All Engines: How To K04 Install
How To K04 Install
How To K04 Install
I am in no way shape or form responsible for any damages to you or your car
On that note let me know if I forgot anything
Feel free to ask questions
Parts Needed
1. LNF K04
2. LNF Turbo Manifold
3. LNF O2 Housing
4. LNF Downpipe
5. LNF Exhaust
6. 12592401 LNF Coolant Pipe
7. 12590275 LNF Thermostat Housing
8. 12605965 Turbo Engine Crankcase Ventilation Fitting
9. 12622404 LNF Oil Feed
10. 12625357 LNF Coolant feed Tube (just the part that bolts to the turbo)
11. 12618973 LNF Coolant Return Tube
12. 12589452 LNF Turbo & O2 Housing Brace
13. 12611448 LNF Mounting Panel For Turbo and O2 Housing Brace
14. 11561875 (QTY 3) Coolant Banjo Bolts
15. 11561946 (QTY 2) Oil Banjo Bolts
16. (QTY 11) M14 Banjo Crush Washers
17. LNF Intake (stock or aftermarket)
18. 12622668 Exhaust manifold Gasket
19. 12618586 Turbo mounting gasket
20. 12609878 O2 Housing Gasket
21. 12609878 Down Pipe Gasket
22. -6AN Hose (Summitracing.com part number SUM-230603)
23. -6AN Hose End (Summitracing.com part number FRA-112006-BL)
24. -6AN Hose Clamp (Summitracing.com part number FRA-280206)
25. 1/4 NPT to -6an Fitting (Summitracing.com part number SUM-220647B)
26. 1/2 NPT to -10an Fitting (Summitracing.com part number SUM-240104B)
27. -10AN Hose End (Summitracing.com part number SUM-220086B)
28. (Treadstone performance.com) Treadstone Performance EFR oil return Fitting
29. (Treadstone performance.com) (QTY 3ft) Goodridge 200 series hose 10AN hose
30. ZZP Turbo Oil Pan
31. Vacuum Hose (for valve cover to intake)
32. Vacuum Plugs
33. Boost Controller
34. Larger Injectors 42 or Bigger
35. ½ brass tube coupler (heater hose)
36. Worm gear clamps (heater hose)
Tools/Materials Needed
1. Tool Set
2. Allen Key Set
3. Torque Wrench
4. ¼ NPT Tap
5. 7/16 drill Bit
6. Cut off saw
7. Oxygen sensor Socket
8. Anti seize compound (Everything
)
9. Pipe thread Tape
10. Silicone Sealant (Oil Pan)
11. Silicone Sealant (Thermostat Housing)
12. Oil
13. Coolant
14. Cobalt 08-10 Repair Manual
1) Ok the first thing that needs to be done is to jack up the car and put stops behind the rear wheels
2) Then you need to remove the entire exhaust manifold downpipe exhaust I’m not going to go into how to do this and quite frankly if you don’t know how to do this then you should not even be looking at this thread.
3) Then you need to drain the coolant all of the coolant and remove this plug from the water pump housing
4) Now remove the heater core hoses
5) Next you need to remove the thermostat housing and coolant tube so unbolt it and be careful not to break the seals you will be reusing them
6) Now is the perfect time to swap the thermostat and coolant temp sensor over to the new housing I suggest using silicone sealant to seal up the housing of the thermostat but only use just enough and be sure to use sealant specifically for use with coolant
7) Ok next you have to remove the cover plate of the water pump, (it’s what the rear coolant pipe plugs into and the housing that the rear coolant drain plug is on) once again be careful with the seals as you will be reusing them the bolts circled in red need to be removed to do this
8) Now you need to drill the hole for the rear coolant plug out using the 7/16 bit and then tap it with the ¼ npt tap
9) Then once you have fully tapped the hole and have cleaned out any metal shavings you need to reinstall the cover plate
10) Then you need to remove the plug for the oil feed
11) Then install the LNF coolant pipe and thermostat housing
12) Next install the bracket for the turbo brace the top bolt is 10mm x 1.5 thread by 20mm long bottom is the same just 25mm long
I am in no way shape or form responsible for any damages to you or your car
On that note let me know if I forgot anything
Feel free to ask questions
Parts Needed
1. LNF K04
2. LNF Turbo Manifold
3. LNF O2 Housing
4. LNF Downpipe
5. LNF Exhaust
6. 12592401 LNF Coolant Pipe
7. 12590275 LNF Thermostat Housing
8. 12605965 Turbo Engine Crankcase Ventilation Fitting
9. 12622404 LNF Oil Feed
10. 12625357 LNF Coolant feed Tube (just the part that bolts to the turbo)
11. 12618973 LNF Coolant Return Tube
12. 12589452 LNF Turbo & O2 Housing Brace
13. 12611448 LNF Mounting Panel For Turbo and O2 Housing Brace
14. 11561875 (QTY 3) Coolant Banjo Bolts
15. 11561946 (QTY 2) Oil Banjo Bolts
16. (QTY 11) M14 Banjo Crush Washers
17. LNF Intake (stock or aftermarket)
18. 12622668 Exhaust manifold Gasket
19. 12618586 Turbo mounting gasket
20. 12609878 O2 Housing Gasket
21. 12609878 Down Pipe Gasket
22. -6AN Hose (Summitracing.com part number SUM-230603)
23. -6AN Hose End (Summitracing.com part number FRA-112006-BL)
24. -6AN Hose Clamp (Summitracing.com part number FRA-280206)
25. 1/4 NPT to -6an Fitting (Summitracing.com part number SUM-220647B)
26. 1/2 NPT to -10an Fitting (Summitracing.com part number SUM-240104B)
27. -10AN Hose End (Summitracing.com part number SUM-220086B)
28. (Treadstone performance.com) Treadstone Performance EFR oil return Fitting
29. (Treadstone performance.com) (QTY 3ft) Goodridge 200 series hose 10AN hose
30. ZZP Turbo Oil Pan
31. Vacuum Hose (for valve cover to intake)
32. Vacuum Plugs
33. Boost Controller
34. Larger Injectors 42 or Bigger
35. ½ brass tube coupler (heater hose)
36. Worm gear clamps (heater hose)
Tools/Materials Needed
1. Tool Set
2. Allen Key Set
3. Torque Wrench
4. ¼ NPT Tap
5. 7/16 drill Bit
6. Cut off saw
7. Oxygen sensor Socket
8. Anti seize compound (Everything
)9. Pipe thread Tape
10. Silicone Sealant (Oil Pan)
11. Silicone Sealant (Thermostat Housing)
12. Oil
13. Coolant
14. Cobalt 08-10 Repair Manual
1) Ok the first thing that needs to be done is to jack up the car and put stops behind the rear wheels
2) Then you need to remove the entire exhaust manifold downpipe exhaust I’m not going to go into how to do this and quite frankly if you don’t know how to do this then you should not even be looking at this thread.
3) Then you need to drain the coolant all of the coolant and remove this plug from the water pump housing
4) Now remove the heater core hoses
5) Next you need to remove the thermostat housing and coolant tube so unbolt it and be careful not to break the seals you will be reusing them
6) Now is the perfect time to swap the thermostat and coolant temp sensor over to the new housing I suggest using silicone sealant to seal up the housing of the thermostat but only use just enough and be sure to use sealant specifically for use with coolant
7) Ok next you have to remove the cover plate of the water pump, (it’s what the rear coolant pipe plugs into and the housing that the rear coolant drain plug is on) once again be careful with the seals as you will be reusing them the bolts circled in red need to be removed to do this
8) Now you need to drill the hole for the rear coolant plug out using the 7/16 bit and then tap it with the ¼ npt tap
9) Then once you have fully tapped the hole and have cleaned out any metal shavings you need to reinstall the cover plate
10) Then you need to remove the plug for the oil feed
11) Then install the LNF coolant pipe and thermostat housing
12) Next install the bracket for the turbo brace the top bolt is 10mm x 1.5 thread by 20mm long bottom is the same just 25mm long
13) You can now proceed to install the turbo manifold make sure you put anti seize compound on the studs and torque the manifold bolts to the proper spec
14) Proceed to place the Turbo mounting gasket over the 4 bolts on the manifold
15) Next thing to do is drain the oil and remove the valve cover which will help make installing the turbo much easier refer to instructions in the cobalt service manual for instructions on how to do both
16) Next it’s time to install the turbo you will have to lift the turbo into place from up under the car and make sure you tighten the turbo bolts to spec
17) Now it’s time to take the oil pan off and install the ZZP oil pan same as above if you don’t know how to do this you’re in the wrong thread
18) Install the Treadstone performance EFR oil return fitting into the turbo
19) Now install the straight -10 an fitting with the ½ npt end into the oil pan bung just for mock up purposes
20) Now install one eng of the 3ft Goodridge 200 series hose 10AN hose into the 45* -10AN fitting
21) Once that is done temporally install the 45*fitting and hose to the Treadstone performance EFR oil return flange and observe the hose length needed to fit to the -10an fitting already installed in the oil pan, mark the length then remove the 45* fitting from the flange and remove the oil pan fitting them then cut the hose to the appropriate length and assemble the parts them put pipe thread tape on the return flange nipple and on the threads of the fitting that go into the oil pan and install the hose
Here is a picture to show where each oil and coolant line should fit into the turbo
22) Now you need to install the coolant return one end goes to the thermostat housing the other goes to the hole labeled in the above picture as coolant return and the below picture circled in red remember to use the crush washers, you should be using 2 for each banjo bolt
23) Then proceed to install the oil feed line, one end bolts into place where you removed the plug on the block and the other goes to the hole goes to the top port on the turbo
24) Ok so now it’s time to install the bracket for the turbo like so
25) Then once that is taken care of we can install the coolant feed In doing so install the -6an braded hose into the 120*-6an fitting
26) Then install the upper coolant feed tube to the turbo it is # 10 in the following picture please note the orientation and assembly process of the coolant lines also note that I specified using crush washers instead of the gm gasket for the banjo fittings the reason for this is both expense and the ability to get them locally if you in the future need to redo or alter your setup
27) Now that the upper coolant feed tube is installed into the turbo, screw the ¼ npt end of the 120* fitting into the water pump housing for mock up purposes like so
28) Measure the hose from the fitting to the upper coolant hose now remove the fitting and hose from the water pump housing and cut remember measure twice cut once (also you don’t have to remove the braded hose from the fitting while you cut
29) Apply pipe thread tape to the fitting and reinstall in place for the final time make sure it is in and tight you don’t want this leaking
30) Then install the -6an hose clamp onto the end of the braded hose and slip the hose onto the upper coolant tube and tighten the hose clamp in place
31) Now install the new O2 housing gasket into place (if you’re using a “used” part make sure to remove all of the old gasket) then install the O2 housing, make note you will have to lift it up in to place from under the car there are 4 studs and the lower one right next to the engine is the hardest to get the nut onto, I also suggest putting anti seize compound on the studs before install
Oh and the reason you need to completely remove the heater core hose, is because it gets in the way of the O2 housing and needs to be modified so it does not melt
This is how I modified mine
32) Now install the Down Pipe Gasket into the down pipe
33) Prep the O2 housing for the down pipe by putting anti seize compound onto the studs and the entire mating surface of the o2 housing so that the O2 housing and down pipe don’t stick together
34) Now it’s time to install the down pipe what I did was placed the down pipe onto the studs and put the lower 2 nuts on loosely and then jacked the other end of the downpipe up with a jack then tighten and install the remaining nuts
35) Go ahead and install the LNF exhaust or whatever other means you came up with for an exhaust (I personally just welded a 2.5” 2 bolt flange onto the LNF down pipe so I could use the exhaust I already had on the car) but for those who can’t do that just buy an LNF exhaust
36) Now it’s time to remove the oxygen sensors from the old exhaust this is what the oxygen sensor socket is for
37) Now prep the oxygen sensors for install by applying anti seize compound onto the threads only
38) Install the oxygen sensors and remember to connect the electrical connectors
39) Now add oil and coolant
40) Install your boost controller (you will need one stock waste gate spring is 4-5 psi)
41) Connect a boost line from the intake manifold to the bypass valve on the turbo
42) Install the intake
The intercooler piping and all other parts of a turbo setup will be different for all setups so I’m not even going to dabble with that
14) Proceed to place the Turbo mounting gasket over the 4 bolts on the manifold
15) Next thing to do is drain the oil and remove the valve cover which will help make installing the turbo much easier refer to instructions in the cobalt service manual for instructions on how to do both
16) Next it’s time to install the turbo you will have to lift the turbo into place from up under the car and make sure you tighten the turbo bolts to spec
17) Now it’s time to take the oil pan off and install the ZZP oil pan same as above if you don’t know how to do this you’re in the wrong thread
18) Install the Treadstone performance EFR oil return fitting into the turbo
19) Now install the straight -10 an fitting with the ½ npt end into the oil pan bung just for mock up purposes
20) Now install one eng of the 3ft Goodridge 200 series hose 10AN hose into the 45* -10AN fitting
21) Once that is done temporally install the 45*fitting and hose to the Treadstone performance EFR oil return flange and observe the hose length needed to fit to the -10an fitting already installed in the oil pan, mark the length then remove the 45* fitting from the flange and remove the oil pan fitting them then cut the hose to the appropriate length and assemble the parts them put pipe thread tape on the return flange nipple and on the threads of the fitting that go into the oil pan and install the hose
Here is a picture to show where each oil and coolant line should fit into the turbo
22) Now you need to install the coolant return one end goes to the thermostat housing the other goes to the hole labeled in the above picture as coolant return and the below picture circled in red remember to use the crush washers, you should be using 2 for each banjo bolt
23) Then proceed to install the oil feed line, one end bolts into place where you removed the plug on the block and the other goes to the hole goes to the top port on the turbo
24) Ok so now it’s time to install the bracket for the turbo like so
25) Then once that is taken care of we can install the coolant feed In doing so install the -6an braded hose into the 120*-6an fitting
26) Then install the upper coolant feed tube to the turbo it is # 10 in the following picture please note the orientation and assembly process of the coolant lines also note that I specified using crush washers instead of the gm gasket for the banjo fittings the reason for this is both expense and the ability to get them locally if you in the future need to redo or alter your setup
27) Now that the upper coolant feed tube is installed into the turbo, screw the ¼ npt end of the 120* fitting into the water pump housing for mock up purposes like so
28) Measure the hose from the fitting to the upper coolant hose now remove the fitting and hose from the water pump housing and cut remember measure twice cut once (also you don’t have to remove the braded hose from the fitting while you cut
29) Apply pipe thread tape to the fitting and reinstall in place for the final time make sure it is in and tight you don’t want this leaking
30) Then install the -6an hose clamp onto the end of the braded hose and slip the hose onto the upper coolant tube and tighten the hose clamp in place
31) Now install the new O2 housing gasket into place (if you’re using a “used” part make sure to remove all of the old gasket) then install the O2 housing, make note you will have to lift it up in to place from under the car there are 4 studs and the lower one right next to the engine is the hardest to get the nut onto, I also suggest putting anti seize compound on the studs before install
Oh and the reason you need to completely remove the heater core hose, is because it gets in the way of the O2 housing and needs to be modified so it does not melt
This is how I modified mine
32) Now install the Down Pipe Gasket into the down pipe
33) Prep the O2 housing for the down pipe by putting anti seize compound onto the studs and the entire mating surface of the o2 housing so that the O2 housing and down pipe don’t stick together
34) Now it’s time to install the down pipe what I did was placed the down pipe onto the studs and put the lower 2 nuts on loosely and then jacked the other end of the downpipe up with a jack then tighten and install the remaining nuts
35) Go ahead and install the LNF exhaust or whatever other means you came up with for an exhaust (I personally just welded a 2.5” 2 bolt flange onto the LNF down pipe so I could use the exhaust I already had on the car) but for those who can’t do that just buy an LNF exhaust
36) Now it’s time to remove the oxygen sensors from the old exhaust this is what the oxygen sensor socket is for
37) Now prep the oxygen sensors for install by applying anti seize compound onto the threads only
38) Install the oxygen sensors and remember to connect the electrical connectors
39) Now add oil and coolant
40) Install your boost controller (you will need one stock waste gate spring is 4-5 psi)
41) Connect a boost line from the intake manifold to the bypass valve on the turbo
42) Install the intake
The intercooler piping and all other parts of a turbo setup will be different for all setups so I’m not even going to dabble with that
Last edited by Axelthered05; Sep 30, 2012 at 05:14 PM. Reason: Automerged Doublepost
Thread
Thread Starter
Forum
Replies
Last Post
Delta coupe
Pictures & Videos
1
Sep 30, 2015 08:11 AM
