Ecotec Engine General Specifications
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n ECOTEC Racing Engine Handbook i CONTENTS INTRODUCTION ..............................1 ENGINE ASSEMBLY ...........................15 GENERAL INFORMATION ........................1 ENGINE BLOCK ............................15 PROGRAM HISTORY ...........................1 CRANKSHAFT ..............................15 GENERAL ENGINE SPECIFICATIONS ..................2 PISTONS AND CONNECTING RODS ..................15 LEGAL INFORMATION ..........................2 CYLINDER HEAD ............................16 ENGINE COMPONENTS .........................4 ENGINE SPECIFICATIONS .......................17 ENGINE BLOCK .............................4 PERFORMANCE .............................17 ENGINE BLOCK MAIN GIRDLE .....................6 TORQUE SPECIFICATIONS ......................18 BALANCE SHAFTS ............................6 PARTS LIST ................................20 OILPAN.................................7 SEALERS AND LUBRICANTS ......................21 CRANKSHAFT ..............................7 SUPPLIERS .................................22 CONNECTING RODS ...........................8 PISTONS .................................8 CYLINDER HEAD .............................9 CYLINDER HEAD COVER .......................12 CAMSHAFTS ..............................12 INTAKE MANIFOLD ..........................12 PUMPS (WATER PUMP AND OIL PUMPS) ..............13 FUEL INJECTION SYSTEM .......................13 IGNITION SYSTEM ...........................14 TURBOCHARGERS ...........................14 n ECOTEC Racing Engine Handbook 1 INTRODUCTION GENERAL INFORMATION There are, of course, many other possible combinations of components and additional modifications that may produce This handbook describes all of the parts used to assemble equal or superior results. However, by using the the ECOTEC 2.0L Race Engine used in NHRA’s Summit combination of parts and procedures described in this Sport Compact Drag Racing Series. The information handbook, an experienced engine builder can build a contained in this handbook was provided by GM Racing, in competitive and reliable ECOTEC Race Engine. conjunction with Bothwell Motorsports and Shaver Specialties. PROGRAM HISTORY This handbook is intended to be used by experienced and knowledgeable race engine builders. It does not cover basic The front wheel drive drag racing program was kicked off at engine blueprinting and assembly procedures, since it is the 2001 International Auto Salon (IAS) in Long Beach, CA. assumed that the reader is already familiar with machining, During the IAS, GM identified sport compact drag racing as measuring, and inspecting of the components. Some of the the best opportunity to gain awareness in the sport compact procedures described require specialized tools and skills. If market. During the 2001 SEMA show, the Chevrolet you do not have the appropriate training and equipment to Cavalier and Pontiac Sunfire race cars were debuted. In perform these modifications safely, this work should be February of 2002 GM Racing and Bothwell Motorsports performed by other professionals. made their competitive debut in Palmdale, CA. Currently both vehicles are competing in the NHRA Summit Sport Compact Drag Racing Series. Figure 1 2002 ECOTEC Powered Cavalier and Sunfire at Houston Raceway 2 n ECOTEC Racing Engine Handbook GENERAL ENGINE SPECIFICATIONS The base engine used to build the ECOTEC Race Engine is the 2.2L ECOTEC engine used in the current Pontiac Sunfire and Chevrolet Cavalier. ECOTEC ENGINE GENERAL SPECIFICATIONS PRODUCTION ENGINE RACE ENGINE Engine Type 2.2L DOHC 2.0L DOHC Configuration Inline 4 Inline 4 Displacement 134 Cubic Inch Displacement 127 Cubic Inch Displacement Bore x Stroke 3.3809 Bore x 3.7209 Stroke 3.4009 Bore x 3.5059 Stroke Material A356-T6 Lost Foam Cast Aluminum A356-T6 Lost Foam Cast Aluminum Cylinder Cylinder Head and Block Head and Block Valvetrain DOHC 4 Valves Per Cylinder Non DOHC 4 Valves Per Cylinder Non Variable Variable Cam Phasing Cam Phasing Compression Ratio 10.0 to 1 10.4 to 1 Firing Order 1-3-4-2 1-3-4-2 Fuel Type Unleaded Gasoline Methanol Engine Oil 5 W 30 15 W 50 MOBIL 1 Peak Horsepower 140 HP @ 5600 RPM 925 HP @ 8500 RPM Peak Torque 150 FT LBS @ 4000 RPM 599 FT LBS @ 7500 RPM Engine RPM Rev 6400 RPM 9700 RPM Limiter Cooling System Production Production Oil Pressure 50-80 PSI @ 1000 RPM Wet Sump System 125 PSI @ 9000 RPM – Dry Sump System 85 PSI @ all engine speeds Ignition System Coil On Plug Waste Spark Ignition MSD Digital 7 Programmable w/Crank Trigger System LEGAL INFORMATION This publication is intended to provide technical information on the GM ECOTEC 2.0L engine used in the National Hot Rod Association (NHRA) Summit Sport Compact Drag Racing Series. This handbook pertains exclusively to engines and vehicles which are used off the public highways. Federal law restricts the removal or modification of any part of a federally required emission control system on motor vehicles. Further, many states have enacted laws which prohibit tampering with or modifying any required emission or noise control system. Vehicles which are not operated on public highways are generally exempt from most regulations, but the reader is strongly urged to check all applicable local and state laws. Figure 2 n ECOTEC Racing Engine Handbook 3 Many of the parts described or listed in this handbook are The information contained in this handbook is subject to merchandised for off-highway application only, and are change. General Motors also reserves the right to make tagged with the following Special Parts Notice: changes at any time, without notice, in equipment, manufacturers, specifications, and materials, or to SPECIAL PARTS NOTICE discontinue items. This part has been specifically designed for Off-Highway The information in this publication is presented without any application only. Since the installation of this part may warranty. All the risk for its use is entirely assumed by the either impair your vehicle’s emission control user. Specific component design, mechanical procedures, performance or be uncertified under current Motor and the qualifications of individual readers are beyond the Vehicle Safety Standards, it should not be installed in a control of the publisher, and therefore the publisher vehicle used on any street or highway. Additionally, any disclaims all liability incurred in connection with the use of such application could adversely affect the warranty information contained in this publication. coverage of such an on-street or highway vehicle. Chevrolet, Pontiac, Cavalier, Sunfire, General Motors, and GM are registered trademarks of the General Motors Corporation. Figure 3 2002 ECOTEC Cavalier at Houston Summit Sport Compact Drag Racing Series Event 4 n ECOTEC Racing Engine Handbook ENGINE COMPONENTS ENGINE BLOCK The engine block used to build this engine is a production GM OE (original equipment) block (Fig. 4). The engine block was prepared by Shaver Specialties, in conjunction with GM Racing and Bothwell Motorsports. This production block is cast from A356-T6 aluminum using a lost foam process. There have been many modifications and checks made to the original production cylinder block including: Figure 5 ² The cylinder sleeves are machined to accept one piece o-rings (Fig. 6). These o-rings are made of one piece .0419 thick stainless steel. The o-rings are installed .0089 proud of the cylinder sleeves. Figure 4 ² The ZYGLOT system is used to check for cracks and imperfections in the engine block. ² All oil gallery plugs are removed to clean and inspect all passages. ² The stock sleeves are machined out and new nodular iron sleeves are installed (Fig. 5). The sleeves are installed .0039 proud above the block deck. The sleeves are also press fit to .0039. The cylinder sleeves are finish honed with deck plates installed and torqued to 85 ft. lbs.. Figure 6 NOTE: The o-rings have a flat and beveled side. The flat side is installed into the cylinder sleeves. ² All cylinder head bolt holes are drilled and roll tapped to fit 1⁄29 13 studs. ² H-11 1⁄29 13 head studs are installed into the block (Fig. 7). n ECOTEC Racing Engine Handbook 5 ² The factory oil bypass is tapped to 1⁄4 pipe thread and plugged (Fig. 9). Figure 7 ² H-11 7⁄16 14 main studs are installed into the block. Figure 9 ² The main oil gallery holes are reamed to .2659. ² The front two oil galleries are plugged with 1⁄2 steel plugs. ² The main journals are line honed to 2.52259. ² The head and main studs are installed using Blue Loctite ² The factory oil pressure sensor location hole is tapped to #242T and torqued to 8ft.lbs.. After the studs are 1⁄4 pipe thread (Fig. 8). installed, main girdle and block deck plates are installed ² The factory crankshaft position location hole is tapped to and torqued to 20ft.lbs.. The studs are allowed to dry for -08 AN thread and plugged (Fig. 8). 24 hours. ² The oil filter housing boss is drilled and tapped to 1⁄2 pipe ² With the deck plates torqued to 85ft.lbs., the cylinders are thread for an oil feed (Fig. 8). honed until .0059 piston to liner clearance is achieved. ENGINE BLOCK SPECIFICATIONS Part # 88958630 Block Bore 3.4009 Block Deck Height 8.7009 Block Main Journal 2.52259 Diameter Cylinder O-ring Thickness .0419 Head Studs Length W/Ball End Seat 7.6259 Seat End Thread Length 1.7509 1⁄2 13 Thread Cap End Thread Length 1.0009 1⁄2 20 Thread Main Girdle Studs Length W/Ball End Seat 6.9009 Figure 8 Seat End Thread Length 1.7509 7⁄16 14 Thread ² The block deck is machined to fit larger cylinder head 9 7 alignment dowels. The new dowels measure