ZZP LNF Cobalt Turbo Upgrade Note: These instructions are intended for installers with previous turbo installation experience. Some procedures will not be described in full detail. If you run into any installation issues or have trouble comprehending any of the procedures, please contact ZZPerformance or a qualified auto shop/technician to help you through the process. 1. Getting started: Unplug the MAF and remove the airbox lid as shown. 2. Remove the passenger side headlight.
3. Remove the plastic headlight bracket assembly. 4. Remove the passenger side tire for access to the airbox snorkel mounting tab. Inside the wheelwell, pull back the plastic liner and pry out the mounting clip.
5. Use a fuel line disconnect tool to unhook the braided hose from the plastic fitting shown. Remove the intake ducting from the turbo. Remove the upper charge tube from the turbo at this time. 6. Remove the factory downpipe from the exhaust manifold and catback.
7. Here is a view of the stock turbo for reference. Remove the heat shield from the top of the turbo. CAUTION! Make sure the engine is completely cooled and there is no pressure in the cooling system before performing the next step! Remove the oil feed line and 2 water lines from the center section of the turbo. Remove the PCV hose and the fitting(shown with arrow) from the valve cover. The fitting is pressed in, but will come loose by rotating and prying it outward. Plug this hole by threading in the 1/8 npt plug provided. Use a drop of Loctite on the threads. 8. Remove the support bracket from underneath the turbo. Remove the O2 housing from the stock turbo. Remove the stock turbo from the exhaust manifold. Remove the Exhaust manifold from the cylinder head.
9. Remove this heatshield from the motor mount and replace the bolt. 10. Remove the oil plug from the location shown and relocate it to where the factory oil line was originally connected. Install the new oil feed fitting in the open hole. Use a tiny amount of grey RTV where the fitting seats on the block.
11. Install the supplied bolt and washer to plug the coolant passage on the driver side rear of the motor, where the factory turbo water line was previously connected. 12. Install the new exhaust manifold to the head. Use the supplied nuts where the clearance is tight on the top studs. Use the supplied gasket and bolt the new turbo to the exhaust manifold.
13. Install the new oil drain fitting in the pan and connect to the turbo with the supplied hose clamps. 14. Install the turbo oil feed line between the feed fittings on the block and the turbo. Use the supplied clamp to keep the oil line away from the turbo exhaust housing. Install the wastegate and dump tube on the perch as shown. Make sure the dump tube does not contact any hoses or wiring below.
15. Install the primary(upper) O2 sensor into the downpipe. Install the downpipe using the supplied V-band clamp. 16. This pic shows the downpipe V-band connection and the wastegate dump tube (external dump).
17. Use the water fitting you removed from the back of the motor to replace the fitting on the front and configure as shown. 18. Install the 90 degree silicone coupler and intake tube. Attach the PCV hose as shown. Use the 2 silicone coupler provided to connect the turbo outlet to the 2 diameter tube provided. Reinstall the factory upper charge tube or optional ZZP charge tube at this time. This pic shows the intake set up for a remote mounted 50mm BOV.
19. Install the air filter on the intake tube. This pic shows the standard bypass valve configuration. Run a vacuum line from the port on the top of the intake to the bypass valve. (Re-use a factory vacuum line of the correct length) 20. ZZP upper charge tube with 50mm blow off valve option- Apply a thin film of grease on the BOV o-ring and mount the BOV to the charge tube with the V- band clamp provided. Run a vacuum line from the top of the intake to the BOV.
21. If installing our lower charge tube, remove the lower tube at this time. Remove the plastic vacuum tank shown here. You may also remove the bypass valve solenoid mounted to the top of the intake. 22. If you are switching to blow-through MAF with our 50mm blow off valve, install the MAF sensor in the lower charge tube at this time. Install the factory boost pressure sensor(stage 1 kits) or new 3 bar MAP sensor(stage 2 kits) in the lower charge tube. Wiring diagrams are provided with the stage 2 sensors. Solder the connections and use the heat-shrink tubing provided. Install the lower charge tube at this time. Lower charge tube installation shown from below with blow-through MAF and extension harness.
23. Find a suitable location to mount the boost control solenoid. Note- this is the solenoid originally mounted to the factory turbo. Connect a vacuum hose from the lower charge tube to the inlet port on the solenoid, next to the electrical plug. Run a vacuum hose from the outlet port shown to the bottom of the wastegate. Be sure to route the hose away from the exhaust manifold so that it does not melt. Leave the top wastegate fitting open to allow the top chamber to vent as the valve moves. 24. Stage 2 kit owners should install the new 3 bar MAP sensor on the intake as shown. Wiring diagrams are provided with the sensors. Solder the connections and use the heat-shrink tubing provided. 25. Install your new ECM at this time. It is located directly in front of the fuse box in the engine bay. 26. We recommend that you change your engine oil after this turbo kit installation. It is very easy for coolant or contaminates to enter the oil pan while the factory turbo is being removed.