EcoTec 2.0 SuperCharged engine with 5 speed transmission

This engine package is possibly the best package you can put in your Fiero when it comes to power to weight ratio, vs dollar for dollar spent.

Could be California legal !

Companies are jumping on the bandwagon in support of the 4 cylinder EcoTec engine program that GM Racing has been developing the last 4-5 years. This little 4 cylinder supercharged package is from the Saturn Ion Redline, and the Chevrolet Cobalt SS. Did you notice Chevrolet was involved? Yes, when Chevrolet gets involved, everyone gets excited. GM supports a racing program, you know quality parts are coming for the product line. Specifications for this 2.0 supercharged engine do not appear impressive at first.

2006 Ecotec 2.0L I-4 Supercharged (LSJ)
Type: 2.0L I-4 supercharged
Displacement: 1998cc (122 ci)
Compression ratio: 9.5:1
Valve configuration:
dual overhead camshafts (4 valves per
cylinder)
Assembly site: Kaiserslautern, Germany
Valve lifters: hydraulic roller finger follower
Firing order: 1 - 3 - 4 - 2
Bore x stroke: 86 x 86mm
Fuel system: sequential fuel injection
Air Delivery
Eaton Helical Roots M62 Supercharger @ 12
psi Boost pressure
Horsepower: 205 hp (153 kw) @ 5600 rpm                 
Torque: 200 lb-ft (272 Nm) @ 4400 rpm
Fuel shut off: 6500 rpm
Emissions controls: three-way catalyst
Applications: Chevrolet Cobalt SS
Saturn ION Red Line
Block: cast aluminum with cast iron cylinder liners
Cylinder head: cast aluminum
Intake manifold: aluminum
Exhaust manifold: cast iron
Crankshaft: forged steel with induction hardened fillet
Camshaft: cast iron
Connecting rods: forged steel
Additional features: high pressure ( 56 psi ) fuel pump
extended life platinum spark plugs
extended life coolant
electronic throttle control
Individual coil on plug high energy ignition

Now, at 205HP from the factory, if you go to the http://www.cobaltss.net/forums/index.php? or the http://www.redlineforums.com/index.php you will find that most 2.0SC cars are dyno'ing 200 at the TIRES ! Yes, GM underrates on purpose sometimes to keep a car in an insurance bracket. Maybe its a honest mistake of bad dyno info that day too... :) Now, what else makes this exciting? The factory is going to release UPGRADE kits to make this engine 250HP at the tires, and still keep the warranty. GM is going to allow a LSD upgrade and still maintain warranty on the transmission. GM has obliviously did its homework and found excellent results from the 5 speed manual transmission the Ion and Cobalt have.

The Stage 1 kit includes higher flow injectors and a new PCM calibration.  The injectors give the engine enough fuel to rev higher, and the new engine calibration allows it all to happen by raising the rev limiter to 6700rpm.  The new calibration also allows full boost instead of limiting it to a 205hp maximum with the stock PCM. Stage 1 would be a modest improvement over the stock configuration, but perhaps that’s because the best is yet to come.

Stage 2 adds the same injectors and calibration as Stage 1, but also includes a smaller 79mm supercharger pulley which increases boost by 2psi.  According to Jim Minneker, Engineering Group Manager at GM HPVO, the Stage 1 calibration is configured to account for the smaller pulley if it is added, so there’s no need for different calibrations for each stage. 

Factory release Stage 1 and Stage 2 upgrades that are currently undergoing CARB certification and will hopefully be released around SEMA time in November.

UPDATE 11-10-05

The kits are hitting the dealers by Dec 5th 2005 according to good rumors...

GM builds Ecotec 2.0 LSJ to 300HP

Transmission specifications:

2006 F35 (MU3)  <<< FastFiero's choice of transmissions for the 3800SC and LS1 future installs.
Type: transverse front wheel drive, five
speed manual transaxle ( optional
with limited slip differential )
Engine range: 2.0L I-4 supercharged
Maximum engine torque: 200 lb-ft ( 271 Nm )
Maximum gearbox torque: 258 lb-ft ( 350 Nm )
Gear ratios: MU3
First: 3.38
Second: 1.76
Third: 1.18
Fourth: 0.89
Fifth: 0.7
Reverse: 3.17
Final Drive 4.05
Maximum validated gross vehicle weight: 5071 lb ( 2300 kg )
Case material: aluminum
Center distance: 76.5 mm
Fluid type: Castrol BOT 0063
Transmission weight: 45 kg ( 99 lb )
Fluid capacity (approximate): 1.7L / 2.0 qt ( dry )
Power take off: no
Applications: Chevrolet Cobalt SS
Saturn Ion Red Line

This transmission comes from European roots. It was designed for 5000lbs GVW packages. This transmission has an LSD already available from Quiafe. There is one coming from Torsen. The transmission was derived from the Saab F25 platform. The F25 has a 6 speed upgrade kit. The upgrade is not targeted to high speed racing however. It is more toward the road racing short course setups. This upgrade however, might be a great improvement for drag racing with this transmission on a LS1, or even a 3800SC.. That's another story however..

Speaking of stories. Here is an article at this GM website http://www.gm.com/company/racing/technology/FWDEngine.htm

The Ecotec 2.2-liter four-cylinder engine is GM's first truly global powerplant. In production trim, the Ecotec delivers exceptional fuel economy and low exhaust emissions in a reliable, low-maintenance package. In racing trim, it delivers astounding horsepower.

"With the GM Ecotec global powerplant, we're making over 1,000 horsepower, and the majority of the engine components are production parts," said Josh Peterson, GM Racing Sport Compact program manager. It's simply amazing what can be done with this basic engine package.

Consider that the turbocharged Ecotec that powers the front-wheel-drive Cavalier drag racer produces more than 1,000 horsepower from only 127 cubic inches of piston displacement - a staggering 7.9 horsepower per cubic inch. If a naturally aspirated 500 ci Pro Stock engine had equivalent output, it would produce more than 3,900 horsepower.

"With the GM Ecotec global powerplant, we're making over 1,000 horsepower, and the majority of the engine components are production parts," said Josh Peterson, GM Racing Sport Compact program manager. "We're using a production block, production main bearing girdle, production cylinder heads, a production oiling system and a production drive chain. It's simply amazing what we can do with this basic engine package. We believe that we will ultimately reach more than 1,150 horsepower before we exceed the limits of the production parts."

Many of the heavy-duty Ecotec components developed by GM Racing for the Sport Compact drag racing program are now available to enthusiasts through GM Performance Parts. These include complete race-prepared blocks, ported cylinder heads, steel billet crankshafts, connecting rods, pistons, copper head gaskets, aluminum intake manifolds, racing camshafts, neutral-balanced countershafts and intake and exhaust manifold flanges.

The Ecotec debuted in the 2000 Saturn L-Series and is used in several European applications, including the Opel Vectra, Astra, Zafira and Speedster models. U.S. applications for Ecotec engines include Chevrolet Cavalier, Oldsmobile Alero, Pontiac Sunfire, Pontiac Grand Am and Saturn VUE. As installed in the 2003 Chevrolet Cavalier, this lightweight aluminum four-valve, DOHC engine is rated at 140 horsepower.

The race-prepared Ecotec engine enjoys certain advantages in addition to its pressurized induction system. First is its robust construction, a trait it inherited directly from its production counterpart. The Ecotec block's rigid bottom end resembles a classic racing engine, with a one-piece casting that incorporates the five main bearing caps (each retained by four fasteners) and mounts a structural cast-aluminum oil pan. The stock four-valve aluminum cylinder head's generously sized intake and exhaust ports provide excellent airflow (250 cfm at .400-inch intake valve lift), while a single centrally located spark plug in each pent-roof combustion chamber provides fast, efficient combustion. The two overhead camshafts actuate the inlet and exhaust valves via roller finger follower rocker arms - another design feature utilized by many high-rpm racing engines.

The Ecotec drag race engine builds on the strengths of these production components. Peterson and GM Racing engineer Russ O'Blenes retained the stock block and head castings. The block was modified with stainless steel O-rings and copper head gaskets to withstand the extreme cylinder pressure produced by turbocharging. The cylinder heads were ported and outfitted with dual-coil valve springs and titanium retainers; reground production camshafts actuate the valves through stock finger followers. The original camshaft drive gears were slotted to allow adjustments in camshaft phasing. The camshaft drive uses a stock timing chain, guides and hydraulic tensioner.

Heavy-duty components replaced the production crankshaft assembly.

A billet steel crankshaft, steel H-beam connecting rods with high-strength bolts, forged aluminum pistons and thick-wall piston pins were designed to GM Racing's specifications. The crankshaft rotates in production thick-wall main bearing inserts.

A custom-built dry-sump oiling system with a five-stage pump provides reliable lubrication at high rpm. An electronic fuel injection system meters methanol into a fabricated aluminum intake manifold. The production water pump and alternator are retained.

The initial goals of the Ecotec drag race engine program were to produce 650 horsepower, a power band that stretched from 5500 to 9200 rpm, and the durability to make 25 full-power passes between rebuilds while retaining stock components whenever possible. By exceeding every one of these objectives, the race-prepared Ecotec engine promises to make Chevy's Cavalier the frontrunner in Sport Compact drag racing and the forerunner of a new generation of GM four-cylinder performance engines.

This is a really nice animation on the water flow of the EcoTec with InterCooler <<< CLICK HERE >>>>
 

I will be starting the development on the complete LSJ with the MU3 to the Fiero in November 05..

Email or call for details.

Loyde@FastFieros.com