Z54 install for 2008 2.2 L61

[SwerveMonkey]

Starting the thread now with planning and updates to follow... any advice from the experienced is always welcome ;-)

This post: acquired used Z54 from fellow Goblin Builder; research has begun on progress path toward full installation.

EDIT: minutia and small ramblings can be found in main build thread > here < but all findings and lessons learned will be posted here

 

[SwerveMonkey]

Initially I was going to wait until the end of Autumn to start on the turbo portion of the build. was hoping to have all my parts ready but it seems as though I have found a new reason to just get started anyway...
I'm noticing the muffler is cracked at the flange.
More parts are needed and still studying up...
Thankfully Bar-Air already did the heavy lifting in his post ---> Normal Aspirated Ecotec (TURBOCHARGED build)

I may eventually also completely rebuild the kit and replace as needed in the winter ❄

 

[SwerveMonkey]

Still doing a lot of research before diving into this...

looking back in the forums, I am glad to see that I am re-inventing the wheel so to speak.

Others may have different ideas, but this is what I have collected over the years for a DIY turbo kit for my L61. It should get you started. That said, even a NA 2.2L Goblin with an automatic transmission is a lot of fun, regardless of being driven on the street, road course, or autox.

some slight changes to the list i am going by currently, with cross outs for items attained:
• exhaust manifold and turbo
• Oil and coolant lines
• LNF/LDK/LHU coolant crossover pipe
• Charge air cooler and plumbing (A2A for simplicity)
• Injectors
• Fuel management (e.g., HPTuners)
• Wideband sensor/controller

still gather the bits, but looking to do a minimum setup to learn what is needed.
I'm not trying to do this absolutely RIGHT, I'm just in it for the challenge of making it work
DesertSasqwatch pointed out what I had in mind as goals already...

You do realize that without upgrading any of the 2.2 engine internals you are limited to 5 PSI boost and about 230 HP...

 

[ah.b.normal]

5# boost limit? That is only if you want to drive that L61 forever. Remember, IF you're not afraid of blowing it up the limits change.(One of my donors had an L61 that PO over boosted until it split cylinder #3. I am keeping the remains around for further research. Sometimes carnage is enlightening, some times it is just a mess.) You "wrecked" a car to build a Goblin, maybe this is just your next bit of destructive testing? I am surrounded by L61's so your results can only help me. Thanks in advance!

 

[ah.b.normal]

Desert Sasqwatch said:
You do realize that without upgrading any of the 2.2 engine internals you are limited to 5 PSI boost and about 230 HP...

On the other hand, You do realize that WITH upgrading SOME/MOST? of the 2.2 engine internals you are NOT limited to 5 PSI boost and about 230 HP... come on, it's a 2.2, common as dirt, have some fun, these ain't Rembrandt's and Monet's.
Or maybe a 2.4 with forged crank and pistons, floating wrist pins, piston squirters and 4 Hot Rods, O ringed block, MLS head gasket, head and bottom end studs, balance shaft delete, a snail that qualifies as an order of Escargot for four and and and..... Well look up my friend 95Blitz, electric water pump system on a SAAB motor. I expect his snail is so big it wears a collar, has to have annual rabies vaccines with the local ASPCA and answers to the name Chuck.

 

[SwerveMonkey]

well with that said Ah.B.Normal... this is mostly an engineering challenge I set for myself.
the main goal is to simply get the car to run, mind you not optimized or efficiently either, but just get the job complete in order to learn.
Part of that engineering challenge is the balance between budget and making the project complete with correct bespoke kit assembled on my own.

no offense intended but I don't have a lot $$$ to spend on this like others might... I'm an absolutely cheap bastard.
So the longer I have the L61 to learn on, the better I guess... speaking off learning ...

I found that the Z54 compressor housing is too large to mate to the exhaust manifold that i initially purchased.

housing touching manifold

it looks like if I were to bolt it up, the housing would press against the manifold
gap at the flanges...

I still need to get an oil drain flange for the bottom of the Turbo, as well as possibly grabbing a new thermostat housing for coolant hookup.

 

[ah.b.normal]

Dear Mr. Swerve
My apologies for my prior posts. As my own life is filled with hot and cold running insanity, often times my exuberance can run well forward of actual possibility! Turbocharging is not within my skill-set but I do enjoy to extrapolate when the notion strikes. So I'm gonna sit back and learn/watch and keep my (possibly megalo-maniacal) boost fantasies in check.
In closing, Sir, Do Carry On!

 

[comegetjoe]

well with that said Ah.B.Normal... this is mostly an engineering challenge I set for myself.
the main goal is to simply get the car to run, mind you not optimized or efficiently either, but just get the job complete in order to learn.
Part of that engineering challenge is the balance between budget and making the project complete with correct bespoke kit assembled on my own.

no offense intended but I don't have a lot $$$ to spend on this like others might... I'm an absolutely cheap bastard.
So the longer I have the L61 to learn on, the better I guess... speaking off learning ...

I found that the Z54 compressor housing is too large to mate to the exhaust manifold that i initially purchased.

housing touching manifold

it looks like if I were to bolt it up, the housing would press against the manifold
gap at the flanges...

I still need to get an oil drain flange for the bottom of the Turbo, as well as possibly grabbing a new thermostat housing for coolant hookup.

Ive seen this z54 clearance issue before. Google it. Pretty sure the answer is to clearance the manifold.

 

[jirwin]

In ZZP's kit they clearance the compressor housing on the turbo. I can get a pic later if you want but it's pretty straight forward. They just grind the section that's going to contact flat.

They also use a spacer plate to space the exhaust manifold out away from the head/block a bit FYI.

 

[jirwin]

Got your pictures to load (wouldn't this morning). Here's a quick video showing how ZZP's Z54 kit works. Download it because its going to expire in ~2 days: https://streamable.com/xbd2rs

 

[SwerveMonkey]

... a quick video showing how ZZP's Z54 kit works. Download it because its going to expire in ~2 days: https://streamable.com/xbd2rs

THIS IS AWESOME! thank you so much.... a lot of this I had some idea, but was uncertain about best choices...

cooling supply / return - I've seen options from ZZP, but no a lot of documentation from chevy on whic ports are available on the L61. I'll check if I can use that banjo bolt location on the bottom of the pump housing.
I did want to put a Tee somewhere in the line that comes off the top of the reservoir, sooo confirmation there i was headed in the right direction, ha ha ha

Oil supply return - i assumed the oil galley plugs are a defacto feed, yeah I think all three plugs are viable options.
oil return however, I was leaning to the same solution of tapping that same location, it is also pointed out in Chevy's build documentation... i think ?!?!

the spacer- I think that was only needed for blocking a few ports for exhasut to push directly out to the manifold instead of recirculation or SAI ports on the block... I think..... anyone can correct me if I am wrong here : )

I think at this point I've got to cry to ZZP for help... either to help understand if the manifold I sourced was the wrong dimensions [ maybe the lenght is too short ] or to see if I can get a flange as a spacer to make due.

Again, THANKS a bunch for that video. it really helps to clarify some of the mysteries and confirm how I thought this would proceed.

 

[Rauq]

the spacer- I think that was only needed for blocking a few ports for exhasut to push directly out to the manifold instead of recirculation or SAI ports on the block... I think..... anyone can correct me if I am wrong here : )

On the listing for ZZP's stainless T3 manifold, they note "The LSJ/2.2/2.4 version comes with a spacer plate to address proper exhaust port coverage."

LSJ head, exhaust side:

LNF head, exhaust side:

I think you're right that they're leftovers from SAI which the LSJ never had. I was curious so I went down a rabbit hole and found a pic of a CA emissions 2006+ L61 exhaust manifold. Secondary air from the pump enters the manifold at the blue arrow and enters the exhaust ports where the red arrows are. Interesting stuff. Also... pics of an LSJ head from the exhaust side are incredibly hard to find!

 

[SwerveMonkey]

So the Exhaust issue is resolved for the most part.... I think

I was able to snap a few pics of the exhaust side of the engine without the manifold

https://imgur.com/rGNg1Tk

I assume that the problem pointed out previously may not be an issue, but I am willing to learn the hard way on fitment before the turbo is fully installed.

https://imgur.com/NA2IVIH

 

[SwerveMonkey]

I was also able to solve the fitment issue i was having with what i didn't realize was an oversized cool side housing...

https://imgur.com/hqJKpmI

I mocked up a cardboard template to trace on to some scrap steel I cleaned up and found that it was enough thickness, 0.17", to put a gap between the housing and manifold.

before ->> no gap image
after ->

https://imgur.com/8ZYtKPC

Now the mounting solution is nearly done, might have to find a way to brace through the rest of the exhaust & the trans-mount.
The next hurdle i can account for is the coolant line and oil line hardware, which I am still trying to fully understand...

banjo bolts for the coolant lines, but still mulling over where to tap into for input and drainage that is most effective for this build.
and finalizing how the oil drainage will be taken care of. I've had a few back and forth emails with ZZP customer service and they have been great with guidance even though the turbo was purchased second hand. there are a few bits that they can provide when I am ready to round that river.