Mikes Extended, Full Frame Goblin - 2009 Cobalt LS with 135k donor

[Ross]

I have an extra set of pedals from a 2006 LSJ SS with the fancy pedals on the G85 optioned Cobalt.
There are 2 switches on the brake pedal, the top one has provisions for 2 electrical connectors. The 2 wire connector was on my wiring harness, but the other 4 wire connector was not used. For my goblin, the top wire switch was removed, to allow the hood to fit, but I don't have cruise control set up, so I don't miss it. If I want to add cruise control, I will have to engineer a new switch and mount.
The wiring harness that the pedals connect to, is in my video here.

 

[mike_sno]

Thanks, great pictures and information. I ordered a bunch of limit switches and plugs. I will just install my own limit switches and connect them to the harness.

Found plugs for the accelerator pedal, missing fuel pump and intercooler pump. Ordered all 3 of them.

I have on the engine harness a plug which fits on the intercooler pump.(Maybe coincidence? ) I do believe that I have pulled 2 wires during building the harness for the intercooler. Does anyone know what's that about?

 

[Robinjo]

If I recall correctly the intercooler pump for the LSJ is on the engine harness. A little black plug with two wires. The plug had a metal snap wife across it.

Edited....

 

[ah.b.normal]

I was helping a guy finish his Goblin in August. Same plug mystery. The way DF did his wiring harness IIRC his power wire to the intercooler pump sprouted out of the back of the center tunnel wiring bundle? I believe it was a red wire and was grounded separately to the block.
We had a similar plug with a heavy foil insulated cover that we couldn't find where it went and thought that was IC Pump, NO! that went to a plug under the inlet to the turbo, near where the inlet plumbing meets the turbo. That sensor is down low and easy to miss.

 

[mike_sno]

Good point... pretty sure I read somewhere the brake and clutch position sensors are different on late models. A cursory look at RockAuto seems to indicate this

Turned out you were right with that statement.

 

[mike_sno]

It can probably be mostly done with what you have but you better have access to the full wiring diagrams and connectors views for both donors. Plus a lot and time and patience.

How true that was!!!

 

[mike_sno]

I have a few bucket full of screw which came with the engine. For sure not all engine screws, but I try to find out which screw goes where.

I can't find a diagram like this one for the LSJ. Does anyone know where I can get one? https://www.wholesalegmpartsonline.com/cars/Chevrolet/2007/Cobalt-4DR/car-parts.html

 

[Desert Sasqwatch]

In this link you can select year and model.

 

[mike_sno]

I know, but when you do it on click on the SC you still see the parts from the 2.2 L engine.

 

[mike_sno]

I need a new belt tensioner. It seems like the GM part is discontinued. Anyone know if this part might fit or has a better alternative?

https://www.fcpeuro.com/products/porsche-belt-tensioner-shock-cayenne-ina-94810225901?ads_cmpid=12182638689&ads_adid=117424816256&ads_matchtype=&ads_network=g&ads_creative=494639080014&utm_term=&ads_targetid=pla-296303633664&utm_campaign=&utm_source=adwords&utm_medium=ppc&ttv=2&gclid=EAIaIQobChMIzvOy-qWkggMV8uWGCh1DzwYXEAQYDSABEgLPXvD_BwE

 

[jirwin]

Look thru my build thread and line it up with the one I bought from a Porsche Cayenne. Looks the same as the one I got.

 

[mike_sno]

Does the supercharger coolant pump uses a sleeve or something to fit in the bracket at the motor? The pumps diameter is smaller than the braket and I can't get it secured.

 

[Ross]

Mike_sno, there is a black rubber gasket/vibration damper that wraps around the electric Bosch pump.

 

[mike_sno]

Ok, don't have that. I'll figure something out.

 

[mike_sno]

Another question: I installed the started but I don't know exactly what kind of screws to use to hold it. The holes of the screws in the motor go through and I wonder if the holes are used from the gearbox side to hold something or if they are just drilled through due to manufacturing reasons.

 

[Ross]

I used bolts to hold the starter... nothing mounted on the transmission side... at least on my LSJ with the F35 transmission.
The bolt is at the bottom of this picture... there is a 2nd bolt on the other side of the starter.

 

[mike_sno]

LSJ driver, can someone let me know what the clearance is between the alternator and the belt going up to the supercharger? I like the right picture a bit better, but I am not sure of that is to close to the alternator.

 

[mike_sno]

Can someone point me in the right direction? I assume that from the picture below A and B need to be connected to C and D.
Does it matter if A --> C and B --> D or A --> D and B --> C ?

 

[mike_sno]

And more coolant questions! Connect E and F since this was the heat exchanger?

What is G used for?

 

[Ross]

My 6 rib belt misses the alternator pulley by a finger width (5/8" or maybe 3/4").

A goes to C, B goes to D.

E goes to your coolant tank, F & G get connected together with a hose loop... was the old cab heater.