will be using it for that and the hot side so both sides match. May need more sections of pipe or to cut and weld some of this pipe for final fitment. I will also be using some of this for the new intake. Note the cost on this may increase as the build progresses.
2.5” OD Slot Style MAF sensor aluminum bung - $23.95 on eBay. This will be welded into the cold pipe coming off the intercooler.
JDM Universal manual boost controller - $12.45 on eBay. Used for controlling the boost pressure of the K04 turbo. Still need to check other boost controller options at this point. Not sold on this one yet.
Aluminum ¼’ hose nipple - $14.95 off eBay. This is to connect the vent line from the head of the 2.4 to the new intake tube. This will be welded on the intake tube.
Tune – Free to $600. Really depends on what you have and what you want to do. I have talked to DDM about this and they said they can sell me the tune for this but still need to work out details. If you already own HPTuners, this is basically free but if not then it will all depend on the options you choose.
Total for Unique Parts: $141.35 - $741.35
Total Build Cost (MSRP): $5,267.63 - $5,867.63
I know that some of this stuff you can get for much cheaper than the listed prices. This isn’t about the LEAST expensive build, just about ALL the parts you need to do this build. Many folks think “Hey, I have the turbo…now just get an intercooler and I’m done.” This list should show that there is a lot more to a turbo kit than a turbo and intercooler.
Just have a few things to pick up still:
Piping for the IC...have the stock LNF parts but have to do something custom for the Cold side and figured might as well do the hot side too. Will be getting the intake parts, MAF bung and getting that welded together and powder coated.
Injectors and Oil Return line from DDM.
Misc. nuts and bolts from the dealer plus the air baffle. All total, under $100 in dealer parts.
Pieces to build the water feed line T fitting into the front radiator line.
Boost controller...still need to do some research on this.
MAP sensor.
And of course the tune.
I must say though I enjoyed reading this post and it brings up a lot of good points I'll keep an eye on in my build. Now to go search the for sale adds here for injectors and oil return lines. LOL
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