Ecotec LSJ for Aveo (supercharged 2.0L engine swap)

[thehotrodguy]

Starting the upgrade the first problem that I had was that I did not have the proper tool to remove the screw from the GM pulley. They are make of soft aluminum so i was able to drill the heads out and remove the pulley not bit deal. As for removing the old hub, do not go out and spend a-lot of money on a puller, I improvised and used an steering wheel puller to get the job don take a look at the pics below, pretty slick if I do say myself.

[Ash2269]

Really curious as to how this panned out? Getting ready to do the swap myself and have many questions.

[BlueBird94]

I picked up a 2006 chevy cobalt ss for 900 bucks and I am planning on doing this swap. The cobalt currently runs and drives very well, but is rusted badly. I'd love to get some more insight on how to do this swap, mainly with engine management (converting to stand alone). Also the modified suspension... any help would be appreciated! Thanks. Rob.

[serega12]

I picked up a 2006 chevy cobalt ss for 900 bucks and I am planning on doing this swap. The cobalt currently runs and drives very well, but is rusted badly. I'd love to get some more insight on how to do this swap, mainly with engine management (converting to stand alone). Also the modified suspension... any help would be appreciated! Thanks. Rob.

If you go through all that work - upgrade to LSJ-t.

[thehotrodguy]

Well if you read some of the post that I left, there is a-lot of custom fabrication the will need to be performed to make this swap work. All of the work was done by myself, I think you will have a hard time finding someone that will be able to do the work locally. I also did the stand-alone conversion, I used HP-Tuners to program out all of the BSM and VAT stuff out. The suspension was also custom work done by me. I can provide you the some part numbers of parts that I used to make the steering work, you will need to change in inner tie-rods if you are going to use the Cobalt knuckle.

Best Regards,


Oscar Rivera

[BlueBird94]

Well if you read some of the post that I left, there is a-lot of custom fabrication the will need to be performed to make this swap work. All of the work was done by myself, I think you will have a hard time finding someone that will be able to do the work locally. I also did the stand-alone conversion, I used HP-Tuners to program out all of the BSM and VAT stuff out. The suspension was also custom work done by me. I can provide you the some part numbers of parts that I used to make the steering work, you will need to change in inner tie-rods if you are going to use the Cobalt knuckle.

Best Regards,


Oscar Rivera

I will be able to do the fabrication/welding/mechanical work. I have done complete frame-off restorations by myself, so that type of work doesn't bother me. The conversion to stand alone is my main hang up, as I don't have too much experience with tuning. I sent you a PM, a few days ago, I'd love to talk with you more that way so we don't clog up this thread.

Thanks

Rob

[Daox]

You should start your own thread. We'd love to follow your progress.

[serega12]

Well if you read some of the post that I left, there is a-lot of custom fabrication the will need to be performed to make this swap work. All of the work was done by myself, I think you will have a hard time finding someone that will be able to do the work locally. I also did the stand-alone conversion, I used HP-Tuners to program out all of the BSM and VAT stuff out. The suspension was also custom work done by me. I can provide you the some part numbers of parts that I used to make the steering work, you will need to change in inner tie-rods if you are going to use the Cobalt knuckle.

Best Regards,


Oscar Rivera

Your build is beyond awesome BTW!!!

[Suprasalas1]

Out of what Hyundai did you get the tie rods from?

In the attached pics you can see the finished suspension, the spindles are from a 2006 cobalt and so are the struts. The struts have been modified with a Ground Control coil over kit and the A-arms have been modified to accept a cobalt ball joint to allow me to mount the spindles. After I mounted the spindles I found that the Aveo tie rod ends would not work and I had to use tie rods from a Cobalt. This created another problem, not only are the Cobalt tie rods two inches too short the thread size is different 14MM for the Aveo and 16MM for the Cobalt. So after some resource I found that as set from a 96 Hyundai would work perfectly. This setup allowed me to use axles from a Suzukit


Attachment 3605Attachment 3606

This setup will allowed me to use axle shafts from a Suzuki Forenza, I will be running this setup with the current 2.0 turbo setup that I have. This is all in preparation for the LSJ install, the hub splines are different between the Avoe and the cobalt. The spline for the Cobalt and the Forenza are the same so this setup will allow me to run the Suzuki shafts now and later the shafts from the Cobalt. As for the the brakes I will be running the Wilwood's that I had previously installed I just have to fab up a custom bracket before I can get the brakes back on. I will be upgrading to the Brembo’s latter on as the project progresses, this will require 17 inch rims.


Attachment 3604Attachment 3603

[thehotrodguy]

This was for the inner tie rods, it was from a Hyundai excel years 1990 to 1994. The MOOG part number is EV223, as for the outer tie rod I used the cobalt OEM rod with the cobalt spindle and I had to modify the factory lower control arm. I modified the A arm to be able to accept the cobalt OEM ball joint.

Regards