2.2L 4-cyl - Vins [g,4] Chevrolet Beretta I

ENGINE IDENTIFICATION

Note. For engine repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article in the GENERAL INFORMATION section.

Engine may be identified by using Vehicle Identification Number (VIN), engine block code, and partial VIN.

VIN is stamped on a metal pad, located near lower left corner of windshield. Eighth character of VIN identifies engine model. Tenth character of VIN identifies model year ("M" indicates 1991 model year; "N" indicates 1992).

Engine block code (3 characters) is stamped on left side of cylinder block at cylinder block-to-transaxle flange. (Scheme 1)

Partial VIN (9 characters) is stamped on left side of cylinder block at cylinder block-to-transaxle flange. (Scheme 1) First character "1" of partial VIN, identifies manufacturer as Chevrolet. Second character "M" identifies model year as 1991; "N" identifies 1992.

ENGINE IDENTIFICATION CODES

Scheme 1

VALVE CLEARANCE ADJUSTMENT

No valve clearance adjustment is required as engine is equipped with hydraulic valve lifters.

TROUBLE SHOOTING

Note. See TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL TROUBLE SHOOTING section.

FUEL PRESSURE RELEASE

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

Disconnect negative battery cable. Loosen fuel tank filler cap to release tank vapor pressure. An internal constant bleed in the throttle body releases fuel system pressure when the engine is turned off; however, some residual line pressure may exist. Cover fuel lines with shop towel before disconnecting.

ENGINE

Note. Engine and transaxle are removed as an assembly from bottom of vehicle.

1. Disconnect battery cables. Release fuel system pressure. See FUEL PRESSURE RELEASE. Drain cooling system. Disconnect hood light wiring and remove hood. Remove throttle body intake duct.
2. On Beretta GTZ, remove cover panels from firewall in engine compartment. On all models, remove battery and air cleaner housing. Remove upper radiator hose. Disconnect brake booster vacuum hose. Remove alternator top bracket. Disconnect alternator wiring.
3. Disconnect upper engine wiring harness. Discharge A/C system. Disconnect A/C refrigerant hoses from compressor. Plug hose and compressor openings. Raise and support vehicle. Remove splash shield from below engine. Disconnect exhaust pipe from exhaust manifold. Remove exhaust system.
4. Disconnect lower wiring harness from engine. Remove flexplate/flywheel inspection cover. Remove front wheels and lower radiator hose. Disconnect heater hoses from heater core. Remove brake calipers and suspend with wire out of way. Separate outer tie rods from steering knuckles.
5. Lower vehicle. Remove clutch slave cylinder (M/T). Disconnect fuel lines as necessary. Disconnect shift cable (A/T) or linkage (M/T) from transaxle. Disconnect control cables from throttle body.
6. Disconnect transaxle fluid cooling lines from transaxle (A/T). Remove power steering pump (leave hoses connected and lay pump aside). Remove 4 center suspension support bolts (2 at center of each suspension support).
7. Position a 4-wheel dolly under suspension supports, engine and transaxle assembly. Lower vehicle onto dolly. Position supports under engine and rear of vehicle.
8. Remove upper transaxle mount and upper strut bolts and nuts. Remove front and rear engine mounts. Remove rear suspension support bolts. Remove front suspension support bolts and wire holes together to prevent axle separation.
9. Raise and support vehicle. Remove engine/transaxle assembly. To install, reverse removal procedure. Fill cooling system and crankcase.

Removal

1. Disconnect negative battery cable. Release fuel system pressure. See FUEL PRESSURE RELEASE. Remove air cleaner assembly. Drain cooling system. Disconnect necessary vacuum hoses, electrical connections and fuel lines.
2. Disconnect control cables from throttle body. Remove throttle body. Remove power steering pump (leave hoses connected and lay pump aside). Disconnect coolant hose from intake manifold. Remove intake manifold nuts. Remove intake manifold.

Installation

To install, reverse removal procedure using new gasket. Tighten nuts in sequence to 18 ft. lbs. (25 N.m)., 1992 models tighten nuts in sequence to 22 ft. lbs. (30 N.m.). (Scheme 2) Fill cooling system.

Scheme 2

Disconnect negative battery cable. Disconnect oxygen sensor electrical connector. Remove serpentine drive belt and alternator. Raise and support vehicle. Disconnect exhaust pipe from exhaust manifold. Lower vehicle. Remove exhaust manifold nuts. Remove oil filler tube. Remove exhaust manifold.

To install, reverse removal procedure using new gasket. Tighten exhaust manifold nuts to 10 ft. lbs. (14 N.m). Tighten exhaust pipe nuts to 18 ft. lbs. (24 N.m).

Scheme 3

1. Disconnect negative battery cable. Release fuel system pressure. See FUEL PRESSURE RELEASE.
2. Remove air cleaner assembly. Drain cooling system. Disconnect exhaust pipe from exhaust manifold. (Scheme 3) Disconnect vacuum hoses, electrical connectors and control cables from throttle body. Remove coolant reservoir, serpentine drive belt and alternator.
3. Remove power steering pump (leave hoses connected and lay pump aside). Remove serpentine drive belt tensioner and spark plug wires. Disconnect canister purge hose, upper radiator hose and heater hoses from intake manifold.
4. Remove intake manifold bracket from power steering bracket. Disconnect fuel lines as necessary. Remove valve cover. Loosen rocker arm nuts, rotate rocker arms to one side and remove push rods.
5. Remove spark plug wire bracket and engine lifting bracket. Remove cylinder head bolts. Remove transaxle fluid level indicator bracket (A/T). Remove cylinder head.

Inspection

Inspect cylinder head for warpage at deck surface and manifold surfaces. DO NOT remove more than .010" (.25 mm) material from cylinder head deck surface.

1. Ensure cylinder head bolt threads and cylinder block bolt hole threads are clean. Install new gasket over dowel pins and ensure all holes align with cylinder block.
2. Install cylinder head. Tighten cylinder head bolts to specification in proper sequence. (Scheme 4) To install remaining components, reverse removal procedure. Fill cooling system.

Scheme 4

1. Disconnect negative battery cable. Remove serpentine drive belt and tensioner. Raise and support vehicle. Remove oil pan. See OIL PAN.
2. Remove right wheel. Remove engine splash shield. Remove 3 crankshaft pulley bolts. Remove crankshaft pulley hub bolt. Remove crankshaft pulley. (Scheme 5) Using Hub Puller (J-24420-B), remove crankshaft pulley hub. Remove front timing case cover bolts and remove cover.

Scheme 5

1. Apply engine oil to front cover oil seal lip. Install cover using new gasket. Apply RTV sealant to crankshaft pulley hub keyway. Position crankshaft pulley hub onto crankshaft. CAUTION: To prevent oil leakage, coat crankshaft pulley hub keyway with RTV sealant before installation.
2. Install crankshaft pulley hub using Hub Installer (J-29113), ensuring at least .24" (6.1 mm) of installer bolt thread is engaged into end of crankshaft.
3. To install remaining components, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS table at end of this article.

1. Disconnect negative battery cable. Remove serpentine drive belt. Raise and support vehicle. Remove right wheel. Remove engine splash shield. Remove 3 crankshaft pulley bolts. Remove crankshaft center bolt. Remove crankshaft pulley.
2. Using Hub Puller (J-24420-B), remove crankshaft pulley hub. Using large screwdriver, pry out oil seal. Use care not to damage seal area of crankshaft or cover. Note direction of seal installation.

1. Apply engine oil to lip of new oil seal. Using Seal Installer (J-35468), drive seal into cover with seal lip toward engine. Ensure seal is fully seated. Apply RTV sealant to crankshaft pulley hub keyway. Position crankshaft pulley hub onto crankshaft. CAUTION: To prevent oil leakage, coat crankshaft pulley hub keyway with RTV sealant before installation.
2. Install crankshaft pulley hub using Hub Installer (J-29113), ensuring at least .24" (6.1 mm) of thread is engaged into end of crankshaft. To install remaining components, reverse removal procedure.

Scheme 6

1. Remove front timing case cover. See FRONT TIMING CASE COVER. Align camshaft and crankshaft sprocket marks with tabs on chain tensioner. (Scheme 6) Remove upper bolt from timing chain tensioner.
2. Loosen timing chain tensioner Torx bolt as far as possible, but DO NOT remove bolt. Remove camshaft sprocket and timing chain. Using Sprocket Puller (J-22888), remove crankshaft sprocket.

1. Install crankshaft sprocket using Sprocket Installer (J-5590). Ensure crankshaft sprocket is fully seated against crankshaft. Compress chain tensioner spring and install small cotter pin in hole of chain tensioner. (Scheme 6)
2. Install timing chain and camshaft sprocket, aligning sprocket marks with tabs on chain tensioner. Ensure hole in camshaft sprocket aligns with camshaft dowel pin. Install camshaft sprocket bolt and tighten to 77 ft. lbs. (104 N.m).
3. Lubricate timing chain with oil. Remove cotter pin from chain tensioner. To install remaining components, reverse removal procedure.

1. Release fuel system pressure. Remove valve cover. loosen rocker arm nut and position rocker arm aside. remove pushrod. Remove rear engine lift bracket.
2. Remove spark plug wires from spark plugs and route under intake manifold. Disconnect electrical, fuel and cable connectors from intake manifold. Disconnect exhaust pipe from exhaust manifold. Remove cylinder head bolts/studs.
3. With an assistant, carefully remove cylinder head and manifolds as an assembly. Remove cylinder head gasket. Remove valve lifter from bore in cylinder block. Keep lifters in order to ensure reinstallation in the same order.

Install valve lifter in original location. To install remaining components, reverse removal procedure.

CAMSHAFT

Note. To replace camshaft, engine must be removed from vehicle.

1. Remove engine. See ENGINE. Remove valve lifters. See VALVE LIFTERS.
2. Remove timing chain and camshaft sprocket. See TIMING CHAIN & SPROCKETS. Remove oil pump drive from right side of cylinder block. (Scheme 5)
3. Remove camshaft thrust plate. Remove camshaft. Use Camshaft Bearing Remover (J-33049) to remove camshaft bearings.

Inspect camshaft journal diameter, lobe lift and oil clearance. Replace components if not within specification. See CAMSHAFT table in ENGINE SPECIFICATIONS at end of this article.

Install camshaft bearings (if removed), ensuring oil holes are aligned. Coat camshaft journals and bearings with Lubricant (1052365). Install camshaft. Install camshaft thrust plate. To install remaining components, reverse removal procedure.

Remove transaxle. Remove flexplate/flywheel. See appropriate CLUTCHES article (M/T) or TRANSMISSION SERVICING article (A/T). Pry seal from housing. Use care not to damage sealing surface of crankshaft. Note direction of seal installation.

Scheme 7

1. Coat inner and outer seal surfaces with engine oil. Install seal on mandrel of Seal Installer (J-34686) until dust lip bottoms against tool collar. (Scheme 7)
2. Align seal installer dowel pin with alignment hole of crankshaft. Install seal installer on crankshaft. Tighten seal installer bolts to 27-62 INCH lbs. (3-7 N.m).
3. Tighten seal installer handle until collar is even with cylinder block. Remove seal installer. To install remaining components, reverse removal procedure. Apply thread sealant to flexplate/flywheel bolts before installation.

WATER PUMP

Disconnect negative battery cable. Drain cooling system. Remove serpentine drive belt. Remove alternator and brackets. Remove water pump pulley. Remove water pump and gasket. To install, reverse removal procedure using new gasket. Fill cooling system.

Disconnect negative battery cable. Disconnect exhaust pipe from manifold. Raise and support vehicle. Drain crankcase. Remove starter bracket from cylinder block. Remove starter and lay aside. Remove flexplate/flywheel cover. Remove oil filter. Remove oil filter adapter (A/T). Remove oil pan bolts and oil pan.

Apply a 1/8" bead of RTV sealant to oil pan-to-cylinder block and oil pan-to-front cover sealing surfaces. Apply RTV sealer to ears of new oil pan rear seal and install onto bottom of rear main bearing cap. Install oil pan. To install remaining components, reverse removal procedure. Fill crankcase.

CYLINDER HEAD OVERHAUL

Inspect cylinder head for warpage at deck surface and manifold surfaces. DO NOT remove more than .010" (.25 mm) material from cylinder head deck surface.

VALVE SPRINGS

Measure valve spring free length, out-of-square and tension. See CYLINDER HEAD table in ENGINE SPECIFICATIONS at end of article. Replace spring if not within specification. Valve spring installed height is not provided by manufacturer.

VALVE STEM OIL SEALS

If oversize valves are installed, oversize seals must be used. Ensure seal is fully seated on guide. Intake and exhaust seals are different.

VALVE GUIDES

DO NOT knurl valve guides. If valve stem oil clearance is not within specification, valve guides must be reamed for an oversize valve. See CYLINDER HEAD table in ENGINE SPECIFICATIONS at end of article.

VALVES SEATS

Measure seat runout and width. See CYLINDER HEAD table in ENGINE SPECIFICATIONS at end of article. If not within specification, machine or replace valve seat as necessary. Valve seat replacement procedure not provided by manufacturer.

VALVES

Measure valve margin and valve stem-to-guide oil clearance. See VALVES & VALVE SPRINGS table in ENGINE SPECIFICATIONS at end of article. If valve margin is not within specification, machine or replace valve. If valve stem-to-guide oil clearance is not within specification, replace valve with an oversize valve.

VALVE SEAT CORRECTION ANGLES

1. If seat contact is too high (too close to margin), lower it using a 30-degree stone. If seat contact is too low (too close to stem), raise it using a 45-degree stone.
2. If seat is too narrow, widen it using a 45-degree stone. If seat is too wide, narrow it using a 60-degree stone.

CYLINDER BLOCK ASSEMBLY OVERHAUL

PISTON & ROD ASSEMBLY

Install piston with arrow on top of piston toward front of engine and connecting rod bearing tang slots facing camshaft side of engine.

FITTING PISTONS

1. Measure cylinder bore diameter at center of bore. Measure piston diameter at 90-degree angle to piston pin and .40" (10 mm) above bottom of piston skirt. Determine piston clearance.
2. If piston clearance is not within specification, machine cylinder bore and/or install oversize piston as necessary. See CYLINDER BLOCK table in ENGINE SPECIFICATIONS at end of article.

PISTON RINGS

1. Measure piston ring end gap and side clearance. If end gap and side clearance are not within specification, replace piston rings and/or piston as necessary. See PISTONS, PINS & RINGS table in ENGINE SPECIFICATIONS at end of article.
2. Install piston rings with identification mark on ring land facing top of piston. Properly position ring end gaps around circumference of piston. (Scheme 8)

Scheme 8

ROD BEARINGS

Measure rod bearing oil clearance. If oil clearance is not within specification, machine crankshaft rod bearing journals and install undersize bearings. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table in ENGINE SPECIFICATIONS at end of article. Install rod bearing cap onto piston rod with rod bearing tang slots facing camshaft side of engine.

CRANKSHAFT & MAIN BEARINGS

Measure crankshaft main bearing oil clearance, out-of-round and taper. If not within specification, machine crankshaft main bearing journals and install undersize bearings. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table in ENGINE SPECIFICATIONS at end of article. Measure crankshaft end play (thrust bearing wear). See THRUST BEARING.

THRUST BEARING

No. 3 main bearing is the thrust bearing. Pry crankshaft toward rear of engine. Measure clearance between thrust bearing face and crankshaft. Clearance should be .002-.007" (.05-.18 mm).

CYLINDER BLOCK

Measure deck surface warpage. DO NOT remove more than .010" (.25 mm) material from deck surface.

VALVE LIFTER BORES

Oversize valve lifters are available. Oversize lifter should be indicated on cylinder block near lifter bore.

ENGINE OILING SYSTEM

A camshaft-driven, gear-type oil pump is mounted to bottom of cylinder block and is accessible with oil pan removed. Oil pump supplies pressurized oil to internal passages of cylinder block. Internal passages intersect with hydraulic valve lifter bosses where oil flows to main and camshaft bearings and lifters. (Scheme 9)

Scheme 9

CRANKCASE CAPACITY

Engine oil capacity is approximately 4 qts. (3.7L) without oil filter change. When changing oil filter, more oil may need to be added.

OIL PRESSURE

Normal oil pressure is 56 psi (3.9 kg/cm 2 ) at 3000 RPM.

Removal & Disassembly

Remove oil pan. See OIL PAN. Remove oil pump-to-rear main bearing cap bolt. Remove oil pump and extension shaft. Remove extension shaft and retainer from oil pump. Disassemble oil pump. DO NOT remove pick-up tube unless loose or broken.

1. Ensure retainer is not cracked. Inspect components for damage. Measure gear housing pocket depth and diameter, gear diameter and gear length.
2. Measure gear lash between the teeth of both gears and gear side clearance between tip of each gear tooth and housing pocket. Using straightedge and feeler gauge, measure gear end clearance.
3. Determine clearance between pressure regulator valve and bore. Replace components if not within specification. See OIL PUMP SPECIFICATIONS table.

Reassembly & Installation

To reassemble, reverse disassembly procedure. Replace pick-up tube if removed and apply Sealant (1050026) to new tube before installation. Install pick-up tube using Tube Installer (J-8369). To install, reverse removal procedure. Tighten oil pump mounting bolt to 32 ft. lbs. (43 N.m).

OIL PUMP SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

GENERAL SPECIFICATIONS

MAIN & CONNECTING ROD BEARINGS SPECIFICATIONS

MAIN & CONNECTING ROD BEARINGS SPECIFICATIONS

CONNECTING ROD SPECIFICATIONS

CONNECTING ROD SPECIFICATIONS

PISTONS, PINS & RINGS SPECIFICATIONS

PISTONS, PINS & RINGS SPECIFICATIONS

CYLINDER BLOCK SPECIFICATIONS

CYLINDER BLOCK SPECIFICATIONS

VALVES & VALVE SPRINGS SPECIFICATIONS

VALVES & VALVE SPRINGS SPECIFICATIONS

CYLINDER HEAD SPECIFICATIONS

CYLINDER HEAD SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

See also:
• ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION