That's for that pressing update! And now we wait for the charge piping to come back from powder coating, it should look hot , red hot!

 

I believe there is someone in Ohio from the Cobalt SS group that tunes with HP and is good, for the life of me i cant remember who, because i was going to hit him up since i have HP tuners too. I also know Slowmotion down here in C-bus can tune too, dont know how good they are. Try Facebook Cobalt SS group here in Ohio and you should find a reputable tuner there if it helps, still looking forward to seeing it sometime down the road! too bad you couldnt get her done for the Good Guys show here a couple weeks back

 

Hello all! Dbeluscak’s wife here.

Just wanted to post an update about the charge pipes; we got them back and re-installed them. We are really pleased with how well they came out. Much better than the black “crinkle” finish they were originally. Having them redone was definitely worth the bit of extra time and money. I can’t wait to show them off at our first car show!

 

So I'll add to that. On top of reinstalling the charge piping, there's s bunch of stuff we took care of.

1: Intercooler officially fits inside the bumper. Had to make new mounting holes and chop about an inch from the bumper frame.

BEFORE



AFTER



2: Installed Mishimoto Baffled Oil Catch Can. The fittings it comes with were too large M20 X 5/8 hose. Our PCV lines are 3/8, no bueno. I found M20 X 1/2"NPT reducer bushings (at work of all places, not an easy thing to come by!). Then we did a home depot run for the 1/2 NPT X 90* 3/8 barb. All plumbed and catching oil (in theory!). This will create many questions so I'm currently working on a how to for catch cans.



3: Increased wastegate spring pressure. With nearly 700 miles on the new engine/turbo I figured it was well broken in and time to start playing. I had only the 8 lb spring installed initially. Now we're set to 23.6 lbs!

Now a question for the tuning crowd. I'll need some help with this one.

Finally got to test drive today. WOW! Still haven't really laid into it WOT. I was merging onto the freeway @45/50mph got into the pedal maybe 3/4 (just enough to downshift) the boost pulls like a freight train. I had my eye peeled to the boost gauge, my 256ET turbo literally tried breaking the needle off my guage!! I got right back off the throttle. It pegged the 30psi guage and would've kept pulling had I not let off.

Mind you, I have a manual boost controller that is still turned down to its LOWEST setting. I still have all the factory relays and solenoids that are "suppose" to contol the boost. Replumbed and in new locations but they're there.

I have ZZP's "canned" 385whp MBC tune. I do have the gen 3 motor but the boost should still be limited to 23-24 lbs. The tune "should" be spot on, everything I have I got it from ZZP.

I don't have HPT yet so I can't look at the tune, nor can I datalog it yet. But I do have a dyno appointment for this Wednesday, they will check the tune. I'm hoping I can get a copy so I can send it out to some knowledgeable friends. MississippISunburst had the same kit/tune and got retuned and is much happier.

Thanks in advance! Hopping over to "fastest auto thread" I used to want to catch the fastest HHR (2005HHR@12.39). Now I just want to catch Tim's (black Tara) new Vette! We're definitely mid 13's hoping to get to the track before the season is over.

 

Looks like I haven't updated on Harley's condition in a while! She's been hibernating out in the garage for a few months now. Well, I forged the cold today and finished removing parts so finally start piecing her back together. I guess I have to start where we left off. Seems I was hoping to make a dyno appointment. That never happened, all the issues I had with bumping and clanging prevented me from making that appointment. I can't blame ZZP for my issues, I could, but that gets us nowhere. Long story short, they sent parts for a manual transmission Cobalt. The "kit" claims to be for an HHR but it has nowhere to mount things like charge pipes or the intake. You have seen the trouble I went through stuffing the large intercooler into place. I don't know how this is even possible when you need to give them your VIN to place the order.

Problem #1: Downpipe re-circulation pipe was jammed against my transmission. Every time the car shifts or hits a bump the clanging would start. I didn't feel like practicing my TIG welds so I sent that back to ZZP for reworking. I had asked for a Wideband Gauge for my troubles but they were only willing to give me a $60 dollar discount. Which, don't get me wrong that's a discount. But I've got at least 20 extra hours of rework making everything fit. They did however install a 3rd O2 bung..which now I'll need to plug. This is puzzling because apparently the SS already has wideband?! I would've thought they would have informed me that this extra hole is unnecessary. Alas, I'll plug it and piggyback off the ECM for Wideband Tuning. The recirc pipe was so tight against the trans that it was a SERIOUS struggle to get the wastegate flange together. It ultimately leaked anyway..

As you can see the flex is useless because it's before the jam. What I had them do was concave the spot that's hitting the trans. Should give me an extra inch at least. The other pic is of the wastegate flange. That was as close as it would get. I had to use longer bolts just to get the V-Band clamp to close!



Problem #2: The Lower Charge pipe has always been a thorn in my side. I didn't realize how bad it was until I pulled everything apart. The connection between the LC and intercooler would blow apart under heavy load. This is where the manual trans comes into place. Apparently the engine sits at a slightly different angle than the automatic. I tried everything to make it align properly. ZZP's solution is to cut 6" off the 90 on the IC side. They sent me a long silicon 90* to replace it with. This is not really acceptable in my eyes. I've seen complete turbo systems made from nothing but silicon tubing, it's just not as effective or clean in my eyes. The other issue I didn't realize I was having is that it hits the mounting bolts for the AC compressor. While I'd love to do an AC delete, I don't think the wife will go for it! I'm afraid if I used the silicon I'd put a whole in it.

See the awkward angle its forced into the IC.


I can't get these to rotate no matter how hard I try...sorry!




Here's the dent from the AC mounting bolt, not nice!

Finally I have a serious problem with the PCV system. I wish ZZP would explain what you're doing with the PCV system by installing this kit. On a DI engine PCV is vital. I was worried they had me plug one of the ports off so that the wastegate would fit. Wastegates are cool, but not at the expense of dirty intake deposits. I have put WAY too many hours into researching the 2.0L PCV system too much to go into here. To get caught up check out; https://www.chevyhhr.net/forums/2-0l...tch-can-54350/

We've been hard at work for months over there and finally I can see light at the end of the tunnel. I tore the intake off of Harley tonight to see what 4000 miles looks like. It ain't pretty! Without modifying the intake manifold, the intake literally acts as a catch can! It isn't designed to keep oil deposits off my valves.. I did borescope the valves I could reach at 1400 miles. The walls of the head have got some serious buildup after only 4000 miles. LoL...I can't locate the borescope so the phone shots will have to suffice for now. (This rotate thing is really getting me, cant wait for HHR.net 2.0 Mike!)


You can see how clean the stems are on Cyls 1 and 4


Here's the intake, rings of very sticky oil on every imaginable surface. You can see where it kicks back from the gasket to each cylinder. That bugger in the middle is the notorious PCV valve I gently removed with a hammer!I know its hard to see, but there's already a pool forming inside the intake. You can see it running down the back. Oil is not suppose to be in there...this I'm sure of.




And here's where brake booster ties in. Again...oil, it's very sticky! Closely resembles molasses.. its also present on the intake tube that tied to the valve cover. Again..PCV realated


Well, there's a 15 pic limit. More on that intake tube later. I didn't get to the fun stuff we're doing yet but I suppose I'll add that later. Can't wait to start wrapping this project up. I have an HHR of my own that needs some TLC. Hopefully, The Joker and Harley make appearances this summer!

 

Wow you have some serious oil pooling in the intake.... You are right, that isn't good.

 

When I had the intake off of my 2.2L I noticed puddles in the catch basin and deposits in the ports.

 

Yep, you got it Don. The valves on the 2.2 were cleaner at 150k. No surprise, it has fuel going over them

 

Wow, with only 4,000 miles, that is alarming, to put it mildly. Any chance they gave you the wrong piston rings?

 

Alarming to say the least! This is what started the catch can thread. I knew it was an issue with direct injection. But seriously, if I just ran it I would assume my valves wouldn't fully shut after 10k, just like the import guy's.

Nope this is a GM assembled crate LDK. Hasn't been opened beyond the manifolds. Inherently I feel it's a bad design on GMs part. But that pressure had to go somewhere. Manufactures have to deal with stuff like regulations and guidelines as far as keeping everything "internal" which is why you don't see any factory blow off valves.