Stage 3 Q & A:

What are the features of the Stage 3 kit?

The Stage 3 kit is an upgrade for vehicles equipped with Stage 2. It is for OFF-ROAD use only. Stage 3 increases includes features that allow for an adjustable rev limiter and proper calibration when using 100 octane fuel and/or a 50 shot of Nitrous. The Stage 3 kit consists of the following:

1. A smaller, 76mm supercharger pulley

2. A 2-pass intercooler end plate

3. A unique PCM which includes a calibration for the smaller pulley, an adjustable rev limiter, a 100 octane mode, and a nitrous control algorithm.

How much power will I get with Stage 3? Compared to the other Stage kits?

When equipped with the Stage 3 kit, the engine will make about 250hp on premium fuel and 260hp on 100octane. For best power, we recommend also installing a high-flow exhaust. In comparison, the stock supercharged engine makes 205hp. The Stage 1 kit increases peak power to 236hp and 205lb-ft of torque. Stage 2 delivers 241hp and 218lbft of torque across a broad rpm range.

Can I install the Stage 3 kit myself?

If you already have Stage 2 installed, it is possible to install Stage 3 yourself. However, installation of this kit, as with most performance parts, requires a level of technical and mechanical skill. It should not be installed by a novice. We recommend dealer installation for the Stage 2 kit due to special tools that are required to press-off the production supercharger pulley and install the kit’s supercharger hub. In addition, the Stage 1 and 2 calibration must be flashed into the production ECU by a GM dealer.

Do I have to install all of the Stage 3 parts at the same time?

The 2-pass intercooler end plate can be installed without the other Stage 3 components and would provide an improvement in performance for Stage 2 equipped car. Due to heat generation, the Stage 3 pulley should not be installed without the 2-pass intercooler. The Stage 3 pulley and 2-pass intercooler will operate with the Stage 2 reflashed PCM.

Are the parts available separately?

The parts will be available separately for service. Additionally, the 2-pass intercooler end plate can be added to a Stage 2 kit for improved performance.

What’s the purpose of the second surge tank?

The second surge tank is for the aftercooler. Without it, it is very difficult to purge the air from the system. Using the additional surge tank ensures a fully purged system with no trapped air. This higher pressure system will provide an added level of efficiency for the intercooler system.

How do you install the second surge tank? Are the parts needed included in the Stage 3kit?

The parts for the aftercooler surge tank are not included in the kit, but can be easily obtained. The surge tank is a production tank and can be purchased from a GM dealer. Hoses, clamps, tees, and air bleed fitting (press-in machined orifice) can be purchased from an automotive parts store. You will need to fabricate a couple simple brackets.
Instructions for plumbing the additional surge tank are included with the Stage 3 kit.

How do you adjust the rev limiter?

The rev limit is adjusted by pressing on the throttle pedal with the ignition on and engine off. At about 50% throttle the tachometer will show the current rev limit. Pressing the throttle further will adjust the rev limit in 250rpm increments.

How high can I set the rev limiter?

The Stage 3 PCM allows you to set the rev limiter up to 8000rpm. However, the engine will not reliably rev greater than 7000rpm without modification. If you would like to maintain a rev limit greater than 7000rpm, we recommend installing high-speed valve springs. Bates engineering offers high-speed valve springs that will fit in the stock head without modification. GM Performance Parts also offers a set of neutral balance shafts for high-rpm operation.

How do you change to 100octane mode? Can you change back?

With the ignition on and engine off, turn on the cruise control and hold the cruise set button for approximately 10 seconds. The shift light will illuminate to indicate 100 octane mode. Repeat this procedure to turn the 100 octane mode off. Note that the PCM defaults to 93 octane mode each time the ignition is switched off, so the process will need to be redone with each start-up.

What if you turn on the 100 octane mode when you do not have 100octane fuel in the tank?

The Stage 3 PCM will default to 93 octane mode when excessive knock is detected. If this happens, the shift light will turn off to indicate that 100 octane mode is off.

How does the Nitrous feature work?

A Nitrous system can be wired in so that the Stage 3 PCM provides the proper control scheme for a 50-shot of Nitrous when the Nitrous trigger is activated. The feature will only enable when the clutch is not depressed, throttle is at 90% or more, rpm is between 3500 and 500 below the rev limit, and no errors are detected.

What Nitrous kit does this work with?

The Stage 3 kit will work with any brand 50-shot Nitrous kit. It was designed around a dry system.

Why is Stage 3 for off-road use only?

This kit is off-road only because it has not gone through the GM standard validation process, nor has it been emissions certified. The Stage 3 kit has been validated in a racing and track environment by GM engineers and sponsored race teams. Note that, because Stage 3 if for off-road use only, the vehicle’s air-conditioning is disabled by the Stage 3 PCM.

Is the Stage 3 kit covered under warranty? Does it void my vehicle warranty?

Because the Stage 3 kit is not for normal on-highway use, it is not covered under

warranty and will void your vehicle warranty.

Why does Stage 3 disable the A/C?

The Stage 3 PCM disables the vehicle’s air-conditioning as a way to curb on-highway use of the kit. Stage 3 has not been durability tested nor emissions certified for on-highway use.

What if I want to use my Stage 3 equipped car as a daily driver?

The production PCM with the Stage 2 reflash will perform acceptably with the Stage 3 hardware. The Stage2 reflashed PCM will also maintain the A/C feature of your vehicle.

What are the part numbers?

88958715 (2004) Ion Redline Stage 3 kit

88958716 (2005) Ion Redline Stage 3 kit

88958717 (2006/2007) Ion Redline Stage 3 kit

88958718 (2005) Cobalt SS Stage 3 kit

88958719 (2006/2007) Cobalt SS Stage 3 kit

88958720 76mm pulley

88958721 (2) pass intercooler endplate

12610641 (2004) Ion Redline Stage 3 PCM

12610642 (2005) Ion Redline Stage 3 PCM

12610643 (2006/2007) Ion Redline Stage 3 PCM

12610644 (2005) Cobalt SS Stage 3 PCM

12610645 (2006/2007) Cobalt SS Stage 3 PCM

Do I have to have the Stage 2 kit before installing Stage 3?

Yes, the Stage 3 kit is an upgrade to vehicles equipped with Stage 2. Stage 3 requires the injectors, pulley hub, and pulley belt from Stage 2.

What fuel does the Stage 3 kit require?

The default mode of engines equipped with Stage 3 requires 93 octane fuel. The Stage 3

PCM is equipped with a 100octane mode.

Does the Time Attack car have the Stage 3 kit? The Grand Am Cup Cobalts?

The Time Attack car uses the Stage 3 pulley and 2-pass intercooler. However, the TimeAttack Cobalt is fitted with a 100 shot Nitrous kit. Therefore, it has a different calibration, and has been upfitted with additional components such as aftermarket pistons, neutral balance shafts, and high-speed valve springs. It also has a short header, large exhaust, and dry-sump oiling system. The Grand Am Cup Cobalts have used the Stage 2 kit in the past, along with the 2-pass intercooler. However, revised rules in the series have made the smaller supercharger pulley illegal.

Company X has an even smaller pulley. Can I use that?

The Stage 3 PCM does not have the proper calibration for a smaller pulley. In addition, supercharger pulleys smaller than 76mm would require an ice-box intercooler and exhaust ported head to control temperature.

What if I want to use a 75 or 100 shot of Nitrous?

The Stage 3 kit PCM has a control algorithm for a 50shot of Nitrous only. It would not work properly with a 75 or 100 shot. In addition, upgraded pistons would be required when using anything more than a 50 shot of Nitrous. Connector Tray 4 rh lower cornner.

Additional Stage 3 Information:

A lot of people wonder why Stage Three is what it is and why we stopped there. The answer is that Stage Three pushes certain production engine components to their limit. Going any farther with Stage Three, or adding more modifications to Stage Three, would put us at a horsepower level that would require internal engine upgrades.

For example, the piston (specifically the second ring) in the LSJ 2.0L Supercharged ECOtec engine can not hold any more than 310 horsepower. This is one of the reasons the Stage Three PCM allows for only a 50 shot of nitrous. Once you have the Stage Three 76-mm pulley and a 50-shot, you’re maxed out. Anything more would require upgraded pistons and rings. Otherwise, you’d see cylinder pressures that could ruin your piston rings and potentially more. This also creates crank case pressure high enough to blow out the dipstick with extended high rpm use.

The Stage Three kit also puts you at the limit of the fuel injectors. With Stage Three, you need to be extra careful about keeping your fuel system (fuel filter, fuel pump, injectors, etc.) well maintained because even a minor issue could cause a lean condition. If you work through our ‘rule of thumb’ fuel injector calculation tool at 310 horsepower supercharged, you get a required flow of 58 lbs/hr. The production injectors flow 55-60 lbs/hr. As you can see, you’re right at the limit with Stage Three.

Many of you wonder why the Stage Three 76-mm pulley is the smallest pulley we offer. The reason is heat. Each incrementally smaller pulley generates more heat, and heat is bad for power. The Stage Three kit includes a two-pass intercooler endplate and recommends a second surge tank to mediate heat build-up. If we were to go to an even smaller pulley, we’d be getting into heat generation that would require things like an exhaust ported head and an ice box.

That’s not a complete list of production parts that have reached their limit with Stage Three, but I think you get the idea. There is some reasoning behind our Stage Three kit!

A couple of additional things I want to point out: first, the Stage Three PCM does allow you to push the production valve springs beyond their limit. Stage Three includes the functionality to adjust the rev limiter up to 8000 rpm. However, the engine won’t rev reliably above 7000 rpm. If you want to take full advantage of the high-rpm feature, we suggest upgrading valve springs (at 7000 rpm) and going to neutral balance shafts (at 7500 rpm). Second, the Stage Three kit is off-highway only and has not been emissions certified.

Stage Three includes some features that are not streetable. As our way of emphasizing off-highway use only, the Stage Three PCM will disable your car’s air-conditioner. Stage One and Stage Two are street legal and plenty of fun. See your GM Performance Parts dealer for parts and availability and check out flickr for more pictures of the parts included in the kits.