Yes I had originally posted on the nitrous page (not that I got any feedback), but I’ve decided to go with a turbo setup now. I’ve been working on cars for 12 years now, but I’m still getting the hang of the high performance stuff, especially for the Cavalier. I’ve run up and down the different threads to find info specific to what I’m trying to accomplish. Here is what I’m working with and my goals for the build. Any feedback would be great.
My goals, parts and mods list for my 96 Z24 Cavalier. It’s the LD9 2.4 motor with the 4T40E 4 speed auto trans. First of all, here are my goals.
I want to stay under $10,000 for the build.
I want to run a T3 60 trim turbo set up.
I want at least 300 crank horsepower with bolt ons,upgrades, turbo and a good tune.
I would hope to get in the 13s in the quarter mile.
Parts list and mods:
Engine
secret cams (maybe), alum pulleys, motor mounts, forged pistons & rods (9:1), iridium spark plugs, valve work, 2.3L oil pump (if I can get my hands on one), YES it is a 96 so I am installing a 97 ecu (16228016) and wiring harness so I can tune it, and a custom turbo kit (T3 turbo, internal wastegate, 60 trim, etc…at 10psi).
Exhaust
custom header, high flow cat, 3 inch tubing throughout, and a Borla Turbo muffler.
Gauges
Auto Meter Ultra-Lite gauges as follows: trans, oil, volts and boost.
Fuel
Walbro 255 fuel pump or part number 25163473 (I’ve read on here it’s a good/easy swap), Venom high flow fuel injectors, high flow filter (is that needed?), FPR, and I plan to run at least 91 oct fuel.
Suspension/Wheels
2 inch drop lowering springs, 300 hp rated axles (what brand/website are others using?), strut and sway bar upgrades, 17 inch ADR wheels wrapped with 215/45/17R tires.
Trans
Trans cooler, trans mounts, modified automatic shifter, trans gauge to keep an eye on it.
Questions
Is there anything anyone would add or suggest to do differently? What are some opinions on removing a/c for a little added power? Is it worth it? With the trans cooler I believe the auto trans should hold up with 10psi boost right? Could the trans handle more stress than that? It seems on here that the 4T40E holds up pretty well. More pictures of the build on my profile coming soon.
2004 Cavalier Sedan
axles/tranny should be fine
try to run a copper/non iridium plug- im running an ngk v-power tr6 stock # 4177
i can get you some injectors
i sure hope you make more than 300 crank on 10psi but who knows
axels will be fine, granted you have good suspension/bushings to prevent wheel hop. Thats what kills them. A T3/T4 turbo would be good. The TO4E is a popular choice with other 4-cylinder motors, but there are many turbo options out there. The A/C delete kit may be worth a little bit of weight. I ditched mine but not sure how much weight it was but I would think it would be good for a few lbs. I'm running iridium plugs and they seem to be good for my setup. I think I had mine gapped to 0.035 (but it may have been 0.030, just can't remember for 100
. I made 250whp on 8.5psi on my TO4E 57 trim with a stage 3 turbine. Everything else on your list seems pretty good. I'm not familiar with the auto tranny so I can't provide any insight on that. There are many options for injectors too, just make sure you go big enough. I went bigger than I needed but I didn't want to have any issues with having to upgrade them if I ran more power.
not sure whats up with the funny face...it was meant to be a percentage sign
Thanks for the comments. I am going to look into injectors more. LAFNGAS what can you hook me up with? As far as plugs go I've heard to just make sure to stay away from platinum.I've got a lot of parts for it already, but not a turbo yet so I'm still researching that. Thanks again.
2004 Cavalier Sedan
Will I need a high flow fuel filter, or is stock good enough?
2004 Cavalier Sedan
For the little power you are running, the stock will be sufficient.
I also agree with using copper plugs with turbos. My old 470AWHP Talon wouldn't run on anything other than copper plugs.
You also never made mention of a manifold, plan on running a cast log manifold or having a tubular one made? Its is very important to keep in mind when selecting a turbo since there isn't much room between the motor and firewall. Im running into issues with my TO4E 57 trim with the .63 AR housing trying to use the STR cast manifold I have. The turbo is too large to fit the correct way so it hits the cam towers.
"Oil Leak ? What oil Leak ? Oh, Thats Just The Sweat From All The HorsePower!!"
Alright you convinced me...copper plugs it is. My dad is making my manifold. When I get a turbo he'll be able to finish it. Would a T28 turbo fit better at all? I should still be able to run my desired power levels with one. Another thing I was wondering about is what happens to your motor if/when a turbocharger fails or ''blows up''?
2004 Cavalier Sedan
DSMskyline wrote:. Im running into issues with my TO4E 57 trim with the .63 AR housing trying to use the STR cast manifold I have. The turbo is too large to fit the correct way so it hits the cam towers.
I am running the same turbo and manifold...I had a 3/8" spacer between the manifold and turbo and just had to shave a little off the turbo housing.
ok so I'm seriously looking at the Turbonetics T3 turbo with the following specs... 60 trim, oil cooled, turbine wheel 62, 4 bolt inlet and 5 bolt discharge and .64 a/r turbine housing. My question is should I go with 2.35'' or 3'' compressor housing inlet? They are rated up to 325 whp so I should be fine with my desired power levels. What do yall think?
2004 Cavalier Sedan
Matthew Jollymore wrote:DSMskyline wrote:. Im running into issues with my TO4E 57 trim with the .63 AR housing trying to use the STR cast manifold I have. The turbo is too large to fit the correct way so it hits the cam towers.
I am running the same turbo and manifold...I had a 3/8" spacer between the manifold and turbo and just had to shave a little off the turbo housing.
Thats what I though. I made a 3/8 Spacer and it still seems to hit. I guess I need to grind more from the compressor housing. Any chance you could snap a picture of the turbo/cam tower?
Do you remember how much was needed to be ground for it to fit?
Edited 1 time(s). Last edited Friday, August 26, 2011 8:33 AM
"Oil Leak ? What oil Leak ? Oh, Thats Just The Sweat From All The HorsePower!!"
