L61 Ecotec - Overview, Torque, Fluid, and Engine Specs
*****Overview*****
The engine is the heart of a competition car. It must be capable of delivering full power reliably run-after-run on race day, at engine and vehicle speeds far in excess of those encountered in normal driving. Every part of a competition engine must be as nearly perfect as possible the slightest failure can put you out of the running or even out of the race.
Since 1955, the Small Block Chevy has proven its versatility, durability, and performance potential with automotive performance enthusiasts. The ECOTEC engine has all the basic mechanical components to repeat this success. A sound base engine structure, excellent airflow capability, easy serviceability, compact size and low weight. These qualities, along with the very successful race program, demonstrate the ECOTEC is a driving force in the Sport Compact Segment.
GMs ECOTEC engine has proven to be a reliable and competitive engine for use in the Sport Compact Drag Racing Series. It has also proven its superior durability in grueling five mile runs at the Bonneville Salt Flats with speeds over 300 MPH and in showroom stock endurance road racing competition. The number of stock components utilized in the race engine demonstrates the robust design of the ECOTEC engine.
The ECOTECs outstanding feature to performance enthusiasts is its impressive strength. GM Racing dynamometer tests confirm that major horsepower gains are possible with minimal modifications. For instance, when building an ECOTEC engine to the 400 hp power level, no modifications to the cylinder head, block, main girdle or crankshaft are required.
The production ECOTEC engine block is manufactured out of aluminum using a lost-foam casting process. This process allows for both a stronger and lighter part. Flanged, thin-wall iron cylinder sleeves are press-fit into a semi-floating aluminum support structure. The ECOTEC block is supported by a massive die-cast aluminum girdle/ main cap assembly and structural oil pan for noise and vibration suppression. The main-cap structures are each supported with six fasteners. Extra-thick main bearings resist the differential thermal expansion of the nodular iron crank and aluminum block.
All ECOTEC blocks are cast with passages for piston-cooling jets and an oil cooler for high-output turbocharged applications. The fully-boxed block requires no windage tray, even on applications up to 600 horsepower. An auxiliary chain drives the water pump and balance shafts from the crank.
To reduce the risk of hot spots, pressure-cast, non-squish dished pistons are manufactured without valve reliefs. The symmetrical, barrel-faced moly-coated top ring fits in an anodized ring-groove below a super-thin 3mmtop ring land, creating a low crevice volume for reduced emissions. The pistons deliver power through full-floating piston pins and powder-metal or forged steel connecting rods.
The ECOTEC twin-cam cylinder head uses low-friction hydraulic roller finger-followers, which have been proven reliable and effective up to 11,000 rpm. Head fastener placement permits cylinder head removal and installation without removing the camshafts. The camshafts are driven directly off the crank by a chain. The design includes provisions for future upgrading to variable cam phasing. The finger-follower design permits a light-weight narrow profile and reduced valve angles(the intake valve is 18 degrees from vertical and the exhaust valve 16 degrees).
The design of the intake manifold eliminates the need for variable-length intake runners and consideration has been made for conversion to gasoline direct-injection.
The ECOTEC engine management system uses a port-EFI design with cassette waste-spark ignition. An integral compression-sense ignition module eliminates the need for a cam position sensor.
GM Sport Compact Performance Build Book
*****The basics*****
-Engine configuration inline 4 cylinder gas engine
-Valve train DOHC 16 valve with hydraulic roller finger followers
-Displacement - 2.2 Liter (134 CID) (2189 CC)
-Bore x Stroke 86 mm x 94.6 mm
-RPO L61
-Vin code F
-HP 140 @ 5600 RPM
-TQ 145 @ 4000 RPM
-Oil pressure @1,000 RPM 50-80 psi
-Engine cranking compression pressure - 185-225 psi
-Compression ratio - 10:1
-Firing order- 1-3-4-2
-Ignition cassette waste spark
-Recommended octane 87
-Fuel Delivery return less Sequential fuel injection (SFI)
-Fuel pressure key on engine off 50-60 psi
-EPA rated fuel economy (manual trans) 26 MPG City & 37 MPG highway 30 MPG combined
-Generator rated output 105 A
-Generator load test output 73 A
-Thermostat opening temperature 180 degrees F
-Emissions Low emissions vehicle equipt with single Catalyst
*****Fluids and Capacities*****
-Brake Fluid Delco Supreme II or equivalent Dot 3 brake fluid
-Clutch fluid - Hydraulic Clutch Fluid (GM Part No. U.S. 12345347, in Canada 10953517) or equivalent DOT-3 brake fluid
-Engine Oil - SAE 5W-30 is the only viscosity grade recommended for your vehicle.
Use only oils which have the API Starburst symbol and which are also identified as SAE 5W-30.If the temperature range is 0°F (-18°C) or above SAE 10W-30 oil which has the API Starburst symbol is acceptable if SAE 5W-30 oil is not available. Areas where the temperature falls below -20°F (-29°C), it is recommended either an SAE 5W-30 synthetic oil or and SAE 0W-30 oil. Both will provide easier cold starting and better protection for the engine at extremely low temperatures. Do not use other viscosity grade oils, such as SAE 10W-40 or SAE 20W-50 under any conditions.
-Engine oil capacity 5 qts
-Coolant Dexcool antifreeze 50/50 mix with drinkable water
-Coolant capacity - 8.6 qts
-Auto trans fluid - DEXRON-III Automatic Transmission Fluid
-Auto trans fluid capacity bottom pan removal 6.9 qts, complete overhaul - 9.5 qts
-A/C refrigerant R134a
-Power steering fluid - GM Power Steering Fluid GM P/N 89021184 (Canadian P/N 89021186) or equivalent
*****Torque Specs *****
NOTE- some specs are FOOT pounds, some are INCH pounds, do not confuse the two. And keep in mind some common sense is your best friend, if you come across something that says valve cover is torqued to 75 lb ft common sense should tell you that is way to much, torque spec listings are not always 100% accurate, just use your head. And BTW I did not copy and paste this list cause I find it somewhere, I looked it all up and recorded them (hand typed them) one at a time, you guys better get some use out of this LOL.
-A/C compressor to block bolt
.
.. 20 N-m / 15 lb ft
-Balance shaft adjustable chain guide bolt
10 N-m / 89 lb in
-Balance shaft bearing carrier to block bolt
..
..10 N-m / 89 lb in
-Balance shaft fixed chain guide bolt
...
.10 N-m / 89 lb in
-Balance shaft sprocket bolt
...50 N-m / 37 lb ft
-Block heater bolt
...
...10 N-m / 89 lb in
-Cam cover to cylinder head bolt
..10 N-m / 89 lb in
-Cam cover to ground cable bolt
10 N-m / 89 lb in
-Cam cover to ground cable stud
10 N-m / 89 lb in
-Camshaft bearing cap bolt
.10 N-m / 89 lb in
-Camshaft sprocket bolt
First pass
............
85 N-m / 63 lb ft
Second pass
..........
30 degrees
-Camshaft timing chain tensioner
..75 N-m / 55 lb ft
-Chain guide plug
.....
..80 N-m / 59 lb ft
-Connecting rod bolt
First pass
..............
25 N-m / 18 lb ft
Second pass
.............
...100 degrees
-Crankshaft bearing lower crankcase to block
First Pass
...............
20 N-m / 15 lb ft
Second pass
.............
70 degrees
-Crankshaft position sensor bolt
...
10 N-m / 89 lb in
-Crankshaft pulley bolt
First pass
...............
100 N-m / 74 lb ft
Second pass
..............
75 degrees
-Cylinder head bolt
First pass
...............
.30 N-m / 22 lb ft
Second pass
...............
155 degrees
-Cylinder head front crankcase bolt
.....
35 N-m / 26 lb ft
-Cylinder head oil gallery plug
......
35 N-m / 26 lb ft
-Dipstick guide to intake manifold bolt
.....
...10 N-m / 89 lb in
-Drive belt tensioner bolt
.......
.45 N-m / 33 lb ft
-E.G.R. cover bolt
.........
25 N-m / 18 lb in
-Elek. ICM cover bolt
..........
..10 N-m / 89 lb in
-Engine coolant temp sensor
........
22 N-m / 16 lb ft
-Engine lift bracket front bolt
........
...25 N-m / 18 lb ft
-Engine lift bracket rear bolt
.......
.25 N-m / 18 lb ft
-EVAP emission canister valve nut
......
..22 N-m / 16 lb ft
-Exhaust manifold to cylinder head nut
.....
12 N-m / 9 lb ft
-Exhaust manifold to cylinder head stud
.....
..10 N-m / 89 lb in
-Exhaust manifold pipe flange stud
.......
16 N-m / 12 lb ft
-Flex plate (AMT) bolt
First pass
....................
53 N-m / 39 lb ft
Second pass
..................
25 degrees
-Flywheel (SMT) bolt
First pass
...................................
.
.53 N-m / 39 lb ft
Second pass
.
..................................25 degrees
-Front cover to block bolt
...........
25 N-m / 18 lb ft
-Fuel pipe bracket bolt
...........10 N-m / 89 lb in
-Fuel rail bracket stud
..........
..10 N-m / 89 lb in
-Generator to block bolt
............
..20 N-m / 15 lb ft
-Heat shield to exhaust manifold bolt
..........10 N-m / 89 lb in
-Intake camshaft rear cap bolt
...........25 N-m / 18 lb ft
-Intake manifold to cylinder head bolt
..........
10 N-m / 89 lb in
-Intake manifold to cylinder head nut
...........10 N-m / 89 lb in
-Intake manifold to cylinder head stud
...........6 N-m / 53 lb in
-Knock sensor bolt
..............25 N-m / 18 lb ft
-Lower crankcase to block peripheral bolt
........
.25 N-m / 18 lb ft
-Oil gallery plug
.
...............35 N-m / 26 lb ft
-Oil gallery plug rear
.............
60 N-m / 44 lb ft
-Oil filter housing cover
..............
..22 N-m / 16 lb ft
-Oil pan drain plug
..............
...25 N-m / 18 lb ft
-Oil pan to block bolts
.............
.25 N-m / 18 lb ft
-Oil pressure switch
............
.10 N-m / 89 lb in
-Oil pump cover bolt
..............
.6 N-m / 53 lb in
-Oil pump pressure relief valve plug
..........
...40 N-m / 30 lb ft
-Oxygen sensor
.............
42 N-m / 31 lb ft
-Power steering pump bolt
..........
...25 N-m / 18 lb ft
-Spark plug
.............
...20 N-m / 15 lb ft
-Starter motor to block bolt
...........
..40 N-m / 30 lb ft
-Thermostat housing to block bolts ............
..10 N-m / 89 lb in
-Throttle body bolt
.................10 N-m / 89 lb in
-Throttle body nut
..............
10 N-m / 89 lb in
-Throttle body stud
...............
6 N-m / 53 lb in
-Timing adjustable chain guide bolt
..........
10 N-m / 89 lb in
-Timing chain oil nozzle bolt
................10 N-m / 89 lb in
-Timing fixed chain guide bolt
..............
10 N-m / 89 lb in
-Timing upper chain guide bolt
...............10 N-m / 89 lb in
-Vent tube to cylinder head
.............
.15 N-m / 11 lb ft
-Water pump access cover bolt
...........
.7 N-m / 62 lb in
-Water pump / balance shaft chain tensioner bolt
..........10 N-m / 89 lb in
-Water pump bolt
...............25 N-m / 18 lb ft
-Water pump sprocket bolt
..............
.10 N-m / 89 lb in
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I started to type out the actual measurements and clearances of moving parts internal to the engine but ran into 2 problems. 1- Conflicting information. And 2- no one really has any need for the info, any good machine shop / machinist has access to all the specs and clearances. So after a good hour and a half of work I scraped the progress on that.
Information taken for 2004 Chevrolet Cavalier
