[insert trendy, witless catch-phrase here]

cross-hatch reinforcement != solid; theres no argument here. the sky is blue. If you'd like i can post a pic of the LSJ manifold flange tonight, even show you the LSJ gasket on the LE5 manifold if you'd like, it's a bad idea. yes same bolt pattern - no question there, but the LSJ manifold is a solid flat piece designed to crush and hold a normal gasket. With the LE5 and the additional gasket your contact with the LSJ gasket would be minimal, and even worse this does NOTHING to solve the issue with the LE5 gasket failing.

The purpose of a gasket is to fail before you create other mechanical failures. How then will adding more points of failure to an already flaky gasket help improve sealing?

What is the purpose of RTV? To create a seal.

those are exactly whats failing it appears...

which engine? the LNF (SIDI 2.0L) uses a aluminum intake, the saab is aluminum... even the LY7 is aluminum... regardless, failure is never a boolean operation.

 

Ok, changed out the gaskets today after work. The stock gaskets were green with little bumps on the edges. the new ones i got from the dealer were orange and totally solid around the edges. The new ones look alot stronger. Manifold has stopped leaking now with new gaskets.

Next issue, Injector #2 is leaking vacuum and I cant get it to stay in hard enough to stop it. Pulled the fuel rail and injectors and everything looks normal.

My tuner said that he remembers pulling apart an ecotec and seeing some kind of internal O ring seated in the head on bank #2 where the injector plugs into. He says that could be the issue. Im taking it to him in the morning since i dont know what else to do. I was starting to think that i could pick up a fatter O ring that fits on the end of the injector but i dont know for sure if thats the issue.

 

I have more power than that with this turbo @ 10psi!

area all your injector o rings properly seated? are the fuel rail clips in place to hold the injector where it belongs?

 

yeah the O rings are seated fine, the clips are on good. the only thing i can see is that injector #2 is slightly tilted at an angle as compared to the other 3 which are all at the same angle when seated. I took them out and tried to align the 2nd one but it just sits right back in at a slight tilt. Like the fuel rail is forcing it to sit that way.

 

If your tuner saw ANYTHING on "bank #2" on a Cobalt I think you've found your first issue....double vision.

 

this might sound hella gay.. but vasoline on the o-rings helps... both on the injector o-rings and the little cup thing they sit in.

 

Despite your sexual orientation, bigworm....

That is actually what GM recommends in their build books!!

 

oh well, there you go... just thought it was an old trick for people that arnt afraid to use a little extra RTV on their cars.

 

Bill has told me that at 14psi, accompanied with 90psi of the on boost fuel psi, should net approx 290whp.


I know the plastic intake manifolds are designed to fail at approx. 15psi.

 

i see injectors failing

 

Got the issue fixed now. no more manifold leak and no more injector leak. Problem was a broken O ring that sits in the adapter in the head. so the O ring on the injectors were fine but i wasnt aware that there was an additional O ring in the head. So now i just gotta get my tuning finsihed next week.

I think my boost psi is being limited by my 2.5 inch exhaust, thats the only other thing i can think of as to why im only getting 11 psi with the wastegate actuator fully turned to capacity.