Base Kit includes:
- Borg Warner S257 Turbo
- TiAl 38 mm Wastegate
- ZZP Turbo Intake (black powder-coat finish)
- K&N Air Filter
- ZZP 304ss Exhaust Manifold
- ZZP Stainless Downpipe
- Oil feed and Drain Kits
- Manual Boost controller
- All necessary hoses, fittings, bolts, and gaskets
Option 1 adds:
- Upper Charge Pipe
- Lower Charge Pipe *required to get our tune
- MAF Relocation Kit *required to get our tune
- ZZP 50mm BOV
- ZZP front mount intercooler
To run our tune, it requires our lower charge pipe with relocated blow through MAF.
External or Recirculated wastegate?
- External dump means that every time you achieve full boost the wastegate will dump the extra exhaust pressure to the atmosphere. This means when the car is at high load and full boost is achieved the car will get very loud.
- Recirculated wastegate dumps the extra exhaust pressure directly into your downpipe and the car is quieter at full throttle. The factory turbo comes recirculated, it just uses an internal wastegate instead of our external TiAl wastegate.
Determine the boost control of the kit. 375-425whp tune is a ZZP ECM with a manual boost controller, that turns the boost up or down with a knob and is (usually) mounted under the hood. This option requires you to either ship us your ECM core to flash(preferred) or pay the refundable core charge.
If you select “I am doing my own tuning” then the kit will come without a PCM. With that option you do not need to pay the refundable core charge.
NOTE: For those looking to do this upgrade on a Regal or a Cobalt with a stock Gen 3 bottom end; you WILL NEED forged rods and pistons before doing this turbo kit. The stock Gen 3 rods are quite weak and will bend/break with this turbo.
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, made as much power, or lasted as long as the Borg Warner S257SXE turbo. We get many requests to use customer’s turbos but we strongly recommend against this route. If you search the forums there is literally no one making big power with successful builds that run well other than people using ZZP setups. This includes our choice of turbos.
The Borg Warner 257SXE turbo reaches maximum efficiency between 20 and 25 PSI on the 2.0. It is normally run at 22psi on pump gas depending on the other mods you have. (We recommend 20psi for 91 octane, 22 for 93) It will make 400whp on most setups but is capable of up to 500 with additional mods to the vehicle and E85. The Gen 2 LNF block, rods and pistons are not reliable above the 380 whp mark so it’s best to address the engine if you plan on making more than that.
We have done custom builds with turbos larger than the 257. They require E85, E98, or C16 to take advantage of the boost levels. Firewall modification, custom 3.5” downpipe. The turbo won’t spool until 4400 rpm making it a race only or dyno queen setup. Drivability is poor.
In the LNF, running E85 or above 450whp on pump gas; requires an intake cam with larger fuel lobe and Opel injectors. High HP builds will need to add our 5th injector.
If you intend on running more than 22 psi of boost with this kit we recommend purchasing the GMS1 sensors. The stock sensors are prone to blowing out at pressure above 25 psi and are only rated for 2.5 Bar.
How a Cobalt with the ZZP kit stacks against a GTR and modified Vette, click here.
These kits are made per order, it can take up to 3-4 weeks to ship.