Ecotec Alero Performance Talk - Page 5

heineck · 07-03-2009, 10:24 PM

nice, so it was all high end? i wouldnt mind a bit more in the 4-5 range

Blktrax · 07-03-2009, 10:25 PM

Stock 2007 Cobalt vs 2.2 with 2.4 Manifold Theres so much potential there, it just needed tuned cause even with the extra air it was still runnin WAY rich.

colonel6632 · 07-05-2009, 11:30 PM

well i'm am going to look into this. i'm going to try to find a 2.4 manifold at a junk yard and buy it. few questions.

can i reuse the gaskets to make things cheaper?

and can someone explain to me more about the aic slot and where it is on our manifolds and what i would need to do to use it on the new one

Blktrax · 07-06-2009, 12:58 PM

You should be able to reuse the gaskets, but really they're not that expensive.

Im not filmilar with the alero TB setup , so someone else will have to chime in on that.

colonel6632 · 07-06-2009, 05:19 PM

i got this from this link
http://www.saturnfans.com/forums/sho...d.php?t=136317

and heres the comparision for the 2 intakes.

2.4 intake

and the 2.2 intake

and the two throttle bodies

like i said... stole those pictures from the link.

so it appears to me (please someone correct me before i do this is screw something up) that you can just take the 2.2 gasket off the original manifold, install it on the 2.4 manifold and cut a little hole in the top of it for the aic.

would that sound good?

AbHeLlRaZoR · 07-06-2009, 08:13 PM

Those are the electronic Throttle bodies there may be a slight difference of how ours is.

Blktrax · 07-06-2009, 08:28 PM

We need pics of the alero 2.2 throttle body off and manifold. Any takers?

heineck · 07-06-2009, 09:15 PM

uhh when i get my 2.4 manifold id be happy to take pics

AbHeLlRaZoR · 07-06-2009, 09:44 PM

here's one of the cable ones its on the 2.2 manifold I took the picture when changing my air intake

Blktrax · 07-06-2009, 10:29 PM

Ok thats 1/2 of what i was lookign for, That shows the IAC is in the same place above the throttle body in the same place the passage is.

Second it shows generaly the throttle body is the same, base type.

Third it doesnt show rather the routing of the brake booster vacuum line, the 2.4 gets moved below the throttle body where the 2.2 has a block plate and its routed up top under #4 intake

See manifole pics above form colonel6632 on the 2.4 manifold where the tube comes out directly under where the throttle body mounts. On the 2.2 its on the underside of the manifold.

CRAP I just saw why its goign to be an issue with the cable throttle body. Lookign ath teh drive by wire pictures a bobe the left side of teh throttle body both the origional and the bidder are double drilled. Both could fir on either manifold. The Alero stock TB is only drilled in the high position becuase of the IAC. The 2.4 manifold uses the lower bolt postion.

When I tested this I didnt need the adapter plate that crateenginedepot's kit has. This is one app that will need the adapter plate.

Note lower left of pic

colonel6632 · 07-07-2009, 04:29 PM

wel i found you can buy just the adapter plates

http://www.crateenginedepot.com/stor...P1820C137.aspx

but does anyone know how to make one?

and will our ecm be ok with the extra air or will the car go into limp mode?

colonel6632 · 07-08-2009, 02:58 PM

blktrax... i'm sorry... but i'm mentally challanged i think... i dont understand what your talking about when you say the cable throttle bodies will have a problem.

i also found this link.
http://ionforums.net/phpbb3/viewtopi...=4987&start=20

and what i was thinking... where i circled in red... just cut a hole on the 2.4 manifold for the aic with a dremel. and put a little slit in the gasket...

AbHeLlRaZoR · 07-08-2009, 05:00 PM

Colonel when you do this can you take some pictures and put together a "How To" for us? I didn't really find the little how to on the Saturn Ion and Ecotec forum not the greatest.

Quote:

Originally Posted by colonel6632

well i'm am going to look into this. i'm going to try to find a 2.4 manifold at a junk yard and buy it. few questions.

can i reuse the gaskets to make things cheaper?

and can someone explain to me more about the aic slot and where it is on our manifolds and what i would need to do to use it on the new one

buy new gaskets they are dirt cheap new.... here's a useful link to help you find the intake manifold at a junk yard http://www.autorecyclers.ca/members.shtml I believe SGI is the Saskatchewan site I did get a result from Manitoba when I searched AARDA the one price that did come up was $65 CDN

Blktrax · 07-08-2009, 09:29 PM

I don't want to repost pics those pics, ignore what you circled in red. Thats not the issue, that can be worked around or may be a non-issue alltogether.

What im talking about is the top 2 bolt holes that hold the throttle body to the manifold. The 2.2 the left bolt is offset higher, Where on the 2.4 the bolts are straight accross from each other. They are double drilled for either or installation. The alero cable TB, is only drilled in the higher offset position because of the IAC motor on the TB. Thats what i was saying about the need for and adapter plate. What i need to see is the underside of an alero TB and see what the IAC passage looks like. As long as opening isnt bigger than the gasket of the 2.4 manifold it should work, then only the issue of holding it on with 3 bolts, or making and adapter plate. The one for the cobalt wont work because it blocks off the IAC passage.

colonel6632 · 07-09-2009, 03:09 PM

ooooooohhhh! thanks Blktrax i see the problem now. sorry about that before, can't beliebe i missed it. i understand... pictures help me alot. lol we can only put 3 bolts to hold it down since the aic is in way of the 4th one. we need the adapter plate to hold it down in the 4th spot. and how bad would it be to hold it down with only 3 bolts? and theoretically one could just make a metal plate to hold it there, and then drill the 4th hole and tap it... correct?

and AbHeLlRaZor... if someone doesn't do this before me. i'll be sure to post pictures. i'm purchasing a 4-2-1 header so help bring the low end power back up from this swap. so i dont know what i'll try to do first... intakes that new are hard to find. i did a search on sgi and didn't find anything... i'll have to try a wrecker.

also... found this http://saskatoon.kijiji.ca/c-cars-ve...AdIdZ127799062

gonna try to contact him to see if it fits the right year

Blktrax · 07-09-2009, 09:44 PM

Quote:

Originally Posted by colonel6632

ooooooohhhh! thanks Blktrax i see the problem now. sorry about that before, can't beliebe i missed it. i understand... pictures help me alot. lol we can only put 3 bolts to hold it down since the aic is in way of the 4th one. we need the adapter plate to hold it down in the 4th spot. and how bad would it be to hold it down with only 3 bolts? and theoretically one could just make a metal plate to hold it there, and then drill the 4th hole and tap it... correct?

Basicly yes, 3 bolts is a bit of a gamble though. The thing is the Crateenginedepot adapter plate would physicaly fix the mounting problem using a countersunk tapered head screw on the 2.4 manifold and use the supplied bolt with the place for the top left hole. However in refrence to what you did circle in red in those pics, is the adapter plate is solid. A hole or holes would have to be cut in the plate to allow the IAC to function properly.

colonel6632 · 07-10-2009, 04:48 AM

well hopefully i can find a 2.4 manifold this weekend... if anyone knows someone who wants to donate one for a good cause lol.

colonel6632 · 07-10-2009, 01:49 PM

called around all my junkyards... no one even has cars that new

AbHeLlRaZoR · 07-10-2009, 01:54 PM

That's why I suggested SGI it's like the inventory for the junk yards.

colonel6632 · 07-10-2009, 01:58 PM

ya... they didn't have one though. i checked online and went in person