How to: LK9 manifold with lsj TB - Cobalt SS Network

ADVANCED Performance Modifications For advanced modification topics only.

How to: LK9 manifold with lsj TB

Old 02-07-2009, 09:12 AM
  #1  
Senior Member
Thread Starter
 
Maxim_X's Avatar
 
Join Date: 10-14-06
Location: New Bedford, MA
Posts: 2,318
Thanks: 0
Thanked 0 Times in 0 Posts
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.

Last edited by Maxim_X; 02-09-2009 at 06:47 PM.
Maxim_X is offline  
Old 02-07-2009, 12:20 PM
  #2  
Senior Member
 
Blown 4-banger's Avatar
 
Join Date: 04-03-06
Location: Mesa, AZ
Posts: 7,571
Thanks: 0
Thanked 0 Times in 0 Posts
Awesome how-to! If I didn't just get my tax refund, I'd probably buy one of those manifolds!
Blown 4-banger is offline  
Old 02-07-2009, 12:30 PM
  #3  
Senior Member
iTrader: (4)
 
glen229's Avatar
 
Join Date: 06-20-08
Location: S. Easton, Ma
Posts: 6,173
Thanks: 0
Thanked 1 Time in 1 Post
nice dana will chime in for sure hes doing this also
glen229 is offline  
Old 02-07-2009, 04:17 PM
  #4  
Senior Member
Thread Starter
 
Maxim_X's Avatar
 
Join Date: 10-14-06
Location: New Bedford, MA
Posts: 2,318
Thanks: 0
Thanked 0 Times in 0 Posts
Originally Posted by Blown 4-banger View Post
Awesome how-to! If I didn't just get my tax refund, I'd probably buy one of those manifolds!
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.
Maxim_X is offline  
Old 02-07-2009, 04:20 PM
  #5  
Banned
iTrader: (39)
 
Join Date: 08-30-05
Location: New Hampshire
Posts: 18,570
Thanks: 0
Thanked 0 Times in 0 Posts
Looks awesome JC.
mkulrey13 is offline  
Old 02-08-2009, 12:15 AM
  #6  
Senior Member
iTrader: (1)
 
Dayta's Avatar
 
Join Date: 12-09-06
Location: MA
Posts: 5,431
Thanks: 0
Thanked 0 Times in 0 Posts
nice! ill deff be doing this also
Dayta is offline  
Old 02-16-2009, 07:41 PM
  #7  
Senior Member
Thread Starter
 
Maxim_X's Avatar
 
Join Date: 10-14-06
Location: New Bedford, MA
Posts: 2,318
Thanks: 0
Thanked 0 Times in 0 Posts
Maxim_X is offline  
Old 02-16-2009, 07:47 PM
  #8  
Senior Member
 
Join Date: 06-28-06
Location: No man's land
Posts: 1,890
Thanks: 0
Thanked 0 Times in 0 Posts
Looks good man. Pulling your stock manifold off was a fun experience.
06blackSC is offline  
Old 02-20-2009, 09:55 AM
  #9  
Member
iTrader: (1)
 
Join Date: 12-25-07
Location: Windsor Ontario
Posts: 291
Thanks: 0
Thanked 0 Times in 0 Posts
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?
05sattyredline is offline  
Old 02-20-2009, 10:06 AM
  #10  
Senior Member
iTrader: (1)
 
Join Date: 03-06-06
Location: MO
Posts: 11,666
Thanked 62 Times in 56 Posts
I think you need more black wrap on that charge piping. Looks good.
umrdyldo is offline  
Old 02-20-2009, 04:10 PM
  #11  
Senior Member
Thread Starter
 
Maxim_X's Avatar
 
Join Date: 10-14-06
Location: New Bedford, MA
Posts: 2,318
Thanks: 0
Thanked 0 Times in 0 Posts
Originally Posted by 05sattyredline View Post
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?

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.

Originally Posted by umrdyldo View Post
I think you need more black wrap on that charge piping. Looks good.
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.
Maxim_X is offline  
Old 02-20-2009, 06:25 PM
  #12  
Member
iTrader: (1)
 
Join Date: 12-25-07
Location: Windsor Ontario
Posts: 291
Thanks: 0
Thanked 0 Times in 0 Posts
oh alright, got ya thanks

maxim did you use the saab exhaust manifold too? just curious
05sattyredline is offline  
Old 02-20-2009, 08:31 PM
  #13  
Senior Member
Thread Starter
 
Maxim_X's Avatar
 
Join Date: 10-14-06
Location: New Bedford, MA
Posts: 2,318
Thanks: 0
Thanked 0 Times in 0 Posts
Originally Posted by 05sattyredline View Post
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.
Maxim_X is offline  
Old 05-22-2009, 12:20 PM
  #14  
Junior Member
 
Join Date: 08-04-08
Location: Waste Allis Wisconsin
Posts: 375
Thanks: 0
Thanked 0 Times in 0 Posts
Perfect. Thanks
LLAMA is offline  
Old 07-06-2010, 12:31 AM
  #15  
Senior Member
 
Join Date: 04-13-09
Location: WI
Posts: 1,450
Thanks: 0
Thanked 0 Times in 0 Posts
Thanks for the how to!
cobaltguy889 is offline  
Old 12-02-2010, 12:13 AM
  #16  
Banned
iTrader: (2)
 
Join Date: 06-03-10
Location: HBG/Hanover
Posts: 6,919
Thanks: 0
Thanked 0 Times in 0 Posts
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
05Slowline is offline  
Old 12-02-2010, 04:52 PM
  #17  
Banned
iTrader: (2)
 
Join Date: 06-03-10
Location: HBG/Hanover
Posts: 6,919
Thanks: 0
Thanked 0 Times in 0 Posts
Bump
05Slowline is offline  
Old 10-02-2014, 11:35 AM
  #18  
New Member
iTrader: (4)
 
Join Date: 10-16-11
Location: Alamosa Colorado
Posts: 159
Thanks: 0
Thanked 0 Times in 0 Posts
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
droponikz is offline  
Old 07-22-2016, 01:20 AM
  #19  
New Member
 
Join Date: 07-22-16
Location: Ohio
Posts: 1
Thanks: 0
Thanked 0 Times in 0 Posts
Originally Posted by droponikz View Post
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.
DavidsBlueBalt is offline  
Related Topics
Thread
Thread Starter
Forum
Replies
Last Post
06MetallicBalt
Mid East
7
06-14-2016 02:17 PM
Supercharged06SS
08-10 SS Turbocharged General Discussion
20
02-08-2016 06:14 PM
KMO43
Front Page News
34
01-12-2016 12:01 AM
Jesse
Parts
15
10-13-2015 09:32 PM
KMO43
Featured Car Showcase
37
09-27-2015 08:53 PM


Thread Tools
Search this Thread
Quick Reply: How to: LK9 manifold with lsj TB


Contact Us Archive Advertising Cookie Policy Privacy Statement Terms of Service

© 2019 MH Sub I, LLC dba Internet Brands

We are a participant in the Amazon Services LLC Associates Program, an affiliate advertising program designed to provide a means for us to earn fees by linking to Amazon.com and affiliated sites.