Sportsman Ecotec Race Engine

n GM SPORT COMPACT Performance Build Book — 3rd Edition i CONTENTS INTRODUCTION ...............................1 CYLINDER HEAD GASKET .......................36 GENERAL INFORMATION ........................1 VALVE SPRINGS AND RETAINERS ..................36 PROGRAM HISTORY ...........................1 VALVES AND KEEPERS ........................36 WHY WE RACE .............................2 ROCKERS AND LIFTERS ........................37 LEGAL INFORMATION ..........................2 CAMSHAFTS ..............................37 ORDERING PARTS IN THIS BOOK ...................3 MECHANICAL TIMING CHAIN TENSIONER ..............38 BASE ENGINE OVERVIEW ........................3 TIMING CHAIN GUIDE ........................39 SPORTSMAN ECOTEC RACE ENGINE ................5 FLYWHEEL AND FLYWHEEL BOLTS ..................39 ADJUSTABLE CAM GEARS .......................6 FRONT HUB ..............................39 SUPERCHARGER .............................6 COOLING SYSTEM ...........................39 NITROUS OXIDE SYSTEMS .......................6 OIL PUMP (WET SUMP) .......................40 TURBOCHARGERS ............................6 OIL PUMP (DRY SUMP) .......................40 CONNECTING RODS ...........................7 INTAKE MANIFOLD ..........................41 PISTONS .................................7 EXHAUST HEADER ...........................41 INTAKE MANIFOLD ...........................7 PROFESSIONAL ECOTEC PARTS LIST .................42 HEAD GASKET AND HEAD BOLTS ...................8 ECOTEC RACE ENGINE CONTROL SYSTEMS ..........45 VALVE SPRINGS AND RETAINERS ...................8 ENGINE METRICS ...........................45 CYLINDER HEAD .............................8 FUEL INJECTORS ............................45 HIGH PERFORMANCE PISTON AND ROD R&R PROCEDURE .....9 FUEL PUMP ..............................46 SPORTSMAN ECOTEC PARTS LIST ...................26 ENGINE MANAGEMENT .........................47 NATURALLY ASPIRATED ECOTEC RACE ENGINE ......27 IGNITION SYSTEMS ..........................48 TURBOCHARGER ............................48 PRO ECOTEC RACE ENGINE......................29 BOOST CONTROLLER .........................49 ENGINE BLOCK ............................29 WASTE GATES .............................49 OILPAN................................31 INTERCOOLER .............................50 CRANKSHAFT ..............................31 CRANKSHAFT MAIN BEARINGS ....................32 4T65E RACE MODIFIED TRANSMISSION ............51 CONNECTING RODS ..........................32 TRANSBRAKE ..............................52 PISTONS, PISTON RINGS AND PISTON PIN LOCKS ........33 TRANSMISSION CASE .........................53 PISTON PINS ..............................34 STATOR SUPPORT ...........................54 CYLINDER HEAD ............................34 TORQUE CONVERTER .........................54 CYLINDER HEAD COVER .......................36 INPUT SHAFT .............................55 ii n GM SPORT COMPACT Performance Build Book — 3rd Edition OIL PUMP SHAFT ...........................55 COOLING SYSTEM ...........................68 DRIVE CHAINS .............................55 FUEL TANK ...............................69 SECOND GEAR CLUTCH ........................56 ELECTRICAL SYSTEM ..........................70 THIRD GEAR CLUTCH .........................56 SWITCHES ...............................70 FOURTH GEAR CLUTCH.........................56 EXHAUST SYSTEM ...........................71 SINGLE WRAP BAND .........................57 ROLL BAR KIT .............................71 OILDAM................................57 SEAT BELT HARNESS ..........................72 PLANETARY SET ............................57 SEATING ................................73 SPRAGS .................................57 THROTTLE PEDAL ASSEMBLY .....................74 SUN GEAR AND SHAFT ........................58 STEERING WHEEL ...........................74 PARK PAWL GEAR ...........................58 GAUGE PANEL .............................75 TORSENT DIFFERENTIAL ........................58 SHIFTER ................................75 RACE OUTPUT FLANGES .......................59 FRONT SUSPENSION ..........................76 ACCUMULATOR AND FORWARD SERVO ...............59 HALF SHAFTS .............................77 MODIFIED FLUID PICK-UP ......................59 OUTPUT FLANGES ...........................77 RACE TRANSMISSION PAN 22° ....................59 STEERING SYSTEM ...........................77 MODIFIED TUBE AND INDICATOR ..................60 REAR SUSPENSION ..........................78 SEPARATORPLATE...........................60 BRAKES .................................78 VALVE BODY ..............................60 HOOD ..................................80 PRESSURE REGULATOR ........................61 PHASE5 PARTS LIST ..........................81 CASE COVER ..............................61 APPENDIX ..................................83 4T65E SHIFT LOGIC ..........................62 2007 PRODUCTION ECOTEC ENGINE SPECIFICATIONS .......83 SHIFT CONTROLLERS .........................62 ECOTEC COMPONENT UPGRADE MATRIX ..............86 TRANSMISSION FLUID INFORMATION ................63 TORQUE SPECIFICATIONS .......................88 4T65E PERFORMANCE TRANSMISSION PARTS LIST..........64 PROFESSIONAL ENGINE BUILDER INSTRUCTIONS .........89 COBALT PHASE5 .............................65 COBALT PRO RACING BODY COMPONENTS .............94 INTRODUCTION ............................65 SUPPLIER CONTACT LIST .......................95 POWERTRAIN ..............................66 LSJ ECOTEC PACKAGING DRAWINGS .................98 ENGINE INSTALLATION ........................66 n GM SPORT COMPACT Performance Build Book — 3rd Edition 1 INTRODUCTION GENERAL INFORMATION Helm Incorporated www.helminc.com PO Box 07130 This handbook describes parts and procedures used to Detroit, MI 48207 prepare ECOTEC race engines used by GM Racing in Observe all safety precautions and warnings in the service professional Sport Compact Drag Racing and Drifting, as manuals. Wear eye protection and appropriate protective well as engine, transmission, and chassis modifications clothing. When working under or around the vehicle designed for sportsman-level drag racers. support it securely with jack stands. Use only the proper This handbook is intended to be used by experienced and tools. Exercise extreme caution when working with knowledgeable race engine and chassis builders. It does flammable, corrosive, and hazardous liquids and not cover all basic engine blueprinting and assembly materials. procedures, since it is assumed that the reader is already familiar with machining, measuring, and inspecting the PROGRAM HISTORY components. Some of the procedures described require specialized tools and skills. If you do not have the The General Motors Sport Compact Drag Racing Program appropriate training and equipment to perform these was kicked off at the 2001 International Auto Salon (IAS) modifications safely, this work should be performed by in Long Beach, CA. During IAS, GM identified Sport other professionals. Compact Drag Racing as the highest opportunity to gain There are, of course, many other possible combinations of awareness in the sport compact market. The first components and modifications that may produce equal or Chevrolet Cavalier and Pontiac Sunfire front-wheel-drive superior results. However, by using the combination of drag race cars were unveiled at the 2001 SEMA show, parts and procedures described in this handbook, an and, in February of 2002, GM Racing made their experienced engine builder can build a competitive and competitive debut in Palmdale, CA. In 2003 and 2004 the reliable ECOTEC Race Engine. GM Racing team won back-to-back championships in both the NHRA Hot Rod and ProFWD categories. In 2005, GM It is not the intent of this book to replace the transitioned from a factory race team to factory support of comprehensive and detailed service practices explained in independant teams. the GM service manuals. GM service manuals are available from: Fig. 1 INTRODUCTION 2 n GM SPORT COMPACT Performance Build Book — 3rd Edition Gary Gardella earned the 2005 NDRA Pro 4 cylinder approach, as a participant in racing, is to take championship in his first year running an ECOTEC race responsibility to support the sport. Someone else might engine. 2006 and 2007 brought more championships, even build a motor that beats the factory team. But it’s this records, and wins for Chevy and ECOTEC. democratization of racing that sets GM apart, and is the cornerstone of GM’s total business approach. WHY WE RACE LEGAL INFORMATION At GM, we race because it’s where we came from and because it fuels our love for competition. This publication is intended to provide technical Racing has been part of the GM culture since auto information on the GM ECOTEC engines, Hydra-Matic pioneers like Louis Chevrolet relied on speed records and transmission, and Chevy Cobalt used in sport compact racing victories to launch his fledgling car company. GM drag racing at the professional and sportsman level. has remained in racing for two basic reasons - to win on This handbook pertains exclusively to engines and the track and win in the marketplace. vehicles which are used off the public highways. Federal Racing is a compelling demonstration of the depth of GM’s law restricts the removal or modification of any part of a technical resources, the capabilities of its people and the federally required emission control system on motor performance, reliability, quality and safety of its products. vehicles. Further, many states have enacted laws

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