ZZP LSJ Turbo Complete Swap Kit

ZZPerformance has worked extensively with turbos on the Ecotec platform and after testing many turbos from Borg Warner, Bullseye, Garrett, and Precision; we concluded that nothing spooled as quickly, and made as much power, as the current Borg Warner 257 SXE We get many requests to use customer’s turbos but we strongly recommend against this route, we do not guaranty that any other turbo will fit in place of the turbos that we offer. If you search the forums there is literally no one making as much power with successful builds that run well other than people using ZZP setups. This includes our choice of turbos.

How to order your turbo kit:

Vehicle:
This determines what charge pipes and intake tube you will receive. The Cobalt and Ion ones are completely different, and not interchangeable.

Wastegate Option:  There are two options here, there is an external dump and a recirculated dump. The external dump will open a hole directly from your exhaust manifold to atmosphere at WOT when full boost is achieved. This kit comes standard with an external dump wastegate tube however we also offer a recirculated option to where it routes back into the downpipe which will make it quite a bit quieter at WOT.

Tune and Core Charge:
This will give you the option to either have us ship you a programmed PCM core, send in your PCM core for the ZZP file, have us email you a ZZP file for the kit, or the final option of no ZZP file at all.

Turbo:
The 257 turbo reaches full boost around 3700 RPM on a LSJ. It reaches maximum efficiency between 25 and 30 PSI on the 2.0 but is normally run a 16-18 psi on pump gas depending on the other mods you have. (We recommend 15-16psi for 91 octane, 18 for 93) It will make 325-400 WHP on 93 but is capable of up to 500 with additional mods to the vehicle and E85. 

We have done custom builds with turbos larger than the 257. They require E85 or E98 or C16 to take advantage of the boost levels. Firewall modification, custom 3.5” downpipe, 2000cc injectors, dual in tank pumps. The turbo won’t spool until ~4500 rpm making it a race only or dyno queen setup. Drivability is poor. In deciding which turbo to use, you need to determine how much HP you want to make and how you are going to drive the car.

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Injectors:
This kit will require larger than stock injectors. 60s will make up to around 400whp, 80s will make up to around 450whp.  *We recommend our BRFPS when running 80lb injectors this greatly reduces idle surge and rich idle conditions associated with large injectors and high factory fuel pressures.  Injectors are sold separately. 

With the manual boost controller turned all the way down, or not installed the LSJ turbo kit will make approximately 10psi of boost. The manual boost controller will allow you to increase the boost pressure above the base setting. Our Mini or Fixed AFC will be required at boost levels over 16psi and our Boost Reference Fuel System (or BRFS) will be required at boost pressures over 17psi.

On our LSJ turbo swap kit, you need to keep your MAP sensor- the one mounted on the intake manifold, as well as the barometric sensor that sits out in the open. You don’t need the blower inlet pressure sensor for a turbo setup. We simply delete that code on turbo swap ECM files.

To keep costs down some of the items in the turbo kit that are included MAY be used such as the intake manifold, alternator, and throttle body

Click here for how a Cobalt with the ZZP kit stacks against a GTR and modified Corvette.

Our complete LSJ turbo kit includes:

• ZZP 304 stainless turbo manifold
• ZZP 3” 304 stainless downpipe
• Heavy duty V-band clamp for downpipe
• Borg Warner 257SXE turbocharger
• ZZP Turbo oil system kit
• ZZP 3.5” aluminum turbo intake
• ZZP air filter
• ZZP 50mm Blow off Valve
• TiAL MVS 38mm wastegate
• ZZP powder-coated aluminum charge tubes
• ZZP silicone couplers
• ZZP T-bolt clamps
• ZZP air/air front mount intercooler (28x8x4 core)
• Intercooler mounting kit
• Saab aluminum intake manifold
• Throttle body and wiring adapter
• Manual Boost Controller
• Standard rotation alternator
• Belt tensioner
• Serpentine belt

These kits are made per order, it can take up to 2 weeks to ship.

If using your own laptop for remote tuning, download the latest stable HPTuners VCM Suite here.

Update note: As of September 2022 we are now including our ZZP stencil with all heat exchangers and intercoolers. This way you can choose to leave the intercooler blank, or spray paint the ZZP logo with your choice of color to match your build. If you’d like to purchase a ZZP stencil for your intercooler or heat exchanger they can be found here.