Here are a bunch or pics and short explanations. ENJOY!
Sorry in advance for the crappy cell pics.

This picture shows the 5 bolts and the 2 nuts that need to be removed on the intake manifold to get that off, also see the next picture showing the bolt on the underside.


Here is the screw that is on the underside of the intake manifold.


Here is the screw that is holding the oil tube in place.


Showing the laminova cores swapped out.


Here is the 1/2" NPT aluminum bung welded to the endplate.


Showing the connection from the intercooler pump the the in on the endplate. The in is the newly added connection.


This is the TEE I made I had this 90 sitting around and it will do the job.


This is the stock filler cap showing where it connects to.


Thats enough pics of the dual pass endplate... thought I might as well throw a 2.8 on there now that my cooling mods are adding up.


Shot of the car while I was waiting for the welds to cool down.


I hope this helps explain the custom dual pass endplate.

 

isnt there a HOW TO GUIDE section?

 

Yes but I basically just wanted to show people how easy this is.

 

I thought it was better put together then the other ones I have seen good job

 

Thanks, if you can weld aluminum you can save big bucks and do this mod.

 

on thing you might want to consider is taking the endplate to a machine shop and mill the the endplate to make sure it is flat so it dosent leak lol like mine did awsome pics nice and clean ride

 

I like that pulley

 

u making those to sell? I want one! GREAT JOB!!

 

no not selling them... just trying to help everyone out. If you buy the right stuff just take the endplate to a welder and have him weld the bung on the endplate it... It would probably cost you $50 for everything including...

 

where did you get the bung?

 

Right here...

 

Approved

 

did you replace the seal also
thanks

 

Or you can drill/tap the endplate if you don't have access to a welder, just a suggestion.

 

i thought blown 4 banger tried that and there wasnt enough material to hold he fitting in?

 

did you replace the endplate gasket??

 

That is asking for failure. there is probably 3mm of nice soft cast aluminum in that spot.

 

No... and I have no leaks, but thats not to say someone else might.

 

No you can drill and tap just fine. It's how I did mine and has held up for months now.

 

really i think im gunna tap it and put a couple tacks on it
where did you get the tap and what size

 

Thanks for that link! I have been looking for a website like that for a while!
Eric

 

ya ill see what condition its it, also what size bit did u use to drill the hole

 

FYI, early model cobalts should replace the intake manifold gasket for the updated part # (available through CED) while your at it. I think 07s came with the redesigned gasket (not 100% sure), but 05 and 06's did not AFAIK. I'll dig up a pic of the redesigned gasket from my gallery so you can compare the new one to the original (shown in the OP).

Nice write up though, this was one of my least favorite jobs to do on the LSJ. Getting the IM/intercooler off is a pain in the ****.

Re-designed gasket

 

Thread merged with your other thread. Please don't make duplicate threads.

 

1/2 in npt pipe tap