2.0L ENGINE Chevy Tracker 1999

2000 Chevrolet Tracker
2000-01 ENGINES 2.0L DOHC
2000-01 ENGINES
2.0L DOHC
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 Code
2.0L 4-Cylinder C
ADJUSTMENT
VALVE CLEARANCE ADJUSTMENT
NOTE: Hydraulic Valve Lash (HVL) adjusters are used. No valve clearance
adjustment is required.
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
CAUTION: Release fuel system pressure before servicing fuel system

components.
1. Loosen fuel tank cap to release fuel tank pressure. Remove fuel pump relay from junction
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box. Start engine and allow engine to stall. Crank engine again for an addition 3 seconds, to
ensure relief of any remaining pressure.
2. Disconnect negative battery cable. Install fuel pump relay in junction box. Tighten fuel filler
cap. Wrap fuel system component or fitting with shop towel during removal.
ENGINE
Removal
1. Disconnect negative battery cable. Release fuel pressure. See FUEL PRESSURE
RELEASE. Raise and support vehicle. Remove front skid plate, if equipped. Drain cooling
system. Drain engine oil. Remove A/T fluid cooler lines from radiator, cap lines to prevent
leakage.
2. Remove flywheel cover. On vehicles with A/T, remove torque converter bolts. Lock
flywheel using Flywheel Holder (J-35271). Support transmission. Remove RH engine to
transmission support bracket. Separate front pipe from exhaust manifold. Lower vehicle.
WARNING: Vehicle should be supported on hoist prior to removing

strut tower brace.
3. Remove hood. Remove strut tower brace. Remove engine block to catalytic converter
support bracket. Remove A/C compressor and position aside. Remove radiator assembly
and fan. Loosen adjusting bolt and pivot bolt. Remove tension in fan belt by rotating tension
bolt counterclockwise. Remove fan belt. Remove tensioner mounting bolts and tensioner.
Rotate belt tensioner clockwise and remove accessory drive belt.
4. Remove throttle cable bracket from intake manifold. Remove throttle cables and throttle
body and position aside. Remove power steering lines from power steering pump, and
position aside. Cap lines to prevent leakage. Remove air cleaner assembly. Disconnect all
electrical connectors. Remove heater hoses from heater core. Mark location of inlet and
outlet hoses for correct installation.
5. Remove ground wires from intake manifold. Remove evaporative emission canister purge
hose from intake manifold. Remove wiring harness from retaining clamps. Remove brake
booster vacuum line from intake manifold. Disconnect starter solenoid. Remove starter
motor. Disconnect crankshaft position sensor.
6. Remove cylinder block to transmission bolts and nuts. Remove upper engine mounts. Install
engine hoist. Ensure all hoses, pipes, electrical wires and cables are disconnected from
engine and positioned aside. Slide engine to front of engine compartment and hoist from
vehicle.
Installation
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To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE
SPECIFICATIONS.
INTAKE MANIFOLD
Removal
1. Disconnect negative battery cable. Release fuel pressure. See FUEL PRESSURE
RELEASE. Drain cooling system. Remove throttle cables from throttle body.
2. Remove air cleaner hose from throttle body. Remove upper air cleaner assembly. Remove
vacuum lines and breather hoses from intake manifold. Remove coolant hoses as necessary.
Remove upper radiator hose support bracket. Disconnect electrical connectors as necessary.
3. Disconnect fuel return line from fuel rail. Disconnect fuel injector connectors. Remove
banjo fitting and washer from rear of fuel rail. Remove intake manifold support bracket
bolts and brackets. Remove intake manifold with throttle body attached. Remove intake
manifold gasket.
Inspection
Check intake manifold for cracks and warpage. Replace intake manifold if warpage
exceeds .004" (.10 mm).
Installation
To complete installation, reverse removal procedure. Install NEW gasket. Tighten all bolts/nuts
to specification. See TORQUE SPECIFICATIONS.
EXHAUST MANIFOLD
Removal
1. Disconnect negative battery cable. Remove exhaust manifold heat shield. Raise vehicle.
Remove exhaust manifold bracket. On models equipped with catalytic converter, remove
catalytic converter from exhaust manifold. Remove engine mount-to-front pipe catalytic
converter bracket.
2. On all models, disconnect oxygen sensor electrical connector, and remove oxygen sensor.
Disconnect exhaust pipe from exhaust manifold. Remove exhaust manifold bolts and nuts,
exhaust manifold and gasket.
Installation
To install, reverse removal procedure. Install NEW gasket. Tighten bolts and nuts to
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specification. See TORQUE SPECIFICATIONS.
CYLINDER HEAD
Removal
1. Release fuel pressure. See FUEL PRESSURE RELEASE. Disconnect battery. On 4WD
models, remove front axle assembly. See DIFFERENTIALS & AXLE SHAFTS -
TRACKER article in DRIVE AXLES. On all models, remove steering gear. Drain cooling
system and engine oil. Remove oil pan. Remove cooling fan and fan shroud. Remove both
serpentine belts and tensioners. Remove serpentine belt idler pulley, water pump pulley, and
crankshaft pulley. Remove A/C compressor bolts, and position compressor aside with
refrigerant lines attached. Remove A/C compressor mounting bracket.
2. Disconnect throttle cable, electrical connectors, and coolant by-pass hoses from throttle
body. Remove air cleaner hose and upper air cleaner assembly. Disconnect temperature
sensor. Disconnect fuel injector connectors, and position injector harness aside. Remove
injector harness retainers and intake manifold support brackets.
3. Disconnect and remove ignition coils with spark plug wires attached. Disconnect fuel line at
fuel rail. Remove fuel rail bolts and fuel rail. Disconnect all electrical connectors, hoses and
vacuum lines as necessary. Remove coolant by-pass pipe. Position wiring harness aside.
4. Remove exhaust pipe bolts and springs, exhaust pipe-to-manifold seal, and exhaust pipe
support bracket bolt. Remove exhaust manifold. Remove valve cover bolts, and remove
valve cover. Remove spark plugs. Mark camshaft position sensor and cylinder head, and
remove camshaft position sensor. Remove timing chain housing. See TIMING CHAIN
HOUSING (FRONT COVER). Remove camshaft and crankshaft timing chains. See
TIMING CHAIN SPROCKETS (CAMSHAFT) and TIMING CHAIN &
SPROCKETS (CRANKSHAFT) .
5. If necessary, raise vehicle to facilitate removal of strut tower support bar. Remove strut
tower support bar. Loosen camshaft bearing cap bolts in sequence. See Fig. 1. Remove
camshaft bearing caps, and remove camshafts. Note Hydraulic Valve Lash (HVL) adjuster
positions, and remove HVL adjusters. See CAMSHAFTS and HYDRAULIC VALVE
LASH (HVL) ADJUSTERS .
6. Remove cylinder head bolts in reverse order of tightening sequence. See Fig. 2. Remove
cylinder head with intake manifold attached. Remove head gasket.
Inspection
See CYLINDER HEAD under OVERHAUL.

Installation
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1. To install reverse removal procedure. Before installing cylinder head bolts, apply light
coating of engine oil to entire length of bolts below bolt heads. Tighten cylinder head bolts,
and camshaft bearing cap bolts in sequence and to specification. See Fig. 2 and Fig. 3 . See
TORQUE SPECIFICATIONS. Align camshaft position sensor and cylinder head marks.
Install camshaft position sensor to rear of camshaft.
2. To complete installation, reverse removal procedure. Tighten bolts and nuts to specification.
See TORQUE SPECIFICATIONS. On 4WD models, adjust front wheel toe-in. See
appropriate SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.
Fig. 1: Camshaft Bearing Cap Bolt Loosening Sequence

Courtesy of GENERAL MOTORS CORP.
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Fig. 2: Cylinder Head Bolt Tightening Sequence

Fig. 3: Camshaft Bearing Cap Bolt Tightening Sequence

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CRANKSHAFT FRONT SEAL
Removal & Installation
NOTE: Crankshaft front seal is mounted in timing chain housing.
1. Remove serpentine belt and crankshaft pulley bolt. Using puller, remove crankshaft pulley.
Pry seal from timing chain housing. DO NOT damage sealing surfaces.
2. To install, coat new crankshaft front seal with chassis grease or equivalent. Using hammer
and appropriate driver, install crankshaft seal by lightly tapping into place until seal surface
is flush with timing chain cover. Install crankshaft pulley and torque to specifications. See
TORQUE SPECIFICATIONS.
TIMING CHAIN HOUSING (FRONT COVER)
Removal
1. Disconnect negative battery cable. On 4WD models, remove front axle assembly. See
DIFFERENTIALS & AXLE SHAFTS - TRACKER article in DRIVE AXLES. On all
models, remove steering gear. Drain engine oil. Remove oil pan. See OIL PAN. Drain
cooling system. Remove cooling fan and shroud. Remove both serpentine belts and belt
tensioners. Remove serpentine accessory belt idler pulley.
2. Remove water pump pulley. Remove bypass hose and by-pass pipe brackets from cylinder
head. Remove crankshaft bolt and pulley. Remove A/C compressor bolts, and position
compressor with refrigerant lines aside. Remove A/C compressor bracket.
3. Remove valve cover. Remove timing chain housing bolts, and remove timing chain housing.
Installation
To install, reverse removal procedure. Apply bead of RTV Sealer (12346240) to timing chain
housing mating surfaces and cylinder head-to-block mating surfaces. Apply engine oil to front
crankshaft seal lip. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS.
On 4WD models, adjust front wheel toe-in. See appropriate SPECIFICATIONS &
PROCEDURES article in WHEEL ALIGNMENT.
TIMING CHAIN TENSIONER (CAMSHAFT)
Removal
1. Disconnect negative battery cable. Remove timing chain housing. See TIMING CHAIN
HOUSING (FRONT COVER).
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NOTE: Align timing marks before disassembly. See Fig. 4. Remove

spark plugs to facilitate crankshaft rotation.
2. Remove spark plugs. Position No. 1 cylinder at TDC. Align crankshaft keyway with mark
on block. Ensure arrow on idler sprocket is at 6 o'clock position, and guide pins on camshaft
sprockets are aligned with notches on cylinder head. See Fig. 4.
3. Release tension on camshaft timing chain by turning intake camshaft slightly
counterclockwise. Remove camshaft timing chain tensioner bolts and nut, and remove
tensioner.
Installation
1. To install, depress timing chain tensioner plunger into tensioner body. Hold plunger in place
with paper clip or similar retainer, and install tensioner. See Fig. 5. Tighten tensioner bolts
and nut to specification. See TORQUE SPECIFICATIONS. Remove plunger retainer.
2. Turn crankshaft 2 revolutions, realigning crankshaft keyway with mark on block. Ensure
arrow on idler sprocket is at 6 o'clock position, and guide pins on camshaft sprockets are
aligned with notches on cylinder head. See Fig. 4. Apply engine oil to timing chains,
tensioner, guides and sprockets. To complete installation, reverse removal procedure.
Tighten bolts to specification. See TORQUE SPECIFICATIONS. Fill crankcase, cooling
system, and power steering system. On 4WD models, adjust front wheel toe-in. See
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Fig. 4: Aligning Timing Marks

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Fig. 5: Depressing Camshaft Timing Chain Tensioner Plunger

TIMING CHAIN TENSIONER (CRANKSHAFT)
Removal

2. Remove spark plugs. Position No. 1 cylinder at TDC. Align crankshaft keyway with mark
on block. Ensure arrow on idler sprocket is at 6 o'clock position, and guide pins on camshaft
sprockets align with notches on cylinder head. See Fig. 4. Remove crankshaft timing chain
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tensioner bolts and remove crankshaft tensioner.

Installation
1. To install, depress timing chain tensioner plunger into tensioner body. Hold plunger in place
with paper clip or similar retainer and install tensioner. See Fig. 6. Tighten tensioner bolts
to specification. See TORQUE SPECIFICATIONS. Remove plunger retainer.
2. Rotate crankshaft until crankshaft keyway lines up with marks on block. Ensure guide pins
on camshaft align with notches on cylinder head. See Fig. 4. Apply engine oil to timing
chains, tensioner, guides and sprockets. To complete installation, reverse removal
procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Fill
crankcase, cooling system, and power steering system. On 4WD models, adjust toe-in. See
Fig. 6: Depressing Crankshaft Timing Chain Tensioner Plunger

TIMING CHAIN & SPROCKETS (CAMSHAFT)
CAUTION: Do not rotate engine with timing chains removed. Valve and
piston damage could result. If necessary, camshafts may be
turned 15 degrees from notches on cylinder head in either
direction. Crankshaft may be turned 90 degrees from mark on
engine block in either direction.
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Removal

2. Remove spark plugs. Position No. 1 cylinder at TDC. Align crankshaft keyway with timing
mark on block. Ensure arrow on idler sprocket is at 6 o'clock position, and guide pins on
camshaft sprockets are aligned with notches on cylinder head. See Fig. 4.
3. Release tension on camshaft timing chain by turning intake camshaft slightly
counterclockwise. Remove tensioner bolts and nut, and remove camshaft timing chain
tensioner. Hold intake camshaft with wrench, and remove sprocket bolts. Remove camshaft
sprockets and chain.
Installation
1. Align crankshaft keyway with timing mark on block. Ensure arrow on idler sprocket is at 6
o'clock position, and guide pins on camshaft sprockets are aligned with notches on cylinder
head. See Fig. 4. Align Yellow link on camshaft timing chain with arrow on idler sprocket.
See Fig. 7.
CAUTION: Ensure all timing marks are aligned after timing chain is
installed.
2. Align Dark Blue links on camshaft timing chain with arrows on camshaft sprockets. See
Fig. 8. Install camshaft sprockets and chain. Install camshaft sprocket bolts and tighten to
3. Depress camshaft timing chain tensioner plunger into tensioner body. Insert paper clip or
similar retainer through hole in tensioner body to keep plunger in place. See Fig. 5. Install
timing chain tensioner bolts and nut. Tighten to specification. See TORQUE
SPECIFICATIONS. Remove plunger retainer.
4. Turn crankshaft 2 revolutions and realign keyway on crankshaft with timing mark on engine.
Ensure guidepins on camshafts line up with notches on cylinder head. Apply engine oil to
sprockets, timing chain, timing chain tensioner, and guides.
5. To complete installation, reverse removal procedure. Tighten bolts to specification. See
TORQUE SPECIFICATIONS. On 4WD models, adjust front wheel toe-in. See
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Fig. 7: Aligning Camshaft Timing Chain & Idler Sprocket

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Fig. 8: Aligning Camshaft Timing Chain & Camshaft Sprockets

TIMING CHAIN & SPROCKETS (CRANKSHAFT)
CAUTION: Do not rotate engine with timing chains removed. Valve and
piston damage could result. If necessary, camshafts may be
turned 15 degrees from notches on cylinder head in either
direction. Crankshaft may be turned 90 degrees from mark on
engine block in either direction.
Removal

2. Remove spark plugs. Position No. 1 cylinder at TDC. Align crankshaft keyway with timing
mark on block. Ensure arrow on idler sprocket is at 6 o'clock position, and guide pins on
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camshaft sprockets are aligned with notches on cylinder head. See Fig. 4.
3. Remove camshaft timing chain and sprockets. See TIMING CHAIN & SPROCKETS
(CAMSHAFT). Remove crankshaft timing chain tensioner and guides. Remove idler
sprocket and crankshaft timing chain. Remove crankshaft sprocket.
Installation
1. Ensure crankshaft keyway is aligned with timing mark on block. See Fig. 4. Install
crankshaft sprocket. Tighten to specification. See TORQUE SPECIFICATIONS. Apply
engine oil to idler sprocket bushing. Install crankshaft timing chain on idler sprocket,
aligning Dark Blue link of timing chain with timing chain alignment mark on idler sprocket.
See Fig. 9.
2. Install crankshaft timing chain to crankshaft sprocket, aligning Yellow link of timing chain
with timing mark on crankshaft sprocket. See Fig. 10. Apply engine oil to idler sprocket
bushing, and install idler sprocket. Install timing chain guides. Depress crankshaft timing
chain tensioner plunger and hold in place with paper clip or similar retainer. Install
tensioner, and tighten bolts to specification. See TORQUE SPECIFICATIONS. Remove
tensioner plunger retainer.
3. Ensure crankshaft keyway is aligned with timing mark on block, and Yellow link on
crankshaft timing chain is aligned with crankshaft timing mark. Ensure Dark Blue link of
crankshaft timing chain is aligned with timing mark on idler sprocket. Install camshaft
timing sprockets and chain. Install camshaft sprocket bolts and tighten to specification. See
TORQUE SPECIFICATIONS.
4. Depress camshaft timing chain tensioner plunger into tensioner body. Insert paper clip or
similar retainer through hole in tensioner body to keep plunger in place. Install tensioner
and tighten to specification. See TORQUE SPECIFICATIONS. Remove plunger retainer
from tensioner.
5. Turn crankshaft 2 revolutions realigning keyway with timing mark on block. Ensure guide
pins on camshafts are in line with notches on cylinder head. Apply engine oil to timing
chains, tensioner, guides, and sprockets. To complete installation, reverse removal
procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS. On
4WD models, adjust front wheel toe-in. See appropriate SPECIFICATIONS &
PROCEDURES article in WHEEL ALIGNMENT.
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Fig. 9: Aligning Crankshaft Timing Chain & Idler Sprocket

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Fig. 10: Aligning Crankshaft Timing Chain & Crankshaft Sprocket

CAMSHAFTS
NOTE: Removal and installation procedures are same for intake and
exhaust camshafts.
Removal
HOUSING (FRONT COVER). Remove camshaft timing chain. See TIMING CHAIN &
SPROCKETS (CAMSHAFT).
2. Rotate crankshaft 90 degrees to prevent interference between valves and pistons. Loosen
camshaft bearing cap bolts in sequence. See Fig. 1. Remove camshaft bearing caps, and
remove camshaft.
Inspection
1. Inspect camshaft lobe height, journal diameter and runout. Replace camshaft if not within
specifications. See CAMSHAFT table under ENGINE SPECIFICATIONS.
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2. Measure cylinder head camshaft bore and camshaft journal diameter. Replace camshaft(s) or
cylinder head if oil clearance is not within specification. If camshaft(s) and cylinder head
exceed specification, replace component with greatest difference to specification. See
CAMSHAFT table under ENGINE SPECIFICATIONS.
Installation
1. Align crankshaft keyway with timing mark on engine block. Apply engine oil to camshaft
journals and lobes. Install camshafts into cylinder head, aligning guide pins with notches on
cylinder head. See Fig. 4. Position slot in exhaust camshaft to accept camshaft position
sensor. Install cylinder head dowel pins. See Fig. 11.
NOTE: Ensure camshaft bearing caps are installed in their original

positions. Bearing caps are marked with "E" (exhaust), or
"I" (intake). Number stamped on bearing cap indicates position
from timing chain, and arrow shows direction toward timing
chain. See Fig. 12.
2. Install camshaft bearing caps in original positions. Tighten camshaft bearing cap bolts in
sequence and to specification. See Fig. 3. See TORQUE SPECIFICATIONS. To
complete installation, reverse removal procedure. On 4WD models, adjust front wheel toe-
in. See appropriate SPECIFICATIONS & PROCEDURES article in WHEEL
ALIGNMENT.
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Fig. 11: Locating Cylinder Head Dowel Pins

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Fig. 12: Identifying Camshaft Bearing Cap Marks

HYDRAULIC VALVE LASH (HVL) ADJUSTERS
CAUTION: Do not disassemble Hydraulic Valve Lash (HVL) adjusters. Do

not compress HVL adjusters. Do not lay HVL adjusters on
their side. Store HVL adjusters submerged in clean engine oil,
camshaft end down, until installation. If left in air, store HVL
adjusters camshaft end up, until installation.
Removal
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Remove camshafts. See CAMSHAFTS. Note HVL adjuster locations for installation reference.
Remove HVL adjusters from cylinder head and submerge in clean engine oil.
Inspection
Inspect HVL adjusters for wear scoring and damage. Measure cylinder head HVL adjuster bore
diameter and HVL adjuster O.D. If oil clearance exceeds maximum specification, replace HVL
adjuster. If oil clearance still exceeds maximum specification, replace cylinder head. See
HYDRAULIC VALVE LASH (HVL) ADJUSTERS table under ENGINE
SPECIFICATIONS.
Installation
Pour engine oil into oil feed hole in HVL adjuster bore to remove debris from oil gallery and
prelube bore. Apply engine oil to HVL adjusters and install adjusters in cylinder head. Align
crankshaft keyway with timing mark on block. See Fig. 4. To complete installation, reverse
removal procedure.
CAUTION: Do not rotate or start engine for 30 minutes after replacing

HVL adjusters and camshafts. Valve operation before this
time could cause valve or piston damage.
NOTE: Valves may make a tapping/ticking sound if air is trapped in HVL

adjuster(s) after replacement. Run engine at 2000 RPM until air is
purged. If noise persists, locate and replace defective HVL adjuster
(s).
CRANKSHAFT REAR OIL SEAL
Removal
Remove transmission. For A/T, see appropriate TRANSMISSION REMOVAL &

INSTALLATION article in TRANSMISSION SERVICING. For M/T, see appropriate article in
CLUTCHES. Place reference mark on crankshaft and flywheel/drive plate for installation
reference. Remove flywheel/drive plate. Pry seal from seal retainer. DO NOT damage seal
retainer or crankshaft.
Installation
Ensure all sealing surfaces are clean. Lubricate seal lip with grease. Using hammer and Seal
Installer (J41172), install oil seal until edge is flush with cylinder block. To install remaining
components, reverse removal procedure. Ensure reference mark on flywheel/drive plate aligns
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with mark on crankshaft. Tighten bolts to specification. See TORQUE SPECIFICATIONS.
THERMOSTAT REPLACEMENT
Removal Procedure
1. Drain the engine coolant.

2. Remove the three bolts (1) and position the A/C compressor aside.
Fig. 13: Removing Three Bolts & Positioning A/C Compressor Aside
3. Remove the radiator hose clamp (1) from the thermostat housing.
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4. Remove the radiator hose from the thermostat housing.
Fig. 14: Removing Radiator Hose Clamp From Thermostat Housing

5. Remove the three bolts and the thermostat housing (3).

6. Remove the thermostat and the O-ring from the thermostat housing.
7. Clean any corrosion or debris from the thermostat housing.
8. Clean the mating surfaces.
9. Inspect the thermostat.
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Fig. 15: Three Bolts & Thermostat Housing

Installation Procedure
IMPORTANT: Position the air bleed valve so that it aligns with the mark on the
cylinder head.
1. Install the thermostat in the described position to the cylinder head.

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2. Install a new thermostat O-ring.

3. Install the thermostat housing (3).
4. Secure the thermostat housing (3) with three bolts.
Tighten
Tighten the thermostat housing bolts to 16 N.m (12 lb ft).
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Fig. 16: Thermostat Housing

5. Install the A/C compressor and secure with three bolts (1).
Tighten
Tighten the A/C compressor bolts to 23 N.m (17 lb ft).
Fig. 17: A/C Compressor

6. Install the radiator hose and clamp (1) to the thermostat housing.
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7. Fill the radiator with approved coolant.

8. Start the engine.
9. Allow the coolant to attain operating temperature (both hoses feel warm and the coolant is
flowing through the radiator).
10. Check for leaks in the cooling system.
11. Shut off the engine.
12. Install the radiator cap.
Fig. 18: Installing Radiator Hose & Clamp To Thermostat Housing

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WATER PUMP
1. Release tension on serpentine belt and remove belt from water pump pulley. Remove water
pump bolts, water pump and gasket. Remove dowel pin from engine block.
2. To install, reverse removal procedure. Install NEW "O" rings to water pump and heater
outlet line. Install NEW water pump mounting bolts and gasket. Tighten bolts to
OIL PAN
1. Raise and support vehicle. Remove skid plate (if equipped). On 4WD models, remove axle
assembly. See DIFFERENTIALS & AXLE SHAFTS - TRACKER article in DRIVE
AXLES. On all models, remove steering gear. See appropriate article in STEERING.
2. Drain engine oil. Remove right engine block-to-transmission support bracket. Remove
flywheel cover. Remove 16 bolts and 2 nuts retaining oil pan to block. Remove oil pan, oil
pump strainer and "O" rings.
3. To install, reverse removal procedure. Install NEW "O" rings, and attach oil pump strainer
to oil pump. Tighten 2 strainer bolts then bracket bolt. Apply a continuous bead of RTV
Sealer (12346240) to oil pan mating surface. Install oil pan. Tighten bolts/nuts to
specification. See TORQUE SPECIFICATIONS. On 4WD models, adjust front wheel
toe-in. See appropriate SPECIFICATIONS & PROCEDURES article in WHEEL
ALIGNMENT.
OVERHAUL
NOTE: For repair procedures not covered in this article, see ENGINE
OVERHAUL PROCEDURES article in GENERAL INFORMATION.
CYLINDER HEAD
Cylinder Head
1. Inspect cylinder head for cracks and warpage. Using a straightedge and feeler gauge, check
cylinder head deck surface for warpage (along all 4 edges and diagonally across cylinder
head). Replace cylinder head if deck warpage exceeds .002" (.05 mm). Check intake and
exhaust manifold mating surfaces. Replace cylinder head if either manifold surface
exceeds .004" (.10 mm).
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2. Measure cylinder head camshaft bores and camshaft journal diameters. Determine camshaft
oil clearances. Replace camshaft(s) or cylinder head if clearance is not within specification.
If camshaft(s) and cylinder head exceed specification, replace component with greatest
difference to specification. See CAMSHAFT table under ENGINE SPECIFICATIONS.
3. Check cylinder head Hydraulic Valve Lash (HVL) adjuster bore I.D. Replace cylinder head
if HVL adjuster bore I.D. exceeds specification. See CYLINDER HEAD table under
ENGINE SPECIFICATIONS.
Valve Springs
Using a valve spring tester, measure tension of valve springs at specified installed height. Ensure
valve spring free length and out-of-square are within specification. See VALVES & VALVE
SPRINGS table under ENGINE SPECIFICATIONS.
Valve Stem Oil Seals
Install valve stem oil seals using Valve Guide Seal Installer (J38232).
Valve Guides
1. Measure valve stem-to-valve guide oil clearance. See CYLINDER HEAD table under
ENGINE SPECIFICATIONS. Ensure valve stem diameter is within specification. Replace
valve guide if clearance exceeds specification.
2. To replace valve guide, use hammer and Valve Guide Remover/Installer (J37968). Drive
valve guide out from bottom of cylinder head toward top of cylinder head. Ream valve
guide bore with .43" (11.0 mm) Reamer (J-37972).
NOTE: New valve guide is .0012" (.03 mm) oversize.
3. Gradually heat cylinder head to 176-212°F (80-100°C). Heat cylinder head uniformly to
prevent head warpage. Install valve guide using hammer and Valve Guide Remover/Installer
(J37968). Drive .0012" (.03 mm) oversize valve guide into cylinder head from top. Install
valve guide so installed height above cylinder head surface is .53" (13.5 mm). Use .24" (6.0
mm) Reamer (J-38342) to ream valve guide and clean hole.
Valve Seat
Valve seats are not replaceable.

Valves
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Inspect valve for wear or burning. Measure valve dimensions after refacing. Ensure valve stem
diameter and valve margin are within specification. Check valve contact pattern and overall
length. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.
Valve Seat Correction Angles
To lower valve seat surface on valve, cut seat at 20 degrees. To raise valve seat surface on valve,
cut seat at 70 degrees.
CYLINDER BLOCK ASSEMBLY
Piston & Rod Assembly
1. Ensure connecting rod and connecting rod bearing cap are marked with matching cylinder
number for installation reference. When removing piston from connecting rod, note
direction of piston installation on connecting rod in relation to front mark (arrow) on piston
head and front mark ("86F") on connecting rod. See Fig. 19.
2. Check rod side clearance, bend, and twist. Replace rods that exceed specifications. See
CONNECTING RODS table under ENGINE SPECIFICATIONS.
3. When installing connecting rod bearing caps, ensure arrow on cap is pointing towards
timing chain end of engine. Tighten rod cap nuts to specification. See TORQUE
SPECIFICATIONS. Connecting rod bushing may be replaced if bore diameter is not
within specification. Ensure bushing oil hole aligns with connecting rod oil hole. Bushing
must be honed to obtain correct piston pin-to-rod clearance. See PISTON, PINS &
RINGS table under ENGINE SPECIFICATIONS.
4. Install piston on connecting rod with arrow on piston head aligned with "86F" mark on
connecting rod. See Fig. 19. Coat piston pin with engine oil, and install. Install NEW snap
ring. DO NOT align ends of snap ring with pinhole (cutout) area on piston.
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Fig. 19: Identifying Piston & Connecting Rod Marks

Fitting Pistons
NOTE: Two standard size pistons and cylinder bore diameters are used.
Pistons are stamped with number "1" or "2" to identify piston
diameter. Cylinder block is coded with a Red or Blue paint mark at
each cylinder to identify cylinder bore diameter. See Fig. 19 and
Fig. 23 . Install piston stamped "1" to cylinder with Red paint mark.
Install piston stamped "2" to cylinder with Blue paint mark. See
MY
PISTONS, PINS & RINGS and CYLINDER BLOCK tables under

1. To determine piston-to-cylinder clearance, measure piston skirt diameter at 90-degree angle

to piston pin, 1.007" (25.6 mm) from top of piston. Measure cylinder bore diameter at a
point 2.5" (64.0 mm) from top and bottom of bore, and at middle of bore. Subtract bore
diameter from piston diameter. Ensure piston-to-bore clearance is within specification. See
PISTON, PINS & RINGS table under ENGINE SPECIFICATIONS.
2. If piston-to-bore clearance exceeds specification and cylinder bore is within specification,
replace piston. If cylinder bore is not within specification, rebore all 4 cylinders and fit with
oversize pistons, or replace cylinder block. See CYLINDER BLOCK table under
Piston Rings
Ensure ring end gap and side clearance are within specification. See PISTONS, PINS & RINGS
table under ENGINE SPECIFICATIONS. Install compression rings with identification mark
facing top of piston. Lower compression (middle) ring is marked "R", upper compression ring is
marked "RN". Position piston ring gaps 90 degrees apart. Ensure ring end gaps are not aligned,
and ensure ring gaps do not align with piston pin. See Fig. 20.
Rod Bearings
NOTE: Standard and undersize connecting rod bearings are available.

Undersize bearings are marked with Red paint. See CRANKSHAFT,
MAIN & CONNECTING ROD BEARINGS table under ENGINE
SPECIFICATIONS.
1. Note direction of connecting rod and cap before disassembly. If bearings are to be reused,
measure bearing oil clearance using Plastigage method before removing pistons. Check rod
side play, and rod bearing bore. No taper or out-of-round should exist. See
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS and CONNECTING
RODS tables under ENGINE SPECIFICATIONS.
2. Install piston and rod assembly. Check rod bearing clearance using Plastigage method.
Tighten rod bolts in 2 steps to specification. See TORQUE SPECIFICATIONS. If rod
bearing clearance is excessive, measure crankpin journal diameter. If crankpin journal
diameter is within specification, replace bearing with a standard bearing. If crankpin journal
is less than minimum specification, an undersize bearing is available. Regrind crankshaft to
fit undersize bearing if necessary.
MY
Crankshaft & Main Bearings
1. Before disassembly, ensure main bearing caps are numbered for location, and arrow on cap
points toward timing chain end of crankshaft. Remove main bearing caps and bolts, along
with lower bearing halves.
2. Cylinder block main bearing bore size is indicated by letter "A", "B", or "C" stamped on
lower crankcase. See Fig. 21. Ensure main bearing bore is within specification. See MAIN
BEARING BORE SPECIFICATIONS table.
3. Crankshaft main bearing journal sizes are indicated by numbers stamped crankshaft. See
Fig. 22. Ensure main bearing journal is within specification. See MAIN BEARING
JOURNAL DIAMETER SPECIFICATIONS table.
MY
Fig. 20: Positioning Piston Rings

MY
Fig. 21: Locating Cylinder Block Main Bearing Bore Codes

MY
Fig. 22: Locating Crankshaft Main Bearing Journal Size Codes

MY
Fig. 23: Locating Cylinder Bore Diameter Paint Codes

NOTE: Main bearings are color code marked. Standard bearings have
one color code mark. All undersize bearings have 2 color code
marks, except undersize bearing with Red only color code
mark.
4. If main bearing journal and main bearing bore are within specification, replace main
bearings with new bearings matching original color code mark. If color code on original
bearing cannot be determined, use letter stamped on lower crankcase to determine proper
bearing size. See MAIN BEARING SELECTION (STANDARD) table. Main bearings
MY
are available in undersizes. All undersize bearings have 2 color code marks, except
undersize bearing with Red only color code mark. See Fig. 24. Undersize bearings are
available in 5 thickness variations. See BEARING THICKNESS SPECIFICATIONS
table.
5. If necessary, regrind main journals to .010" (.25 mm) undersize with a 2.2729-
2.2736" (57.732-57.750 mm) finished diameter. Using finished journal diameter and letter
marked on lower crankcase, determine undersize main bearing color code. See MAIN
BEARING SELECTION (UNDERSIZE) table. Measure reground crankshaft journals to
ensure out-of-round and taper do not exceed .0004" (.01 mm).
6. When installing main bearing caps, ensure arrow on cap points toward timing chain end of
crankshaft. Tighten 10 main bearing cap bolts and 12 lower crankcase bolts in sequence and
to specification. See Fig. 25. See TORQUE SPECIFICATIONS.
Fig. 24: Identifying Main Bearing Color Codes

MY
Fig. 25: Main Bearing Cap Bolt & Lower Crankcase Bolt Tightening Sequence
MAIN BEARING BORE SPECIFICATIONS

Lower Crankcase Letter
Code Diameter - In. (mm)
"A" 2.4409-2.4412 (62.000-
62.006)
"B" 2.4412-2.4414 (62.006-
62.012)
"C" 2.4414-2.4416 (62.012-
62.018)
MAIN BEARING JOURNAL DIAMETER SPECIFICATIONS
MY
Crankshaft Number
Code Diameter - In. (mm)
1 2.2832-2.2834 (57.994-
58.000)
2 2.2830-2.2832 (57.988-
57.994)
3 2.2828-2.2829 (57.982-
57.988)
MAIN BEARING SELECTION (STANDARD)

Lower Crankcase Crankshaft Bearing Color
Letter Code Number Code Code
"A" 1 Green
"A" 2 Black
"A" 3 No Color
"B" 1 Black
"B" 2 No Color
"B" 3 Yellow
"C" 1 No Color
"C" 2 Yellow
"C" 3 Blue
BEARING THICKNESS SPECIFICATIONS

Bearing
Color
Code In. (mm)
Standard Bearings
Green .0785-.0786 (1.993-
1.999)
Black .0786-.0787 (1.996-
2.000)
No .0787-.0788 (1.999-
Color 2.003)
Yellow .0788-.0789 (2.002-
2.006)
Blue .0789-.0790 (2.005-
2.009)
MY
Undersize Bearings
Green .0834-.0835 (2.118-
& Red 2.122)
Black .0835-.0836 (2.121-
& Red 2.125)
Red .0836-.0837 (2.124-
(Only) 2.128)
Yellow .0837-.0838 (2.127-
& Red 2.131)
Blue & .0838-.0839 (2.130-
Red 2.134)
MAIN BEARING SELECTION (UNDERSIZE)

Finished Lower
Journal Crankcase Bearing Color
Diameter Letter Code
2.2729-2.2731 "A" Red
(57.732-57.738) "B" Yellow & Red
"C" Blue & Red
2.2731-2.2733 "A" Black & Red
(57.738-57.744) "B" Red
"C" Yellow & Red
2.2734-2.2736 "A" Green & Red
(57.744-57.750) "B" Black & Red
"C" Red
Thrust Bearing
Standard and oversize thrust bearings are available. Replace thrust bearing if crankshaft end play
is not within specification. See CRANKSHAFT, MAIN & CONNECTING ROD
BEARINGS table under ENGINE SPECIFICATIONS. Install thrust bearing on main bearing,
with grooves toward crankshaft, away from cylinder block.
Cylinder Block
NOTE: Cylinder block is coded with a Red or Blue paint mark at each
cylinder to identify cylinder bore diameter. See Fig. 23. See
CYLINDER BLOCK table under ENGINE SPECIFICATIONS. See
FITTING PISTONS.
MY
1. Using feeler gauge and straightedge, check cylinder block deck surface in 6 places for
warpage. If warpage exceeds .0024" (.06 mm), replace cylinder block.
2. Measure cylinder bore diameter at a point 2.5" (64.0 mm) from top and bottom of bore, and
at middle of bore. If cylinder bore diameter or taper is not within specification, rebore all 4
cylinders and fit with oversize pistons, or replace block. See CYLINDER BLOCK table
under ENGINE SPECIFICATIONS.
ENGINE OILING
ENGINE LUBRICATION SYSTEM
Oil pump is crankshaft-driven and provides lubrication to the main gallery.

Crankcase Capacity
Crankcase capacity with oil filter change is 5.5 qts. (5.2L).

Oil Pressure
NOTE: Oil pressure at idle specification is not available from

manufacturer.
With engine at normal operating temperature, oil pressure range should be 56-67 psi (3.9-4.7
kg/cm2 ) at 4000 RPM.
OIL PUMP
Removal & Disassembly
1. Disconnect negative battery cable. Remove oil level indicator. Raise and support vehicle.
Remove skid plate (if equipped). On 4WD models, remove front axle assembly. See
DIFFERENTIALS & AXLE SHAFTS - TRACKER article in DRIVE AXLES. On all
models, remove steering gear.
2. Drain engine oil. Remove right engine block-to-transmission support bracket bolts, and
remove support bracket. Remove flywheel cover. Remove oil pan. Remove oil pump
strainer, and oil pump drive chain cover. Remove oil pump mounting bolts, and remove oil
pump. Remove 5 bolts, and separate oil pump halves. Remove retainer, spring and relief
valve.
Inspection
MY
1. Apply light air pressure to oil jet passage to ensure it is not plugged. Inspect components for
damage. Ensure relief valve slides freely in bore. Measure outer rotor-to-pump body radial
clearance. Replace oil pump if measurement exceeds specification. See OIL PUMP
SPECIFICATIONS table.
2. With rotors in oil pump housing, place straightedge across housing. Measure side clearance
between outer rotor and straightedge. Replace oil pump assembly if clearance exceeds
specification. See OIL PUMP SPECIFICATIONS table.
OIL PUMP SPECIFICATIONS

Application In. (mm)
Radial Clearance .0059 (.150)
Rotor Side Clearance .0043 (.110)
Reassembly & Installation
1. To reassemble, reverse disassembly procedure. Ensure gears are installed in pump body with
reference marks facing up. Fill oil pump with petroleum jelly to prime pump. Tighten oil
pump cover bolts to specification. See TORQUE SPECIFICATIONS.
2. To install, reverse removal procedure. Use NEW "O" rings. Apply continuous bead of RTV
Sealant (12346240) to oil pan mating surface. Tighten bolts and nuts to specification. See
TORQUE SPECIFICATIONS. On 4WD models, adjust front wheel toe-in. See
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
A/C Compressor-To-Bracket Bolt 17 (23)
A/C Compressor Bracket-To Block Bolt 40 (55)
Camshaft Position Sensor Bolt 11 (15)
Camshaft Sprocket Bolt 58 (80)
Connecting Rod Nut 33 (45)
Coolant By-Pass Pipe Bolt 11 (15)
Crankshaft Pulley Bolt 109 (150)
Cylinder Head Bolt (1)
Step 1 (Bolts 1-10) 39 (53)
Step 2 (Bolts 1-10) 61 (84)
MY
Step 3 (Bolts 1-10) (2)

Fully Loosen Bolts
Step 4 (Bolts 1-10) 39 (53)
Step 5 (Bolts 1-10) 61 (84)
Step 6 (Bolt 11) 76 (105)
Engine Mounts
Bracket-To-Block Bolt 37 (50)
Bracket-To-Body Bolt 62 (85)
Insulator Nuts 37 (50)
Exhaust Bracket-To-Manifold Nut 37 (50)
Exhaust Heat Shield Bolt (Upper & Lower) 11 (15)
Exhaust Manifold-To-Cylinder Head Bolt/Nuts 37 (50)
Exhaust Pipe-To-Manifold Nuts 37 (50)
Flywheel/Flex Plate Bolt
A/T 51 (70)
M/T 51 (70)
Fuel Rail Banjo Fitting 22 (30)
Fuel Rail-To-Cylinder Head Bolt 17 (23)
Lower Crankcase Bolts(3)
Step 1 14 (19)
Step 2 20 (27)
Idler Pulley Nut 33 (45)
Intake Manifold Bolt/Nut 19 (25)
Intake Manifold Support Bracket Bolt
Front 33 (45)
Top 11 (15)
Main Bearing Cap Bolt (3)
Step 1 31 (42)
Step 2 44 (60)
Oil Drain Plug 26 (35)
Oil Pump Bolt 20 (27)
Power Steering Pump Bolt 19 (25)
Serpentine Belt Tensioner Bolt 18 (24)
Spark Plugs 18 (24)
Starter Bolt 22 (30)
MY
Timing Chain Tensioner Nut (Camshaft) 33 (45)

Transmision-To-Engine Bolt 62 (85)
Water Pump Mounting Bolt 20 (27)
Wheel Lug Nut 76 (103)
INCH Lbs. (N.m)
Camshaft Bearing Cap Bolt (4) 97 (11)
Crankshaft Position Sensor Bolt 53 (6)
Oil Pan Bolt 97 (11)
Oil Pump Housing Bolt 106 (12)
Oil Pump Pick-Up Tube Bolt 97 (11)
Rear Seal Retainer Bolt 106 (12)
Timing Chain Housing (Front Cover) 97 (11)
Timing Chain Tensioner Bolt (Camshaft) 97 (11)
Timing Chain Tensioner Bolt (Crankshaft) 97 (11)
Timing Chain Tensioner Guide Bolt (Crankshaft) 80 (9)
Valve Cover Bolt 97 (11)
Water Pump Pulley Bolt 97 (11)
(1) Tighten bolts in sequence. See Fig. 2.
(2) Loosen bolts in reverse order of tightening sequence. See Fig. 2.

ENGINE SPECIFICATIONS
GENERAL ENGINE SPECIFICATIONS

Application Specification
Displacement 122 Cu. In. (2.0L)
Bore 3.31" (84 mm)
Stroke 3.54" (90 mm)
Compression Ratio 9.7:1
Fuel System SFI
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

MY
Crankshaft
End Play
Standard .0039-.0138 (.100-
.350)
Wear Limit .0165 (.420)
Maximum Runout At Center Journal .0023 (.060)
Thrust Washer Thickness
Standard .0984 (2.500)
Oversize .0049" (.125 mm) .1009 (2.563)
Main Bearings (1)
Main Bearing Thickness (Standard)
Size Mark Green .0785-.0786(1.993-
1.997)
Size Mark Black .0786-.0787 (1.996-
2.000)
Size Mark No Color .0787-.0788 (1.999-
2.003)
Size Mark Yellow .0788-.0789 (2.002-
2.006)
Size Mark Blue .0789-.0790 (2.005-
2.009)
Main Bearing Thickness 0.098" (0.25 mm) Undersize
Size Mark Green & Red 0.0834-0.0835 (2.118-
2.122)
Size Mark Black & Red 0.0835-0.0836 (2.121-
2.125)
Size Mark Red (Only) 0.0836-0.0837 (2.124-
2.128)
Size Mark Yellow & Red 0.0837-0.0838 (2.127-
2.131)
Size Mark Blue & Red 0.0838-0.0839 (2.130-
2.134)
Journal Diameter (2)
Size Mark 1 2.2832-2.2834
(57.994-58.000)
Size Mark 2 2.2830-2.2832
MY
(57.988-57.994)
Size Mark 3 2.2828-2.2829
(57.982-57.988)
Bearing Bore Diameter (Without Bearing) (3)
Size Mark "A" 2.4409-2.4412
(62.000-62.006)
Size Mark "B" 2.4412-2.4414
(62.006-62.012)
Size Mark "C" 2.4414-2.4416
(62.012-62.018)
Journal Taper Or Out-Of-Round .0004 (.01)
Oil Clearance
Standard .0010-.0018 (.026-
.046)
Wear Limit .0023 (.060)
Reground Journal Finished Diameter 2.2729-2.2736 (57.732-
57.750).
Connecting Rod Bearings
Journal Diameter
Standard 1.9678-1.9685
(49.982-50.000)
Undersize 098" (0.25 mm) 1.9580-1.9586
(49.732-49.750)
Journal Taper Or Out-Of-Round .0004 (.010)
Oil Clearance
Standard .0018-.0025 (.045-
.063)
Wear Limit .0031 (.080)
(1) Use illustration for bearing thickness paint mark location. See Fig. 24.
(2) Use illustration for journal diameter size mark location. See Fig. 22.
(3) Use illustration for bore diameter size mark location. See Fig. 21
CONNECTING RODS
Maximum Bend .0020 (.050)
MY
Maximum Twist .0039 (.10)

Side Play
Standard .0099-.0157 (.25-.40)
Wear Limit .0177 (.45)
PISTONS, PINS & RINGS

Pistons
Piston-To-Cylinder Bore Clearance .0008-.0015 (.002-.038)
Diameter (1)
Standard (Marked 1) 3.3063-3.3066 (83.980-
83.990)
Standard (Marked 2) 3.3059-3.3062 (83.970-
83.980)
Oversize .0098" (.25 mm) 3.3157-3.3165 (84.220-
84.240)
Oversize .0196" (.50 mm) 3.3256-3.3263 (84.470-
84.490)
Pin Diameter .8267 (21.000)
Rings
No. 1
End Gap
Standard .0079-.0137 (.20-.35)
Wear Limit .0276 (.07)
Groove Clearance .0012-.0027 (.030-.070)
No. 2
End Gap
Standard .0138-.0196 (.35-.50)
Wear Limit .0276 (0.7)
Groove Clearance .0008-.0023 (.020-.060)
No. 3 (Oil)
End Gap
Standard .0079-.0275 (.20-.70)
Wear Limit .0709 (1.8)
(1) Piston size mark is located on piston head. See Fig. 19.
MY
CYLINDER BLOCK
Cylinder Bore Diameter (Standard) (1)
Color Code Blue 3.3071-3.3074 (84.000-
84.01)
Color Code Red 3.3075-3.3078 (84.01-
84.02)
Cylinder Bore Limit 3.3090 (84.050)
Out-Of-Round & Taper (Maximum) .0039 (.10)
Maximum Deck Warpage .0024 (.06)
(1) Cylinder bore diameter codes located on block deck. See Fig. 23.
VALVES & VALVE SPRINGS

Valve Face Refinishing Angle 45°
Valve Face Contact Width .0433-.0512" (1.10-1.13 mm)
Valve Guide I.D. .2362-.2366" (6.000-6.012 mm)
Valve Head Thickness
Intake Valve
Standard .039" (1.00 mm)
Minimum .024" (.60 mm)
Exhaust Valve
Standard .047" (1.20 mm)
Minimum .027" (.70 mm)
Valve Stem Diameter
Intake .2348-.2354" (5.965-5.980
mm)
Exhaust .2339-2344" (5.940-5.955
mm)
Valve Stem-To-Guide Clearance
Intake Valve
Standard .0008-.0018" (.020-.047
mm)
Maximum .0027" (.070 mm)
Exhaust Valve
MY
Standard .0018-.0028" (.045-.072

mm)
Maximum .0035" (.090")
Valve Spring Free Length
Inner Spring
Standard 1.4204" (36.08 mm)
Minimum 1.3780" (35.00 mm)
Outer Spring
Standard 1.5921" (40.44 mm)
Minimum 1.5441" (39.22 mm)
Lbs. @ In. (kg @ mm)
Valve Spring Pressure (Valve Closed)
Inner Spring
Standard 15.2-17.4 @ 1.08 (6.9-7.9
@ 27.5)
Minimum 13.6 @ 1.08 (6.2 @ 27.5)
Outer Spring
Standard 33.9-39.2 @ 1.25 (15.4-17.8
@ 31.7)
Minimum 30.4 @ 1.25 (13.8 @ 31.7)
CYLINDER HEAD
Maximum Warpage
Cylinder Block Surface .002" (.05 mm)
Manifold Surfaces .004" (.10 mm)
Valve Seats
Contact Surface Refinishing Angles
Above Seat Contact Surface 15°
Seat Contact Surface 45°
Below Seat Contact Surface (Exhaust Only) 60°
Valve Seat Contact Width .0433-.0512" (1.10-1.13
mm)
Valve Guides
Valve Guide I.D. .2362-.2366" (6.000-
6.012 mm)
MY
Valve Guide Installed Height .0012" (13.5 mm)

Valve Stem-To-Guide Oil Clearance
Intake Valves
Standard .0008-.0018" (.020-
.047 mm)
Maximum .0027" (.070 mm)
Exhaust Valves
Standard .0018-.0028" (.045-
.072 mm)
Maximum .0035" (.090 mm)
Hydraulic Valve Lash (HVL) Adjuster Bore 1.2205-1.2214" (31.000-
31.025 mm)
CAMSHAFTS
Camshaft Runout Limit .0039 (.10)
Camshaft Journal Bore Clearance
Standard .0008-.0029 (.020-.074)
Maximum .0047 (.120)
Camshaft Journal Diameter
Inner (Bore) 1.0236-1.0249 (26.000-
26.033)
Outer 1.0220-1.0228 (25.959-
25.980)
Lobe Height
Exhaust
Standard 1.5717-1.5780 (39.921-
40.081)
Minimum 1.5638 (39.721)
Intake
Standard 1.5906-1.5969 (40.402-
40.562)
Minimum 1.5827 (40.202)
HYDRAULIC VALVE LASH (HVL) ADJUSTERS

MY
Adjuster Diameter 1.2188-1.2194 (30.958-

30.973)
Oil Clearance
Standard .0010-.0025 (.025-.064)
Maximum .0059 (.150)
MY

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2000 Chevrolet Tracker

2000-01 ENGINES 2.0L DOHC

ENGINE IDENTIFICATION CODES

NOTE: To trouble shoot engine mechanical components, see appropriate

REMOVAL & INSTALLATION

NOTE: For installation reference, label all electrical connectors, vacuum

FUEL PRESSURE RELEASE

CAUTION: Release fuel system pressure before servicing fuel system

WARNING: Vehicle should be supported on hoist prior to removing

specification. See TORQUE SPECIFICATIONS.

See CYLINDER HEAD under OVERHAUL.

Fig. 1: Camshaft Bearing Cap Bolt Loosening Sequence

Fig. 2: Cylinder Head Bolt Tightening Sequence

Fig. 3: Camshaft Bearing Cap Bolt Tightening Sequence

CRANKSHAFT FRONT SEAL

Removal & Installation

NOTE: Crankshaft front seal is mounted in timing chain housing.

TIMING CHAIN HOUSING (FRONT COVER)

TIMING CHAIN TENSIONER (CAMSHAFT)

NOTE: Align timing marks before disassembly. See Fig. 4. Remove

Fig. 4: Aligning Timing Marks

Fig. 5: Depressing Camshaft Timing Chain Tensioner Plunger

TIMING CHAIN TENSIONER (CRANKSHAFT)

NOTE: Align timing marks before disassembly. See Fig. 4. Remove

tensioner bolts and remove crankshaft tensioner.

Fig. 6: Depressing Crankshaft Timing Chain Tensioner Plunger

TIMING CHAIN & SPROCKETS (CAMSHAFT)

NOTE: Align timing marks before disassembly. See Fig. 4. Remove

Fig. 7: Aligning Camshaft Timing Chain & Idler Sprocket

Fig. 8: Aligning Camshaft Timing Chain & Camshaft Sprockets

TIMING CHAIN & SPROCKETS (CRANKSHAFT)

NOTE: Align timing marks before disassembly. See Fig. 4. Remove

Fig. 9: Aligning Crankshaft Timing Chain & Idler Sprocket

Fig. 10: Aligning Crankshaft Timing Chain & Crankshaft Sprocket

NOTE: Ensure camshaft bearing caps are installed in their original

Fig. 11: Locating Cylinder Head Dowel Pins

Fig. 12: Identifying Camshaft Bearing Cap Marks

HYDRAULIC VALVE LASH (HVL) ADJUSTERS

CAUTION: Do not disassemble Hydraulic Valve Lash (HVL) adjusters. Do

CAUTION: Do not rotate or start engine for 30 minutes after replacing

NOTE: Valves may make a tapping/ticking sound if air is trapped in HVL

CRANKSHAFT REAR OIL SEAL

Remove transmission. For A/T, see appropriate TRANSMISSION REMOVAL &

with mark on crankshaft. Tighten bolts to specification. See TORQUE SPECIFICATIONS.

1. Drain the engine coolant.

4. Remove the radiator hose from the thermostat housing.

Fig. 14: Removing Radiator Hose Clamp From Thermostat Housing

5. Remove the three bolts and the thermostat housing (3).

Fig. 15: Three Bolts & Thermostat Housing

1. Install the thermostat in the described position to the cylinder head.

2. Install a new thermostat O-ring.

Tighten the thermostat housing bolts to 16 N.m (12 lb ft).

Fig. 16: Thermostat Housing

Tighten the A/C compressor bolts to 23 N.m (17 lb ft).

Fig. 17: A/C Compressor

7. Fill the radiator with approved coolant.

Fig. 18: Installing Radiator Hose & Clamp To Thermostat Housing

Removal & Installation

Removal & Installation