I Supercharged a 2005 Cavalier - Boost Forum

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I Supercharged a 2005 Cavalier
Wednesday, August 21, 2019 2:43 PM
All parts from a 2004 Ion Redline in the junk yard. I was able to mostly follow the GMPP kit instructions.

List of modifications required:
Intercooler inlet/outlet bent down
lower air dam removed
custom intercooler brackets out of pipe hanger straps.
Intercooler pump wired to ignition switched source with toggle switch to kill it if needed.
Intake elbow from a 2002 cavalier (works with stock airbox or cone filter)
cut stock airbox where it connects to the throttle body to use as an adapter/spacer for 2002 intake elbow
bent the dipstick tube
custom throttle body adapter plate made with a drill press
HP Tuners custom 1 bar tune I did myself
I had to put 14mm stainless steel flat washers under the injector spacers because they are shorter than stock.
broke off two static fins from the cooling fan to clear intercooler plumbing
extended MAP and IAT wires
used TMAP for IAT signal
blocked off supercharger silencer ports with stainless shetmetal
boost referenced fuel pressure
shortened the coolant overflow hose by 1 inch

I'm not sure I'm posting the pictures correctly.

Pics are in a Google album here

Re: I Supercharged a 2005 Cavalier
Friday, August 23, 2019 4:21 AM
A few other mods required:
Ground a 1/4 in off an unused mounting boss on the passenger side of th block to clear the belt tensioner.
Ground a 1/16 in deep x 1/4 in wide by 1 in long groove on the head to connect the pcv ports.
Cut 1 rib off of the LSJ belt from 6 to 5 with sheet metal snips.
***The intake duct was specifically from an LD9 engine.
Had to pull the TPS and IAC wires out of the harness and re-loom them to reach the relocated throttle body.
Used a long piece of pcv hose and pcv adapter fitting to conect the valve cover vent to the LD9 intake duct.
Made a braket to mount the fuel rail cover to the head.
I bent an ac line a little from the compressor to clear the LSJ alternator. There was a bit of persuading of wires, hoses, and brackets between the intake manifold and radiator to keep stuff from rubbing over time.
I think thats it...
Re: I Supercharged a 2005 Cavalier
Wednesday, September 18, 2019 8:49 AM
Also the starter wire needed to be rotated about 90 to miss the intake manifold.

Another picture

small 20181203_080715.jpg (1502k)

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