Hello, I'm helping my brother out today with the Cobra Heat Exchanger install on his 04 Cavalier. I was searching through some of the threads, but couldn't find anything like a walkthrough on the Cavaliers for this. I did find a Cobalt one over on ecotecforums, but I'm not sure how similar it will be. He's got the GM performance SC kit on there, which, to those who haven't done it, wasn't that bad of an install. We're upgrading to the 3" pulley, and putting the H/E on there tonight, or at least starting tonight anyways. How did everyone go about mounting this up there. Also, is there any other tricks we should know for any of this?

listening..............

I had a shop weld on some "L" brackets for me and then I drilled holes in the front bumper support to mount it up. I've heard of some guys using metal zip ties to hold it up as well.

Best effect would be to mount it as close to the radiator as you can too so the fans can pull the air through both the HE and radiator.

It's fine if it's out from the radiator though...just you'll get a better effect from the fans and help some to cool the coolant while sitting still.

Other tips...not much really. You'll need several 90 degree rubber elbows to route everything and some hose connectors to tie everything in. I think I used about 8 - 10 90 degree elbows and each elbow had a hard plastic hose connector.

Get reinforced heater hose for all your lines and elbows as well. While it may not be needed on the cool side of the HE, coming out of the SC the coolant can and will get pretty warm!

I zip tied my pump to the sub-frame brace and ran the wires back to a relay and then to the ignition so the pump is always on while the ignition is turn to either start or ACC.

Let me know if any questions and I'll try to answer them for you.


Eh...old man with a Corvette now...it was bound to happen sooner rather than later right?

I know I might sound stupid but what is this H/E and how is it post to work?


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Ryan Thompson wrote:I know I might sound stupid but what is this H/E and how is it post to work?

HE = Heat Exchanger.

Acts like an intercooler but it's an air to water rather than air to air like you see on turbos.

Basically it cools the air charge going into the engine...cooler air means more hp and less chance for B O O M!

The intake manifold has intercooler cores that when hooked up to an air to water HE, will run coolant over them and cool the air before it enters the engine. Most are running 03/04 Cobra HEs and some are running aftermarkter ones (little larger).

mapping is like this....

intake manifold > resevior > heat exchanger > pump > back to the intake manifold

Hope that helped.


Eh...old man with a Corvette now...it was bound to happen sooner rather than later right?

www.bwoodyperformance.com has the l brackets your looking for
blue duce did you solder the conections?


ZZPerformance is the leader in intercooler research, testing and performance. With over 200 intercooler systems sold, we know what pumps work best for various applications and why. We now offer 4 different intercooler pumps for your needs.



Pump 1 is a Flojet Quad series positive displacement pump. It is optimum for the SS intercooler. Available stand alone or with fittings to convert from your current SS kit. Works with our standard IC as well but flow is not optimum. In some 1.9” cores and in Thrasher units where the threaded inlet of the core is small, this pump is a good choice. This pump will not work with variable speed pump controllers.

3.2 GPM rated, nearly 3GPM actual with minimal loss when restricted
3.9 pounds
Self priming
Draws 2.5 amps continuous
Noise is 4 on a scale of 1 to 5 (1 being quietest, 5 loudest)
2 year warranty
Pump 2 is a Central Machinery pump. This pump is no longer available.



Pump 3 is a Rule centrifugal pump. It does not handle liquid temps over 150F and should only be used on our stage 3 core or with our EP intercooler pump controller. Being a centrifugal pump, it will not work well in systems with lines, fittings, or cores that have internal diameters less than ½”.



11 GPM rated, 6 GPM actual with 5/8” line, 7 GPM actual with ¾” lines
Weighs 14 ounces
Draws 1.8 amps continuous
Motor assembly is available separately
1” inlet, ¾” outlet
Noise level 2
90 day warranty


Pump 4 is a GM pump used on GM cars with liquid to air intercooler systems. It is the quietest, longest lasting pump you can buy. The GM pump has reliability high enough to install without and external relay! Being a centrifugal pump, it will not work well in systems with lines, fittings, or cores that have internal diameters less than ½”.



6 GPM actual flow in unrestricted systems
Weighs 13 ounces
Draws 2 amps continuous
Removable power connector included
¾” inlet and outlet
Noise level 1
1 year warranty


i copied this from zz performance
so how would this pump be hooked up?
thank you

BlueDeuce (dnt02cavls) wrote:I had a shop weld on some "L" brackets for me and then I drilled holes in the front bumper support to mount it up. I've heard of some guys using metal zip ties to hold it up as well.

Best effect would be to mount it as close to the radiator as you can too so the fans can pull the air through both the HE and radiator.

It's fine if it's out from the radiator though...just you'll get a better effect from the fans and help some to cool the coolant while sitting still.

Other tips...not much really. You'll need several 90 degree rubber elbows to route everything and some hose connectors to tie everything in. I think I used about 8 - 10 90 degree elbows and each elbow had a hard plastic hose connector.

Get reinforced heater hose for all your lines and elbows as well. While it may not be needed on the cool side of the HE, coming out of the SC the coolant can and will get pretty warm!

I zip tied my pump to the sub-frame brace and ran the wires back to a relay and then to the ignition so the pump is always on while the ignition is turn to either start or ACC.

Let me know if any questions and I'll try to answer them for you.

I also did everything he did but instead of drilling holes into the bumper support, I used the pre existing holes the support and drilled the holes in the L brackets to line up with those.

[mapping is like this....

intake manifold > resevior > heat exchanger > pump > back to the intake manifold
]

why would you set it up this way?

Intake manifold > heat exchanger > resevoir > pump > intake manifold

Wouldn't this work better if you are packing ice in the resevior...


"Smoked"

becouse the the coolest point in the system is when the fluid leaves the h/e


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Those so naive, so hard headed, so narcissistic, that think that buy their own efforts can single handedly change the world, are always the ones that do.

carnivorous mouse wrote:blue duce did you solder the conections?/quote]

If you are talking about all the electrical connections...yes of course I did! Only way to do them!

If you are talking about the L brackets...I had them welded to the HE first then tapped and drilled holes in the bumper support and mounted it.

NUTCASE . wrote:becouse the the coolest point in the system is when the fluid leaves the h/e

Correct!


Eh...old man with a Corvette now...it was bound to happen sooner rather than later right?

Thanks guys for the info.... Im actually his brother that hes talking about . We got the h/e done, and had it from the top core of the manifold, to the resorvoir, then down to the driver side of the h/e, then the passenger side of the h/e goes to the pump, then straight up to the bottom core of the manifold... Is this correct?

Yep that's it.




Eh...old man with a Corvette now...it was bound to happen sooner rather than later right?

will th 2003-04 cobra/lighting intercooler pump work???thats the last part i need for myt heat exchanger set up.
thanks,james

Yes it will work, thats what I am using

Any Pics of the install???

This would be a good place to put them for future reference unless someones wants to create a post wth the intention of a sticky!


(Im planning on this as well)





now DIE!

I would like to see picks of the heat exchanger. I saw a heat exchanger being sold and then from the same guy also selling what he called the supercharger intercooler which one do I need?

If you have the GMPP Kit, you only need the HE. The manifold is the intercooler (well...have the cores in there).

Get the HE only or you'll have two manifolds.




Eh...old man with a Corvette now...it was bound to happen sooner rather than later right?

pics would be sweet. i gotta find a way to mount the pump and still need to find some L brackets..

any measurements on the L brackets? thanks



12.33 @ 111.67 mph [Oct 2009]
Dyno'd on 08/02/09 - Mustang Dyno:
327.6 WHP 333.6 WTQ [10.1 AFR]

Thanks for clearing up the heat exchanger Q. I have a Cobra heat exchanger on the way!

evilmonkitar wrote:pics would be sweet. i gotta find a way to mount the pump and still need to find some L brackets..

any measurements on the L brackets? thanks [/quote

I'm selling the lsj pump bracket, lines up and bolts up to our motor as well pm me.