This page contains information from this post at j-body.org.
It is meant to be used as a guide; please use the information at your own risk.
Last Updated: January 16, 2008
There are many variations of GM's Ecotec engine, such as the 2.0L Supercharged LSJ on the 2004-2007 Saturn ION Red Line/2005-2007 Chevrolet Cobalt SS Supercharged Coupe, the 2.0L Turbocharged LNF on the 2007 Solstice GXP/2007 Saturn Sky Red Line/2008 Chevy HHR SS/2008 Chevrolet Cobalt SS, and the 2.4L LE5 available on many models including the 2006-present Chevrolet Cobalt/2006-present Chevrolet HHR/2006-present Pontiac G5 (Pursuit)/2006-present Pontiac G6/2006-present Pontiac Solstice/2006-present Saturn Sky/2006-2007 Saturn ION.
This page specifically discusses the 2.2L L61 available on the 2002-2005 Chevrolet Cavalier/2002-2005 Pontiac Sunfire.
"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.
GM's ECOTEC engine has proven to be a reliable and competitive engine for use in the Sport Compact Drag Racing Series. It has also proven it's 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 ECOTEC's outstanding feature to performance enthusiasts is it's 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."
– Source: GM Sport Compact Performance Build Book
Images:
General Engine Data:
- 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:
All capacities are approximate; add fluid as necessary.
- 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 – 3-spd transaxles: 7.0 qts / 4-spd transaxles: 9.5 qts
- Manual trans fluid - DEXRON-III Automatic Transmission Fluid
- Manual trans fluid capacity - 1.8 qts
- A/C refrigerant – R134a
- Power steering fluid - GM Power Steering Fluid GM P/N 89021184 (Canadian P/N 89021186) or equivalent
Brief Engine Differences:
Much of this information on L61 improvements is summarized from this thread at j-body.org, and from GM Media Online.
2002 Improvements (done over the Saturn's L-series' Ecotec)
- Cylinder head casting revisions
- Common oil pan for all applications
- Purge valve relocated for Saturn L-Series
- Engine block bosses
- Revised thermostat housing
- Starter
- New common powertrain control module (PCM)
- Heated rear oxygen (02) sensor
- Engine block heater
- Higher compression 9.5:1 to 10.0:1
2003 Improvements
- New Fuel rail
- Reinforced block
- 2.2L L42 capable of operating on compressed natural gas.
2004 Improvements
- Standard engine in the 2004 Chevrolet Malibu and Malibu Classic
- Unitized exhaust manifold/catalytic converter (Malibu)
- Higher compression and output (Saturn L-Series)
- Air-injection reaction (AIR) eliminated in all applications
- Fuel-pulse dampener for returnless fuel injection
- More efficient catalytic converters in under-floor applications.
2005 Improvements (final year for Chevrolet Cavalier and Pontiac Sunfire)
- Improved Block Structure
- Improved main and rod bearing material and shape
- Added polymer coating to piston and changed piston profile for noise reduction
- Added boss on oil pan for powertrain stiffening
- Acoustic cover for (Chevrolet Cobalt)
- Electronic throttle (Saturn ION and Chevrolet Cobalt)
- New fuel rail supplier (Chevrolet Cobalt.)
- Modified timing chain tensioner for noise improvement.
- New evap valve and tube.
- E16A controller (Chevrolet Cobalt and Saturn ION)
2006 Improvements
- New application: Chevrolet HHR
- Acoustic cover for Chevrolet Cobalt and Saturn ION
- Larger intake plenum for HHR
- Block modifications for increased strength
- New emissions standards
- Teflon front and rear crankshaft seals
- Two mounting bosses added to oil pan for increased rigidity
2007 Improvements
- Gen II Engine Block
- Cylinder Head Improvements
- New Camshaft Design
- E37 Engine Control Module (32-bit)
- 58X Crankshaft Reluctor Ring
- Digital Crank and Cam Sensors
- Individual Coil-on-Plug Ignition
- Vented Starter Solenoid
- New MAP Sensor
- New Intake Manifold Seals
- New Oil Filter Element
- Improved Emissions Performance
2008 Improvements
- Carried-over from 2007 (aka. none!)
Torque Specifications:
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.
- 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
GM Supercharger Overview:
There are many options for adding forced induction to the L61 Ecotec engine. There are several companies such as Hahn Racecraft who offer aftermarket solutions, and there are individuals who have managed to bolt on the 2003 Saab 9-3 turbocharger or the Cobalt SS/Ion Redline supercharger.
However, GM offers a factory supercharger kit for the 2003-2005 L61 Chevrolet Cavalier and Pontiac Sunfire.
The factory supercharger is available under GM part number 17800003, and is similar to the Cobalt SS/Ion Redline supercharger. It can be purchased from CrateEngineDepot.com, Pace Performance, and many GM dealerships across North America. Detailed installation instructions are written up in the Ecotec L61 Build Book.
It includes many parts, such as the supercharger, intake manifold, hoses, pullies, and PCM reflash. This kit will also work on 2002 models, but a new fuel rail and injectors may be required. Pace Performance offers a bundle containing the supercharger kit and the additional necessary parts to complete the installation on 2002 models.
The reflash is a key component, allowing the vehicle to operate properly with the supercharger. An alternative to the reflash is tuning software known as HP Tuners; this software only works on a stock PCM - it will not work with a reflashed PCM.
The supercharger kit, without any additional modifications, brings the stock horsepower up to about 200hp. It has the ability to be intercooled, however these parts are not included with the kit. The supercharger requires premium fuel, is 50 state legal, and meets GM standards for performance, drivability, and durability.
