For Release: April 1, 2004, 12:01 a.m. EST
Ecotec Engine Lineup for the 2005 Chevrolet
GM Delivers High-Performance for Chevrolet's
New Premium Small Car
DETROIT - The all-new 2005 Chevrolet Cobalt
relies exclusively on Ecotec power from GM. Standing out as one
of GM's most prolific families of engines, the Ecotec powers every
Cobalt from the base to the Cobalt SS Supercharged model.
GM’s Ecotec four-cylinder engine family - GM’s first
truly “global” engine design - was launched in 2000.
For the 2005 model year, a new, larger-displacement 2.4-liter
variant with variable valve timing (VVT) joins the original 2.2-liter
and recently introduced 2.0-liter supercharged engines.
205 hp @ 5600 rpm
200 lb-ft torque @ 4400 rpm
Ecotec 2.4L VVT
170 hp @ 5600 rpm (est.)
170 lb-ft torque @ 4400 rpm (est.)
Cobalt LS, Cobalt LT
140 hp @ 5600 rpm (est.)
150 lb-ft torque @ 4000 rpm (est.)
Ecotec 2.0L SC: Reliable supercharged performance.
The supercharged Ecotec 2.0-liter powerplant is now available
in the Cobalt SS Supercharged coupe. The Ecotec 2.0L SC coupe
produces 205 horsepower at 5600 rpm and 200 lb.-ft. of torque
at 4400 rpm. Development of this high performance Ecotec variant
leveraged several areas of GM engineering expertise, including
GM Racing, GM High Performance Vehicle Operations (HPVO) and Saab.
To attain the durability targets GM engineers require of every
GM engine, the Ecotec 2.0L SC received upgraded components in
critical stress areas. Experience in the National Hot Rod Association’s
Championship Drag Racing series told engineers where the Ecotec
would most benefit from heavy-duty components. Modified Ecotec
engines routinely produce more than 1,000 horsepower in drag racing
trim. Additionally, the supercharged Ecotec 2.0L borrows knowledge
gleaned by Saab engineers when they adapted the Ecotec to the
demands required by high-output turbocharged engines. A turbocharged
variation of the Ecotec 2.0L in a Saturn ION coupe raced into
the record book at the Bonneville Salt Flats on Oct. 17, 2003,
establishing a new mark in the G/Blown Fuel Altered class at 212.684
At the heart of the Ecotec 2.0L SC is an Eaton M62 helical roots-type
supercharger. “Engineers selected the Eaton unit because
of its optimum response characteristics and ease of ‘packaging’
with the Ecotec architecture,” according to Grant Brady,
design system engineer. Maximum supercharger boost pressure is
12 pounds per square inch (psi), and the system includes an air-to-water
intercooler that cools the incoming air charge to increase intake-charge
density, which in turn enhances power and reduces the engine’s
propensity to “knock” at high boost levels.
The Ecotec 2.0L SC is fitted with numerous upgraded components
to assure reliability and superior performance:
- Sodium-filled exhaust valves more effectively dissipate exhaust
- A forged-steel crankshaft with induction-hardened fillets
and four counterweights
- Oil jets that cool the underside of each piston with a continuous
- A block-mounted oil cooler and a higher-capacity seven-quart
- Forged steel connecting rods with a larger I-beam section
- Heavy-duty pistons with a 23-mm piston pin for increased
- High-capacity cooling system with larger radiator core and
larger dual cooling fans
- Coil-on-plug ignition ensures optimum spark under all operating
- High-flow, 2.5-inch exhaust system – an almost 50-percent
increase - with increased muffler volume reduces power-robbing
- Electronic throttle control (ETC), which eliminates the cable
connection between the accelerator pedal and the engine throttle
and provides improved performance, economy and emissions performance.
The 2.0L SC engine is built exclusively at the Fiat-GM Powertrain
(FGP) engine-manufacturing facility in Kaiserslautern, Germany.
This plant uses a lost foam production technique that yields a
block that is well suited for high-stress applications including
turbocharging and supercharging. Variations of this block are
also found in various Saab and Opel models. Compared to the original
2.2-liter Ecotec, the 2.0L SC features the same cylinder bore
with a shorter stroke (94.6 mm vs. 86.0 mm). The shorter stroke
helps the engine rev quickly and deliver lively throttle response.
All-new Ecotec 2.4L VVT: Torque-rich driving experience
The 2005 Cobalt SS features the new Ecotec 2.4L VVT built at the
Spring Hill, Tenn., facility. The largest member of the Ecotec
family delivers a demonstrable horsepower and torque upgrade over
the standard Ecotec 2.2L. Equipped with variable valve timing
and a host of new features and improvements, the Ecotec 2.4L VVT
impressive 170 horsepower (estimated) at 5600 rpm and 90 percent
of the 170 lb.-ft. (estimated) peak torque over a wide 2400-5600
engine rpm range. The engine's infinitely variable camshaft phasing
contributes to this high torque plateau, and the responsive engine
performance that results.
The new variable valve timing system uses electronically controlled
hydraulic camshaft phasers to alter the relationship of the intake
and exhaust camshafts as much as 50 degrees relative to the crankshaft.
The ability to adjust the timing and the duration of intake and
exhaust valve opening and closing expands the operating range
where the engine makes its power. This system adds little weight
or assembly complexity to the basic Ecotec DOHC architecture because
the Ecotec family was designed from the beginning to easily accept
Torque is the engine characteristic that benefits most drivers
in most driving situations by providing the power to accelerate
a vehicle quickly. The Ecotec 2.4L VVT’s expected 170 lb.-ft.
of torque surpasses many other normally aspirated, four-cylinder
engines of similar displacement that are offered in the United
States (based on Ward’s 2003 model-year market data).
But the Ecotec 2.4L VVT story isn’t just about churning
out class-leading torque. Numerous component and design upgrades
ensure the newest member of the Ecotec family backs up its reputation
for unsurpassed durability, efficiency and cost of ownership with
a host of technically advanced features:
- Electronic throttle control - the ETC system eliminates the
physical connection between the accelerator pedal and the engine
throttle. This allows for remarkably precise engine control
and response, while simultaneously enhancing the engine’s
interface with other vehicle systems.
- An advanced engine control module (E67) – the Ecotec
2.4L VVT is one of the first GM engines to employ this sophisticated
controller that leverages 32-bit processing power. It incorporates
32 megabytes of burst flash memory, 32 kilobytes of external
RAM and 36 kilobytes of internal RAM, as well as a high- speed
CAN bus to deliver optimal networking capability.
- Individual coil-on-plug ignition modules – improves
upon the two-coil “cassette” of the original Ecotec
2.2L. The individual ignition modules for each spark plug enhance
combustion and engine energy efficiency.
Along with significant technologies, the new Ecotec 2.4L VVT
enjoys numerous upgrades to the robust basic Ecotec engine architecture.
Leveraging several heavy-duty components and systems borrowed
from the high-performance Ecotec 2.0L SC engine program, engineers
also added unique components to the new Ecotec 2.4L VVT:
- An auxiliary oil cooler that is approximately 30 percent
smaller (dimensionally) than similar-capacity oil coolers used
on other engines
- Piston-cooling oil jets that spray the underside of each
piston with a continuous bath of engine oil, increasing longevity
by reducing engine-operating temperatures
- Redesigned cylinder head with structural improvements and
new multi-layer steel gasket
- New camshafts with optimized lobe profiles
- Enhanced lubrication system to provide for the extra requirements
of the camshaft phasers and piston-cooling jets, along with
a deeper oil sump to handle the higher potential cornering forces
possible with the Ecotec 2.4-liter-equipped Cobalt.
For the new 2.4L VVT, both cylinder bore and stroke are increased
in comparison to the original Ecotec 2.2L. The new engine’s
bore is 88 mm and stroke is 98 mm, versus the 2.2-liter’s
86mm bore and 94.6mm stroke. These increases, multiplied by four
cylinders, yield a total displacement of 2,384 cubic centimeters
versus the original 2.2-liter’s 2,189 cubic centimeters.
Ecotec 2.2L: The original is better than ever
The Ecotec 2.2L was the first production version of GM’s
Ecotec modular, all-aluminum four-cylinder engine architecture.
“Ecotec is one of the highest-volume four-cylinder engine
programs in the world,” said Jay Subhedar, Ecotec global
four-cylinder engine assistant chief engineer. “Its efficiency
and reliability are well-established – now we are adding
a new variant to prove the Ecotec architecture’s performance
potential.” The Ecotec 2.2L engine currently powers 12 GM
models in North America and Europe, and is standard on the 2005
Cobalt, Cobalt LS and Cobalt LT.
“In the global engine family, we look at various engine
components to evaluate which are the right ‘fit’ for
any given engine application,” said Subhedar. “Commonality
is a vital part of the Ecotec program - it’s like an interlocking
puzzle. We try to choose the best combination of components from
the myriad of available technologies.” In keeping with this
thinking, Ecotec iterations appear in a range of displacements
and include naturally aspirated, turbocharged, and supercharged
Although each Ecotec engine has distinct hardware differences
and performance characteristics, all share the Ecotec 2.2L solid
basic architecture and all-aluminum construction:
- Dual overhead camshafts (DOHC) and four valves per cylinder
- Twin counter-rotating balance shafts to cancel the second-order
shaking forces that cause noticeable vibration in four-cylinder
- Low-friction, roller-finger follower valvetrain with hydraulic
- Zero-maintenance chain camshaft drive
- Extremely compact dimensions and low mass
- Direct mounting of all accessories to the engine structure
to eliminate common sources of noise, vibration and harshness
- Full circle transmission attachment, which is more rigid
than most four-cylinder powertrains for reduced noise and vibration.
- GM Oil Life System for optimum oil change frequency
- No routine maintenance apart from oil and oil filter changes
- Innovative cast-in oil filter housing eliminates crawling
under the car to perform filter changes. The design also eliminates
throwaway oil-filter “cans”.
The Ecotec 2.2L is built in Tonawanda, N.Y., Spring Hill, Tenn.,
and Kaiserslautern, Germany.
GM Powertrain is a global producer of engines, transmissions,
castings and components for GM vehicles and other automotive,
marine, and industrial OEMs. Headquartered in Pontiac, Mich.,
GM Powertrain has coordinating responsibility for General Motors
powertrain manufacturing plants and engineering centers in North
America, South America, Europe, and the Asia-Pacific region.
General Motors Corp. (NYSE: GM), the world’s largest vehicle
manufacturer, employs about 325,000 people globally. Founded in
1908, GM has been the global automotive sales leader since 1931.
GM today has manufacturing operations in 32 countries and its
vehicles are sold in 192 countries. In 2003, GM sold nearly 8.6
million cars and trucks, about 15 percent of the global vehicle
market. GM’s global headquarters are at the GM Renaissance
Center in Detroit. More information on GM and its products can
be found on the company’s corporate website at www.gm.com.