How to: LK9 manifold with lsj TB
02-07-2009, 09:12 AM
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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.
Opened up a little
A comparison half way through with the TB spacer.
The final port opening.
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.
This is a close up of them opened up.
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.
The whole setup all together.
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.
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.
Opened up a little
A comparison half way through with the TB spacer.
The final port opening.
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.
This is a close up of them opened up.
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.
The whole setup all together.
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.
Last edited by Maxim_X; 02-09-2009 at 06:47 PM.
02-07-2009, 04:17 PM
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02-20-2009, 09:55 AM
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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?
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?
Looks good.
02-20-2009, 04:10 PM
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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?
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?
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.
02-20-2009, 08:31 PM
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10-02-2014, 11:35 AM
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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?
Last edited by droponikz; 10-02-2014 at 02:38 PM. Reason: additional question
07-22-2016, 01:20 AM
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