How to: LK9 manifold with lsj TB
 

Every one knows the problems with the lsj intake manifold. And those who go to a turbo setup have a few options to use or get rid of it. As of right now there are 2 aftermarket options to get rid of it. The Hahn and Vulcan intake manifold are both great pieces but they are up in the $600 range. The 2.2 and 2.4 manifolds would be a good fix but they dont cover A port on the lsj head. So, that leaves budget minded tuners to turn to things like the ATP sc delete kit and using the stock intake manifold in conjunction with it.

But, there is an alternative. An lk9 intake manifold from the engine of a Saab 93 2.0 bolts to an lsj because they share they same head. The part new from Saab with a gasket is only $150. It has equal length runners and is a compact design. But, it's not perfect. The LSJ throttle body doesn't bolt up. There is a solution and I can show you how to do it.

Here is the LK9 mani. in stock form. It has been marked to show you how much it needs to be enlarged.

http://i2.photobucket.com/albums/y1/...203091346a.jpg

Opened up a little

http://i2.photobucket.com/albums/y1/...0203091519.jpg

A comparison half way through with the TB spacer.

http://i2.photobucket.com/albums/y1/...203091519a.jpg

The final port opening.

http://i2.photobucket.com/albums/y1/...0205091618.jpg

After I opened up the intake port on the mani I had to concentrate on making the bolt holes line up. The threads on the LK9 mani are slightly inward compared to the lsj TB threads. I had the luxury or being able to use my ATP tb spacer to hold the TB off or the manifold. If you don't have one you will need to have a machine shop make one for you. It should not be a difficult job for any real machine shop.I recommend having them make the bolt holes match the manifold so that you don't have to modify them like me.


Here is the measure of how far you need to bring the bolt holes on the TB over to match the mani. I found that 1mm on either side worked.

http://i2.photobucket.com/albums/y1/...0203091523.jpg


This is a close up of them opened up.

http://i2.photobucket.com/albums/y1/...203091523a.jpg

You need to lop off some pieces to make the TB fit on the side. They are a vacuum port and a thread hole that you don't need.

http://i2.photobucket.com/albums/y1/...205091618a.jpg

The whole setup all together.

http://i2.photobucket.com/albums/y1/...0207090753.jpg

Hope you liked my how to.



Extra:: After you mount the Tb you will find that thew bolts don't fit thought he holes in the manifold. You will have to widen them slightly from the center. Do not move the center of the hole or you will have difficulty lining them up. I am just working a little at a time using one of the bolts from the old manifold as my design. You could also drill them out or helicoil the head and put a smaller bolt into it.

Awesome how-to! If I didn't just get my tax refund, I'd probably buy one of those manifolds!

nice dana will chime in for sure hes doing this also

Thank you I appreciate it. I've been back and forth buying a Hahn manifold but I couldn't help myself when I found out how cheap these were.

Looks awesome JC.

nice! ill deff be doing this also

Looks good man. Pulling your stock manifold off was a fun experience.

this is awesome, thanks for sharing the info maxim

one question though what do you mean about the TB bolts not fitting through the manifold, do the bolts bottom out in the mani holes before tightening against the surface of the TB or are they just different threads than the ones in the mani?

I think you need more black wrap on that charge piping. :) Looks good.

Thank You!!

The bolts for the throttle body to the manifold don't fit because they don't line up. The holes in the TB don't line up with the holes in the manifold. So, you have to widen the holes in the throttle body inward slightly to get them to line up with the holes on the manifold. I hope that answered your question.

Thank you!!

It's actually just a long piece of silicon. It's not wrap or anything, it's like a really long coupler. The bov is mounted to the motor and the IC is mounted to the frame so I figured I could use that to have some give when the motor moved.

oh alright, got ya thanks

maxim did you use the saab exhaust manifold too? just curious

No, I bought an E-Bay Cavalier manifold and modified it to work on a Cobalt. The Saab Manifold doesn't fit conventional turbos.

Perfect. Thanks

Thanks for the how to!

do all the sensors and lines, brake booster, map sensor, etc transfer over or do you need to accommodate them...haven't seen a clear pic of one to be able to tell

Bump

Nice, should be doing this soon. Would it be better to use the le5 or even the ls4 TB with that manifold, or is it even possible?

If you're interested I should have a LS4 tb slapped on a LK9 intake very soon.