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2000 Chevrolet Prizm 2000-01 ENGINES 1.8L 4-Cylinder - Prizm

2000-01 ENGINES 1.8L 4-Cylinder - Prizm

ENGINE IDENTIFICATION NOTE:

For repair procedures not covered in this article. See ENGINE OVERHAUL PROCEDURES article in GENERAL INFORMATION.

Vehicle Identification Number (VIN) is located on top of dash panel, near lower left corner of windshield. Engine may be identified by the eighth character of VIN. ENGINE IDENTIFICATION CODES Application Prizm LSi 1.8L

Code 8

ADJUSTMENT VALVE CLEARANCE ADJUSTMENT

NOTE:

Adjust valve clearance with engine cold.

1. Disconnect negative battery cable. Disconnect all necessary control cables, hoses and electrical connections. Remove valve cover and gasket. 2. Rotate crankshaft so cylinder No. 1 is at TDC of compression stroke. Valve lifters on cylinder No. 1 should be loose and valve lifters on cylinder No. 4 should be tight. If they are not, rotate crankshaft one revolution. Ensure timing mark on crankshaft pulley aligns with "0" mark on timing belt cover. 3. Using feeler gauge, check clearance between camshaft lobe and adjusting shim for the following: all valves on cylinder No. 1, intake valves on cylinder No. 2 and exhaust valves on cylinder No. 3. Record all readings. 4. Rotate crankshaft 360 degrees. Check clearance between camshaft lobe and adjusting shim for the following: all valves on cylinder No. 4, intake valves on cylinder No. 3 and exhaust valves on cylinder No. 2. If clearance is not within specification, adjust by replacing adjusting shim. See VALVE CLEARANCE SPECIFICATIONS table. VALVE CLEARANCE SPECIFICATIONS Application Clearance: In. (mm) (1) Intake .006-.010 (.15-.25) MY Tuesday, March 31, 2009 10:43:23 10:43:14 AM

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2000 Chevrolet Prizm 2000-01 ENGINES 1.8L 4-Cylinder - Prizm

Exhaust

(1)

.010-.014 (.25-.35) (1) Adjust valve clearance with engine cold.

5. Rotate engine until camshaft lobe faces away from valve to be adjusted. Insert Valve Spring Depressor (J-39871-1) between camshaft and adjusting shim. See Fig. 1 . 6. Install Valve Lash Spring Spacer (J-39871-2) between camshaft and valve lifter. Ensure bottom edge of valve lash spring spacer contacts valve lifter, NOT adjusting shim. Remove valve spring depressor. Using small screwdriver and magnet, remove adjusting shim from valve lifter.

Fig. 1: Adjusting Valve Clearance (Typical) Courtesy of GENERAL MOTORS CORP. 7. To determine correct adjusting shim thickness for shim replacement, measure and record thickness of removed shim. Locate measured values of removed shim and valve clearance on appropriate adjusting shim selection chart to determine correct shim thickness. See Fig. 2 MY Tuesday, March 31, 2009 10:43:14 AM

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2000 Chevrolet Prizm 2000-01 ENGINES 1.8L 4-Cylinder - Prizm

and Fig. 3 . 8. Install correct shim thickness to obtain proper clearance. See VALVE CLEARANCE SPECIFICATIONS table. Repeat procedure if necessary. Before installing valve cover, install NEW gasket to cylinder head and NEW seal washers to valve cover. Install valve cover in reverse order of removal.

Fig. 2: Exhaust Valve Adjusting Shim Selection Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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2000 Chevrolet Prizm 2000-01 ENGINES 1.8L 4-Cylinder - Prizm

Fig. 3: Intake Valve Adjusting Shim Selection Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TROUBLE SHOOTING NOTE:

To trouble shoot engine mechanical components, see appropriate table in TROUBLE SHOOTING article in GENERAL INFORMATION.

REMOVAL & INSTALLATION NOTE:

For installation reference, label all electrical connectors, vacuum hoses and fuel lines before removing. Also place mating marks on engine hood and other major assemblies before removing.

FUEL PRESSURE RELEASE

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2000 Chevrolet Prizm 2000-01 ENGINES 1.8L 4-Cylinder - Prizm

1. Loosen fuel tank cap to release fuel tank pressure. Disconnect circuit opening relay located behind radio. Start engine and allow engine to stall. Crank engine again for an additional 3 seconds, to ensure relief of any remaining pressure. 2. Disconnect negative battery cable. Connect circuit opening relay and tighten fuel filler cap. Wrap fuel component or fitting with shop towel during removal. ENGINE Removal

NOTE:

Engine and transaxle are removed separately.

1. Release fuel pressure. See FUEL PRESSURE RELEASE . Disconnect battery cables, and remove battery. Remove hood. Raise and support vehicle. Drain engine oil and cooling system. Remove lower engine splash covers. 2. Disconnect necessary coolant hoses and fuel lines. Remove air intake duct and control cables from throttle body. Remove air cleaner. Disconnect necessary vacuum hoses, electrical connections and engine ground wires. Remove cruise control actuator (if equipped). Remove 4 ignition coil bolts. Remove ignition coils with spark plug wires attached. 3. Remove serpentine belt. Unplug and remove washer reservoir. On M/T models, remove crankshaft pulley, generator, and drive belt tensioner. Disconnect and remove oxygen sensor and gasket. Unbolt ground wire at engine lift hook. Disconnect starter wiring, then remove starter. Unbolt all wiring harness brackets. Ensure all electrical connectors are disconnected, then reroute harness off to side. 4. On A/T models, remove torque converter access cover, then remove 6 torque converter bolts. Remove power steering through-bolts and nuts. Secure power steering pump aside. Remove exhaust pipe retainer bolts and springs from exhaust manifold. Also remove heat shield around axle shaft boot. Remove the 4 bottom transmission-to-engine mounting bolts. 5. Lower vehicle and connect engine hoist. Unbolt upper transmission-to-engine mounting bolts. Remove right side engine mount and bracket. Verify all hoses and wires are disconnected from engine, then lift engine out of vehicle. Installation

To install, reverse removal procedure. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS . Adjust all control cables. Adjust fluid levels. INTAKE MANIFOLD MY Tuesday, March 31, 2009 10:43:14 AM

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2000 Chevrolet Prizm 2000-01 ENGINES 1.8L 4-Cylinder - Prizm

Removal

1. Disconnect negative battery cable. Drain cooling system. Disconnect throttle cable and TV cable (A/T models) from throttle body. 2. Unhook IAT sensor from air cleaner, and remove air cleaner hose from throttle body. Remove air cleaner top assembly. Disconnect all electrical components and coolant by-pass hoses from throttle body. 3. Disconnect fuel injector connectors. Remove harness bolts, then disconnect wiring harness from intake manifold. Remove intake manifold support bracket bolts and bracket. Disconnect upper radiator hose at radiator, then remove radiator hose support bracket. Remove injector harness support brackets. Remove intake manifold with throttle body. Inspection

Check intake manifold for cracks and warpage. Replace intake manifold if warpage exceeds .004" (.10 mm). Installation

NOTE:

Always install NEW gasket whenever intake manifold is removed.

To complete installation, reverse removal procedure. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS . EXHAUST MANIFOLD Removal

Disconnect negative battery cable. Disconnect oxygen sensor wiring connector. Remove exhaust manifold brace. Disconnect exhaust pipe from exhaust manifold. Remove heat shield from exhaust manifold. Remove exhaust manifold bolts/nuts, exhaust manifold and gasket. Inspection

Check exhaust manifold for cracks and warpage. Replace exhaust manifold if warpage exceeds .004" (.10 mm). Installation

To install, reverse removal procedure. Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS . MY Tuesday, March 31, 2009 10:43:14 AM

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2000 Chevrolet Prizm 2000-01 ENGINES 1.8L 4-Cylinder - Prizm

CYLINDER HEAD Removal

NOTE:

Manufacturer recommends removing timing chain and camshaft sprockets when removing cylinder head.

1. Release fuel pressure. See FUEL PRESSURE RELEASE . Disconnect battery. Drain cooling system and engine oil. Disconnect throttle cable, all electrical components and 2 coolant bypass hoses from throttle body. Remove air cleaner hose and upper air cleaner assembly. 2. Disconnect temperature sensor. Disconnect fuel injector connectors and move injector harness aside. Remove upper radiator hose, injector harness brackets, intake manifold support brackets, oxygen sensor and gasket, and all necessary vacuum hoses. 3. Disconnect and remove ignition coils, with spark plug wires attached. Disconnect fuel line at fuel rail, then unbolt and remove fuel rail. Disconnect all electrical connectors, hoses and vacuum lines. Remove coolant bypass pipe. Position wiring harness aside. Remove camshaft position and coolant temperature sensors. 4. Remove exhaust pipe bolts and springs, pipe-to-manifold seal, and support bracket bolt. Remove PCV valve and hoses, then unbolt and remove valve cover. Remove timing chain. See TIMING CHAIN . 5. Remove intake and exhaust camshaft sprockets. Note original location of camshaft bearing caps for installation reference. Remove camshaft bearing cap bolts in sequence. See Fig. 4 . Remove camshafts. 6. Using a wooden block, lift engine with a floor jack and reposition holding fixture. Loosen cylinder head bolts in sequence. See Fig. 5 . Remove head bolts and washers. Remove cylinder head.

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2000 Chevrolet Prizm 2000-01 ENGINES 1.8L 4-Cylinder - Prizm

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2000 Chevrolet Prizm 2000-01 ENGINES 1.8L 4-Cylinder - Prizm

Fig. 4: Camshaft Bearing Cap Bolt Removal & Installation Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 5: Cylinder Head Bolt Removal & Installation Sequence MY Tuesday, March 31, 2009 10:43:14 AM

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2000 Chevrolet Prizm 2000-01 ENGINES 1.8L 4-Cylinder - Prizm

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 6: Exploded View Of Cylinder Head & Timing Chain Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. MY Tuesday, March 31, 2009 10:43:14 AM

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2000 Chevrolet Prizm 2000-01 ENGINES 1.8L 4-Cylinder - Prizm

Inspection

Inspect cylinder head surface and manifold sealing areas for cracks and warpage. Replace cylinder head if warpage exceeds specification. Inspect cylinder block deck warpage along all 4 edges and diagonally across cylinder head. Replace cylinder block if warpage exceeds specification. See CYLINDER HEAD and CYLINDER BLOCK tables under ENGINE SPECIFICATIONS. Installation

1. Before installing cylinder head bolts, apply light coat of engine oil onto threads and below bolt heads. Using multiple steps, tighten cylinder head bolts in sequence to specification. See Fig. 5 . See TORQUE SPECIFICATIONS . Install manifolds, if removed. See INTAKE MANIFOLD and EXHAUST MANIFOLD . 2. Reposition engine holding fixture, and support engine by support hook. Remove floorjack. Install camshafts and timing chain. See CAMSHAFT and TIMING CHAIN . If cylinder head components were serviced, check valve clearance. See VALVE CLEARANCE ADJUSTMENT under ADJUSTMENTS. Install valve cover. 3. Install coolant temperature and camshaft position sensors. Tighten camshaft position sensor bolt to specification. See TORQUE SPECIFICATIONS . Install coolant bypass pipe to cylinder head, and tighten bolt to specification. See TORQUE SPECIFICATIONS . 4. Reinstall engine ground wires. Use new "O" rings on fuel injectors and install fuel rail to cylinder head. Secure fuel rail with 3 bolts, and reconnect fuel line to fuel rail. Install 2 ignition coils and spark plug wires. Tighten 4 bracket bolts to specification. See TORQUE SPECIFICATIONS . Reconnect coil connectors. 5. Raise vehicle and install exhaust manifold bracket bolt. Replace exhaust pipe seal, and secure pipe onto manifold using 2 springs and bolts. Tighten exhaust pipe-to-manifold bolts to specification. See TORQUE SPECIFICATIONS . Lower vehicle. Install oxygen sensor, harness and manifold support brackets, all vacuum hoses, and all electrical connectors. 6. Install upper radiator hose and reconnect coolant bypass hoses to throttle body. Install air cleaner, and reconnect IAT sensor. Use 2 bolts to attach generator to engine. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Connect positive cable and electrical connector to generator. Install serpentine belt. 7. Reconnect fluid line and washer pump connector to window washer reservoir, then reinstall reservoir. Refill engine oil and coolant. CRANKSHAFT FRONT SEAL Removal & Installation MY Tuesday, March 31, 2009 10:43:14 AM

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2000 Chevrolet Prizm 2000-01 ENGINES 1.8L 4-Cylinder - Prizm

1. Crankshaft front seal is mounted in timing chain cover. See Fig. 6 . Remove serpentine belt and crankshaft pulley bolt. Using puller, remove crankshaft pulley. Pry seal from timing chain cover. DO NOT damage sealing surfaces. 2. Coat lip of NEW seal with grease. Using hammer and Seal Installer (SST 09309-37010), install seal until seal surface is flush with timing chain cover. Install crankshaft pulley and torque to specifications. See TORQUE SPECIFICATIONS . To install remaining components, reverse removal procedure. TIMING CHAIN Removal

IMPORTANT: When performing any service procedure that pertains to the camshaft or the camshaft actuator, unlock the camshaft actuator locking pin.

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2000 Chevrolet Prizm 2000-01 ENGINES 1.8L 4-Cylinder - Prizm

Fig. 7: Removing Or Installing Serpentine Belt Courtesy of GENERAL MOTORS CORP. 1. Remove the accessory drive belt. 2. Remove the generator from the engine. CAUTION: Before servicing any electrical component, the ignition and start switch must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its MY Tuesday, March 31, 2009 10:43:14 AM

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2000 Chevrolet Prizm 2000-01 ENGINES 1.8L 4-Cylinder - Prizm

components. 3. 4. 5. 6. 7. 8. 9. 10.

Disconnect the negative battery cable. Drain the cooling system. Remove the windshield washer fluid reservoir mounting bolt. Disconnect the windshield washer pump connector. Disconnect the windshield washer pump fluid line. Plug the pump outlet. Remove the windshield washer fluid reservoir. Install the engine support fixture.

Fig. 8: Engine Mounting Hardware Courtesy of GENERAL MOTORS CORP. MY Tuesday, March 31, 2009 10:43:14 AM

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2000 Chevrolet Prizm 2000-01 ENGINES 1.8L 4-Cylinder - Prizm

11. Remove the following fasteners from the right side engine mount: The 2 nuts (3), The 4 bolts (1). 12. Loosen the A/C receiver pinch clamp. 13. Lift the A/C receiver in order to access the right side engine mount. 14. Remove the right side engine mount. 15. Remove the cylinder head cover.

Fig. 9: Aligning Engine To TDC Courtesy of GENERAL MOTORS CORP. 16. Set the number one piston to the top dead center position. MY Tuesday, March 31, 2009 10:43:14 AM

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2000 Chevrolet Prizm 2000-01 ENGINES 1.8L 4-Cylinder - Prizm

17. 18. 19. 20.

Align the camshaft timing sprockets. Disconnect the power steering oil pressure switch connector. Raise and properly support the vehicle. Remove the right side lower engine splash shield.

Fig. 10: Power Steering Mounting View Courtesy of GENERAL MOTORS CORP. 21. Remove the two power steering pump through bolts and the nuts (1). 22. Remove the power steering pump from the mounting surface. Move the pump to the side.

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1998 TOYOTA COROLLA Service Repair Manual  

1998 TOYOTA COROLLA Service Repair Manual  

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