supercharger project
 

I ordered the stage 2 zzp supercharger kit from zzperformance .com mid august. The kit comes with almost everything you need to supercharge the hhr or cobalt except the tune.
The intake manifold
https://www.chevyhhr.net/gallery/fil...0923223957.jpg
The blower
https://www.chevyhhr.net/gallery/fil...0923223575.jpg
The first thing my dad and I started was mounting the intercooler. The intercooler is fairly large and won't fit under the stock 2.2 front fascia so we had to cut off the bottom lip of the bumper.
Here it is mounted before the fascia was put on
https://www.chevyhhr.net/gallery/fil...0923206350.jpg
This is the intercooler pump and the 2 hoses that connect to it.
https://www.chevyhhr.net/gallery/fil...0923218584.jpg
After we got the intercooler on we took out my old weapon r intake and the entire intake manifold and here is where the problems began. ZZP hadn't shipped us the lower manifold support bracket so we were stuck and culdn't do anything. I went to chevrolet and picked one up and then after I had bought zzp told us it wasn't necessary. It probably wasn't needed but I liked having just because the whole assembly would put alot of strain on the manifold bolts.
Here is the manifold installed
https://www.chevyhhr.net/gallery/fil...0923219244.jpg
After a little struggle trying to get the manifold worked down in there we were back on track. While we were waiting on the bracket we installed the new colder spark plugs and 60# injectors no problems. now for the fun part.
https://www.chevyhhr.net/gallery/fil...0923212979.jpg
Mounted the blower and installed the new throttlebody
https://www.chevyhhr.net/gallery/fil...0923218902.jpg
The top TB is stock for 2.2 and the other one is the lsj throttlebody. The lsj is noticeably bigger.
Now the next big problem was the belt we tried to acces the release the the little hole in the passengers side wheel well but no luck. We tried everything we could think of even a special tool my dad had wouldn't work so in the end we had to take the engine mount out to get to the release. but we got the thing routed and then the installation was almost done
https://www.chevyhhr.net/gallery/fil...0923215534.jpg
we re-installed the engine mount and took it off the jacks and finished the installation by filling the intercooler and re-wiring the TAC. but this is what gave us the most trouble outside the tune. the first tie we re-wired it the car started idle extremely rough and then the revs just took off. after finally fnding the correct sequence it was good to go. we drove off and it pulled hard. After a couple days reality set in. The tune was way too lean and our ghetto air intake sucked
https://www.chevyhhr.net/gallery/fil...0923218177.jpg
So after a long 2 month battle trying to get trifecta to send me a retune I gave up and took the car to a local dyno shop in bowie called behe performance. They got the car running better but due to my stock clutch giving at the dyno could only do so much. So far the car is at 250 whp/236 wtq with a slipping clutch. After this I got the stage 2 kevlar clutch with fidanza lightened flywheel from zzp broke it in for 1000 miles and now I just need to take it back to behe to finish the tune.
https://www.chevyhhr.net/gallery/fil...0923198970.jpg
https://www.chevyhhr.net/gallery/fil...0923200853.jpg
The results from this mod are crazy 100 hp overstock and the tunes not even finished. The car also has a full exhaust from magnaflow including zzp midlength header and downpipe so it's loud.
New Spectre intake
https://www.chevyhhr.net/gallery/fil...6057318907.jpg
https://www.chevyhhr.net/gallery/fil...6057319750.jpg
https://www.chevyhhr.net/gallery/fil...6057320269.jpg
I plan on putting a twm short throw shifter in and getting a ss front clip then this spring i'll be rtuning and doing supension work on it and then it'll be done!!!
Happy holidays,
Michael

Very cool. Are going to do something with that front bumper to help keep the water in the heat exchanger? It would suck to have a rock with a bad attitude decide to jump up and put a hole in it.

:thumb:

Yea that's why im getting the ss front bumper plus you can't see it in the picture bit the hoses for the fluid bends the driver's side tic tac up just a little and it's bothering the heck out of me

If you havent already found one, try here. :thumb:

http://www.autobodyfit.com/products-...=2008&limit=90

Awesome! That's for the write up and the pics. I'm also looking forward to A & P's blower install.

I plan on ordering the zzp kit myself when I have some play money and personally, I like the look of the exposed intercooler. Although it may not be practical for a daily driver.

What is the purpose of an intercooler? I thought it cooled the air entering the intake, but I see the air filter on top of motor. Looks like it would suck hot air.

Thanks,

The intercooler does lower charge temps before entering the manifold. That's why it sits low and in front of the radiator. What you are looking at is the air filter which will suck in some of the underhood heat, but it will not have much of an affect on performance or the intercoolers job of lowering charge temps.

In the case of this supercgarger I believe it is all water cooling. If you look at the close up pic of the cooler where it shows the hoses you will see that those are water lines and there is a pump connected inline. If you look at the lower manifold in the pic below you can see the two water nipples that connects to those hoses. The pump can be seen in this pic at the tip of the supercharger pulley. In the second pic you can see that the air is drawn thru the filter, on thru the maf, then into he throttle body. That cooler never sees that actual air that goes into the engine.

https://www.chevyhhr.net/gallery/fil...0923218584.jpg

http://shop.zzperformance.com/store/...&bw=600&bh=600

http://shop.zzperformance.com/store/...&bw=600&bh=600

The heat exchanger is plumbed up to the intake manifold. It cools the air after the supercharger. The HE cools the water after it pulls heat from the air passing through the IM which has its own heat exchanger(laminova). Check out pictures and info on the LSJ intake manifold for a better understanding. This setup does not use a typical intercooler(air to air) which is commonly seen on TC setups.