service repair manual

1. 2000-01 ENGINES
1.8L 4-Cylinder - Prizm
ENGINE IDENTIFICATION
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
ADJUSTMENT
VALVE CLEARANCE ADJUSTMENT
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
NOTE: For repair procedures not covered in this article. See ENGINE
OVERHAUL PROCEDURES article in GENERAL INFORMATION.
Application Code
Prizm LSi 1.8L 8
NOTE: Adjust valve clearance with engine cold.
Application Clearance: In. (mm)
Intake (1)
.006-.010 (.15-.25)
2000 Chevrolet Prizm
2000-01 ENGINES 1.8L 4-Cylinder - Prizm
2000 Chevrolet Prizm
2000-01 ENGINES 1.8L 4-Cylinder - Prizm
MY
Tuesday, March 31, 2009 10:43:14 AM Page 1 © 2005 Mitchell Repair Information Company, LLC.
MY
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2. 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
Exhaust (1)
.010-.014 (.25-.35)
(1) Adjust valve clearance with engine cold.
2000 Chevrolet Prizm
2000-01 ENGINES 1.8L 4-Cylinder - Prizm
MY
Tuesday, March 31, 2009 10:43:14 AM Page 2 © 2005 Mitchell Repair Information Company, LLC.

3. 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.
2000 Chevrolet Prizm
2000-01 ENGINES 1.8L 4-Cylinder - Prizm
MY
Tuesday, March 31, 2009 10:43:14 AM Page 3 © 2005 Mitchell Repair Information Company, LLC.

4. Fig. 3: Intake Valve Adjusting Shim Selection Chart
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
TROUBLE SHOOTING
REMOVAL & INSTALLATION
FUEL PRESSURE RELEASE
NOTE: To trouble shoot engine mechanical components, see appropriate
table in TROUBLE SHOOTING article in GENERAL INFORMATION.
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.
2000 Chevrolet Prizm
2000-01 ENGINES 1.8L 4-Cylinder - Prizm
MY
Tuesday, March 31, 2009 10:43:14 AM Page 4 © 2005 Mitchell Repair Information Company, LLC.

5. 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
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
NOTE: Engine and transaxle are removed separately.
2000 Chevrolet Prizm
2000-01 ENGINES 1.8L 4-Cylinder - Prizm
MY
Tuesday, March 31, 2009 10:43:14 AM Page 5 © 2005 Mitchell Repair Information Company, LLC.

6. 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
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 .
NOTE: Always install NEW gasket whenever intake manifold is removed.
2000 Chevrolet Prizm
2000-01 ENGINES 1.8L 4-Cylinder - Prizm
MY
Tuesday, March 31, 2009 10:43:14 AM Page 6 © 2005 Mitchell Repair Information Company, LLC.

7. CYLINDER HEAD
Removal
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.
NOTE: Manufacturer recommends removing timing chain and camshaft
sprockets when removing cylinder head.
2000 Chevrolet Prizm
2000-01 ENGINES 1.8L 4-Cylinder - Prizm
MY
Tuesday, March 31, 2009 10:43:14 AM Page 7 © 2005 Mitchell Repair Information Company, LLC.

8. 2000 Chevrolet Prizm
2000-01 ENGINES 1.8L 4-Cylinder - Prizm
MY
Tuesday, March 31, 2009 10:43:14 AM Page 8 © 2005 Mitchell Repair Information Company, LLC.

9. 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
2000 Chevrolet Prizm
2000-01 ENGINES 1.8L 4-Cylinder - Prizm
MY
Tuesday, March 31, 2009 10:43:14 AM Page 9 © 2005 Mitchell Repair Information Company, LLC.

10. 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.
2000 Chevrolet Prizm
2000-01 ENGINES 1.8L 4-Cylinder - Prizm
MY
Tuesday, March 31, 2009 10:43:14 AM Page 10 © 2005 Mitchell Repair Information Company, LLC.

11. 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
2000 Chevrolet Prizm
2000-01 ENGINES 1.8L 4-Cylinder - Prizm
MY
Tuesday, March 31, 2009 10:43:14 AM Page 11 © 2005 Mitchell Repair Information Company, LLC.

12. 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.
2000 Chevrolet Prizm
2000-01 ENGINES 1.8L 4-Cylinder - Prizm
MY
Tuesday, March 31, 2009 10:43:14 AM Page 12 © 2005 Mitchell Repair Information Company, LLC.

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14. 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
2000 Chevrolet Prizm
2000-01 ENGINES 1.8L 4-Cylinder - Prizm
MY
Tuesday, March 31, 2009 10:43:14 AM Page 13 © 2005 Mitchell Repair Information Company, LLC.

15. 3. Disconnect the negative battery cable.
4. Drain the cooling system.
5. Remove the windshield washer fluid reservoir mounting bolt.
6. Disconnect the windshield washer pump connector.
7. Disconnect the windshield washer pump fluid line.
8. Plug the pump outlet.
9. Remove the windshield washer fluid reservoir.
10. Install the engine support fixture.
Fig. 8: Engine Mounting Hardware
Courtesy of GENERAL MOTORS CORP.
components.
2000 Chevrolet Prizm
2000-01 ENGINES 1.8L 4-Cylinder - Prizm
MY
Tuesday, March 31, 2009 10:43:14 AM Page 14 © 2005 Mitchell Repair Information Company, LLC.

16. 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.
2000 Chevrolet Prizm
2000-01 ENGINES 1.8L 4-Cylinder - Prizm
MY
Tuesday, March 31, 2009 10:43:14 AM Page 15 © 2005 Mitchell Repair Information Company, LLC.

17. 17. Align the camshaft timing sprockets.
18. Disconnect the power steering oil pressure switch connector.
19. Raise and properly support the vehicle.
20. 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.
2000 Chevrolet Prizm
2000-01 ENGINES 1.8L 4-Cylinder - Prizm
MY
Tuesday, March 31, 2009 10:43:14 AM Page 16 © 2005 Mitchell Repair Information Company, LLC.