So the facelift on my car his complete, looking at installing the heat exchanger now before my other parts arrive. What have you guys been doing to mount the heat exchanger? There are holes that the intercooler lines up to but they're boxed in. I have called around town looking for jack nuts, rivnuts and pop nuts and if I want to buy them I have to buy them in bulk. What other solutions have people come up with or is something like that really the way to go? (The hole size is 25/64)

Thanks for the help as always!

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DD: Cruze LT
04 Comp G: All dash no flash.
"I'm not an alcoholic but I keep a gallon of whine under the hood."
"My Grand Prix has a first name its W H I N E R."

I took tons of pics when i did my 06, check my car domain. (if u got any questions PM me, im barely here anymore)
http://www.cardomain.com/ride/3088935/2 ... grand-prix
as for installation instructions, i found the zzp ones r useless, so i used a video i found on line for changing the LIM gasket, very hepfull video (which i still have if needed to b uploaded)
and if your changing ur LIM your gona need new collant elbows, cause most likely u will break one of them
The heat exchanger I used i cant remember if the holes lined up with existing holes in the lower plastic part (what ever its called) or i drilled new ones, but the instructions say that you have to cut ur hood latch for it to fit right, i just kept it a little crooked and used a little bracket to hold it (check out the pics)

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Black 06 GP GT
S2 IC, 1.9 Rockers, TOG Headers w/ full custom exhaust, CAI, 104 Autolites, Custom Tuned PCM, 3.3....
And still Working its way up....

Good link GTPmchn. looks like the stock gasket's were just a little too thin to open up to the full size of the IC core?

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Comp G: 3.2-E85-65's-headers-rockers-104's-DHP tune & "other stuff that doesn't matter"

wat do u mean? sorry i didnt get it!

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Black 06 GP GT
S2 IC, 1.9 Rockers, TOG Headers w/ full custom exhaust, CAI, 104 Autolites, Custom Tuned PCM, 3.3....
And still Working its way up....

My core is a lot smaller than yours. It does line up with the holes in the bumper but they're blind holes and that is my issue right now with getting them mounted.

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DD: Cruze LT
04 Comp G: All dash no flash.
"I'm not an alcoholic but I keep a gallon of whine under the hood."
"My Grand Prix has a first name its W H I N E R."

cant u drill it though?

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Black 06 GP GT
S2 IC, 1.9 Rockers, TOG Headers w/ full custom exhaust, CAI, 104 Autolites, Custom Tuned PCM, 3.3....
And still Working its way up....

I wanted to try not to have to drill through it just to avoid any rust issues. I'll probably just end up drilling through.

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DD: Cruze LT
04 Comp G: All dash no flash.
"I'm not an alcoholic but I keep a gallon of whine under the hood."
"My Grand Prix has a first name its W H I N E R."

drill it out and fill it with some sealant around it and u should b just fun?

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Black 06 GP GT
S2 IC, 1.9 Rockers, TOG Headers w/ full custom exhaust, CAI, 104 Autolites, Custom Tuned PCM, 3.3....
And still Working its way up....

So I found the nuts I was looking for:

My dad gave me the idea to use these, they've been given the ok to be used on planes so I figure they can hold a heat exchanger in place.

Currently I'm working on plumbing the intercooler in such a way that the black hose isn't really visible and has no kinks and that I can still get my fill reservoir in a decent spot. Also wiring, I need to get my Aeroforce gauges wired in along with the pump. Not looking forward to this...
What did you use to bolt the alternator relocation bracket to the block? My bracket only came with 3 bolts, the original doesn't have enough threading on it to hold the bracket in place. The bolt that came off of it doesn't have threads all the way up it and the bracket is too thin, maybe a piece of steal tubing will make it work if I can't find a proper bolt.

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DD: Cruze LT
04 Comp G: All dash no flash.
"I'm not an alcoholic but I keep a gallon of whine under the hood."
"My Grand Prix has a first name its W H I N E R."

they guy that i bought it from he sent me the bolts with it, ill take a look at it tonight and may b snap a pic

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Black 06 GP GT
S2 IC, 1.9 Rockers, TOG Headers w/ full custom exhaust, CAI, 104 Autolites, Custom Tuned PCM, 3.3....
And still Working its way up....

I only got 3 bolts with the kit. 2 to hold on the "cradle" and one to connect the alternator to the other bracket.

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DD: Cruze LT
04 Comp G: All dash no flash.
"I'm not an alcoholic but I keep a gallon of whine under the hood."
"My Grand Prix has a first name its W H I N E R."

mine has 4, pm me ur email and i can send u a little video
where u in canada anyways?

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Black 06 GP GT
S2 IC, 1.9 Rockers, TOG Headers w/ full custom exhaust, CAI, 104 Autolites, Custom Tuned PCM, 3.3....
And still Working its way up....

I live in Manitoba. Yea, they're would be 4 all together, but I only got 3 with the kit. I did end up getting a bolt from work that should work.

Hey, did you need a new belt having the relocation bracket?

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DD: Cruze LT
04 Comp G: All dash no flash.
"I'm not an alcoholic but I keep a gallon of whine under the hood."
"My Grand Prix has a first name its W H I N E R."

i think i did
supercharged-3800-l67-l32-f16/belt-size-list-t10547.html

""930 - 04+ Alt Relocation Bracket & Stock WP""

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Black 06 GP GT
S2 IC, 1.9 Rockers, TOG Headers w/ full custom exhaust, CAI, 104 Autolites, Custom Tuned PCM, 3.3....
And still Working its way up....

I've seen that before, totally forgot about it. Thanks for the reminder!

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DD: Cruze LT
04 Comp G: All dash no flash.
"I'm not an alcoholic but I keep a gallon of whine under the hood."
"My Grand Prix has a first name its W H I N E R."