I haven't been on here in a while, but I had an issue like what you describe. After MUCH frustration a fellow HHR guy saved the day. I copied my question and his response. After moving one vacuum line, everything worked. Terminator2 then tuned my setup to my liking. One note, I did not use a manual boost controller. Here's what my issue was:


mississippisunburst Wrote:
I am looking for some advice on how to get my new setup to respond. I had the zzp s256 kit installed as per their instructions and the car runs like crap. I have exhausted any help I would get from them. Their instructions say the wastegate will be controlled by the ecm. A vacuum line is run from the lower charge tube to the inlet port on the boost solenoid that came off the stock turbo. Another vacuum line is run from the outlet port on the solenoid to the bottom of the wastegate. Does this sound correct? My tuner (terminator2) can't make anything change through the ecm. Any thoughts you may have would be greatly appreciated. From one som hhrss to another, even if yours is covered up. Thanks

Mad Dr Phil wrote:

hey I'm always here to help where I have mine run is from just as they said the lower charge pipe to the front of the boost control solenoid the part that mounts on the turbo then from the top not the back porch you want to run from the top the one that sticks out 90 degrees from the from the rest of the ports that will then run to the bottom of your waste gate then from the top of the wastegate you want to just leave that open so that it doesn't have any kind of a disturbance of anything that should be what it is you also want to check what spring is in the wastegate you want between us five pound which is what the stock spring is I have a 15 pound in mine on a similar size wastegate and need about 65 to 70 percent duty cycle for it to function correctly


You are the man!!! vacuum line was not on the 90 degree part of the solenoid. Now back to tuning, thanks so much

 

Agreed, was "tongue in cheek" comment ! but download the manual at the end of one of my previous posts, & have sweet dreams of a 1,000 + HP ecotec under yer bonnet!

 

Jeez, ZZP had me leave the solenoid completely unhooked from vacuum. It's plugged in, but no vacuum lines going to it. I'm going to route as Tial suggests and see where that gets me. I'll be tuning soon. With some advice from CSS and HPT forums.

@Mississippi- is your pcv still plugged behind the wastegate? This was per ZZP instructions. It's really a bad idea to mess with our PCV system. I've got less than 4000 miles and serious coking on the intake and valves. We're working on a permanent solution over on the installing a catch can thread.
Check it out; https://www.chevyhhr.net/forums/2-0l...n-54350/page4/
Page 4 is a good place to start. ZZP has no consideration for longevity obviously. If I we're to keep driving I suspect by 10k miles I'd be losing compression through the intake valves. The engine comes with a 12,000 mile warranty that surely I voided by using aftermarket parts...nonetheless. Modifications NEED to be made to correct this. I, like yourself, have worn out my welcome with ZZP. These are my problems now. It's good to see you back, what's the show season look like this year? We definitely want to get out and about this spring. Maybe we can meet in the middle!

Made myself a tool so I can change the wastegate spring while it's still on the car.


I'm at 15.68lbs as of today. I'm hoping to get the back half of the motor together this weekend (manifold, turbo, downpipe) I can only hope the modifications that ZZP made to the downpipe keep it from rubbing the trans. If not, I'm not looking forward to the emails that follow...

 

ZZP sells parts. Some of them are nice parts. Their answer to every question is to buy more parts. I have a catch can on the shelf, but don't know where to install it. Too many opinions, no real evidence. I'm watching your thread for proof it works at all. So far, I've signed up for Super Chevy in Memphis in April and the Power Tour in June. Planning on Baton Rouge, Houston, Austin, Dallas, and Oklahoma City.

 

Been there done that, it would seem that most people who sell parts that is a common answer.

 

The real answer to that burning question of does it or doesn't it work is trial and error, not all setups are identical, no two engines are identical, close but not identical.
All things being equal, you should have the same results as the directions tell you, but then you are only trusting the author of those directions , confirmation it works involves installing and driving the car.
Trust me , I've had years of trial and error, and a huge garage sale a few years ago to clear away the what didn't work, parts and pieces!