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2.0 engine overhaul manual

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2.0 engine overhaul manual
« on: February 14, 2009, 01:29:22 PM »
Just got my engine back from the rebuild shop and now I have to re-install all the stuff that bolts on the outside.  I need all the torque values for everything.  Down loaded a manual from someones site, but it only has the diesel engine.   Thanks.

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Offline nprecon

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Re: 2.0 engine overhaul manual
« Reply #1 on: February 14, 2009, 09:26:28 PM »
Fastener tightening specs from a 2002  2.0 Liter Chevy factory manual 
(pay close attention to the inch versus foot pounds):

Air Cleaner mounting bolts -  89 lb in
AC Compressor Mount Bolts - 17 lb ft
AC Compressor Mounting bolts -  40 lb ft
Camshaft Bearing cap bolts - 97 lb in
Camshaft position sensor bolt - 11 lb ft
Camshaft timing sprocket bolts - 58 lb ft
Connecting rod bearing cap nuts  -  33 lb ft
Coolant by-pass pipe to cylinder head bolt  -  11 lb ft
Crankshaft position sensor bolt  - 11 lb ft
Crankshaft pulley bolt  - 109 lb ft
Cylinder head cover bolts - 97 lb in
Cylinder head bolts
     first pass - 39 lb ft
     second pass  - 61 lb ft
     third pass  - Loosen to zero
     fourth pass - 39 lb ft
     fifth pass - 61 lb ft
     sixth pass (final torque) - 76 lb ft
Cylinder head M6 bolt - 97 lb in
Drive belt idler pulley nut - 33 lb ft
Drive belt tensioner bolts
     Cooling fan drive belt tensioner bolts - 33 lb ft
     Accesory Drive belt tensioner bolts - 19 lb ft
Engine cooling fan nuts - 97 lb in
Engine ground wire bolts - 11 lb ft
Engine mount bracket bolts (engine side) - 37 lb ft
Engine mount bracket bolts (body side) - 62 lb ft
Engine mount nuts - 37 lb ft
Engine oil drain plug - 26 lb ft
Engine oil pan nuts and bolts - 97 lb in
Exhaust manifold flange bolts - 37 lb ft
Exhaust manifold heat shield bolts - 11 lb ft
Exhaust manifold-to-cylinder head nuts - 37 lb ft
Exhaust manifold-to-bracket bolts-  37 lb ft
Exhaust pipe PUP catalytic converter clamp bolt - 37 lb ft
Fuel rail to cyclinder head bolts -  17 lb ft
Fuel rail banjo fitting - 22 lb ft
Flywheel retaining bolts  (auto and manual) - 51 lb ft
Generator mounting bolts and nuts - 17 lb ft
Heated oxygen (HO2S1 and HO2S2) sensor - 33 lb ft
Iginition coil bolts - 89 lb In
Intake manifold bolts and nuts - 19 lb ft
Intake manifold front support bracket bolts - 33 lb ft
Intake manifold Top support bracket bolts -11 lb ft
Lower crankcase bolts
     first pass - 14 lb ft
     second pass (final torque) - 20 lb ft
Main bearing caps
     first pass - 31 lb ft
     second pass (final torque) -44 lb ft
Negative battery cable - 11 lb ft
Oil filter adapter - 17 lb ft
Oil pressure switch - 11 lb ft
Oil pump sprocket cover bolts - 97 lb in
Oil pump bolts - 20 lb ft
Oil pump case bolts - 106 lb in
Oil pump strainer bolts - 97 lb in
Oil pump relief valve retainer - 21 lb ft
Power steering pump bolts - 19 lb ft
Spark plugs - 19 lb ft
Starter bolts - 22 lb ft
Strut tower brace - 37 lb ft
Throttle body bolts and nuts - 19 lb ft
Timing chain cover nuts and bolts - 97 lb in
Timing chain tensioner bolts (camshaft) - 97 lb in
Timing chain tensioner bolts (crankshaft) - 97 lb in
Timing chain tensioner nut (camshaft) - 33 lb ft
Timing chain tensioner guide bolts (crankshaft) - 62 lb in
Timing chain tensioner shoe nut (crankshaft) - 19 lb ft
Transmission bracket bolts  - 37 lb ft
Transmission to engine mounting bolts - 62 lb ft
Water pump bolts - 20 lb ft 
« Last Edit: February 19, 2009, 07:55:50 AM by nprecon »
'02 Chezuki Tracker with a 2 Liter and 5spd.  It works for me!!!

Re: 2.0 engine overhaul manual
« Reply #2 on: February 15, 2009, 03:26:13 PM »
Thanks a lot.  All the info I have found so far on line are all relating to the diesel.