2009 Ecotec 2.

4L I-4 VVT ( LE9 )

ECOTEC 2.4L I-4 VVT (LE9) CAR AND TRUCK ENGINE
2009 Model Year Summary

 New E85 Flex Fuel engine (rpo) for Chevrolet HHR Panel and Passenger Van.

New Engine Application for the 2009 Chevrolet HHR Panel and Passenger Vans
The Ecotec 2.4L VVT (LE9) powers the Chevrolet HHR Panel and Passenger vans
and is mated with the Hydra-Matic 4T45 (MN5) four speed FWD automatic transmission
or the Getrag F23-5 (M86) five speed manual transmission. .

Carryover Features and Benefits from 2008 model year ( LE5 ). The LE9 is an E85
Variant of the 2.4L I-4 VVT ( LE5 )

Optimized Piston Skirt

Ecotec 2.4L I-4 VVT pistons have been redesigned with a slightly different profile. The
piston skirt has been optimized with a slight barrel shape, helping to smooth its glide
through the cylinder bore and reduce lateral movement. The new pistons reduce
operational noise, particularly during cold starts, and enhance overall smoothness.

Vented Starter Solenoid

A new starter solenoid helps ensure starting performance in extreme cold temperatures.
The solenoid case now has a micromesh-covered vent and an O-ring between the case
and the starter motor. The mesh protects the solenoid from debris particles but prevents
moisture buildup in the case. When the Ecotec 2.4L I-4 VVT is warm, any moisture on
the solenoid evaporates through the vent. The vented solenoid virtually eliminates the
possibility of cold-start problems associated with solenoid icing.

Eliminate External Oil Cooler

The Ecotec 2.4L I-4 VVT is no longer fitted with an external oil cooler. Validation tests
have demonstrated that, with durability enhancing features such as increased coolant
capacity and targeted oil jets that cool the underside of the pistons, the oil cooler is not
required even during extreme operating conditions. Deleting the cooler eliminates a
potential leak source and reduces complexity and cost of ownership.

E85 Flexible-Fuel Capability (LE9)

GM has led the industry in introducing flex-fuel capability to its cars and trucks, and the
new flex-fuel 2.2L I-4 VVT ( LE8 ) extends availability to an even broader range of
customers. E85 is a clean-burning alternative fuel made in the United States from corn
and other crops, composed of 85 percent ethanol alcohol and 15 percent gasoline. The
2.2L’s flex-fuel technology is both sophisticated and durable.

Flex fuel engines require special valves and valve seats to withstand the wear and
corrosive effects of ethanol. The nitrided Silcrome 1 intake valves and 21-43 exhaust
valves used in the 2.2L I-4 are up to the challenge. Compared to conventional iron-alloy
valve material, nitrided Silcrome 1 includes tungsten, vanadium, manganese, silicone
and higher chromium content. It is harder, and it improves durability, even under the
rigors of ethanol operation. The 21-43 exhaust valves work equally well. Valve seat
inserts have been upgraded to premium materials with a high percent of tool steel and
solid lubricants resulting in excellent durability whether E85 or gasoline is run in the
engine.
Hardware changes for flex-fuel operation are limited to the injectors. Because ethanol
has fewer BTUs (less energy) than the same volume of gasoline, more fuel is required to
produce the same horsepower at wide-open throttle. Flex fuel engines use unique
stainless injectors with a greater cone angle and higher maximum fuel-flow rate. The
fuel rail matches the injectors, but it’s manufactured of the same stainless steel used for
all 2.2L I-4 fuel rails.

The flex-fuel 2.2L doesn’t require a special fuel sensor. The first flex-fuel engines used a
light-reactive sensor to measure fuel composition from 100 percent gasoline to 85
percent ethanol. The 2.2L has a virtual sensor—software programmed in the E37 ECM
with no separate physical sensor whatsoever. Based on readings from the oxygen (O2)
sensors, fuel level sensor and vehicle speed sensors, the ECM adjusts the length of time
the fuel injectors open for the type of fuel used. Within a few miles after filling up, the
E37 controller determines what fuel is powering the 2.2L I-4 and manages the engine
accordingly.

E85 fuel provides an environmentally friendly companion or alternative to gasoline. It is

biodegradable and doesn’t contaminate the water supply. Ethanol can be produced from
various feed stocks, including corn and wheat stalks, forestry and agricultural waste, and
even municipal waste.

Overview
The 2.4L I-4 VVT was the third North American engine in GM Powertrain’s innovative
line of Ecotec four-cylinders, and the largest displacement Ecotec to date. It was
introduced for model year 2006 in several cars and trucks, including the Chevrolet HHR,
Chevrolet Cobalt, Saturn ION, Pontiac G6 and Pontiac Solstice.

The 2.4L VVT’s roots date to 2000 and launch of the Ecotec 2.2L (RPO L61). Often
referred to as the global four cylinders, the Ecotecs harness Powertrain’s global design
and engineering capability by applying the best practices of technical centers in Europe
and North America. The Ecotec 2.2L created a blueprint for subsequent global
powertrain development, and such engines as Powertrain’s global V-6 VVT. It also laid
the foundation for a line of engines that share core components with minimal casting
changes, yet deliver unique performance and market characteristics with a range of
displacements, turbocharging, supercharging and front-, rear- and all-wheel drive
applications in both cars and trucks.

Displacement in the Ecotec 2.4L I-4 VVT was increased to 2,384 cubic centimeters by
increasing bore and stroke to 88 mm and 98 mm, respectively, compared to 86 mm and
94.6 mm in the Ecotec 2.2L. The 2.4L VVT introduced a Gen II engine block that
strengthened the block bulkheads to improve both durability and vibration control,
without significantly increasing mass. The 2.4L VVT uses forged C70 steel connecting
rods that are shorter than those in the 2.2L with a stroked cast nodular iron crankshaft.
The 2.4L increases horsepower at least 20 percent compared to all 2.2L applications, yet
it is only 13.2 pounds heavier than the 2.2L (which is the lightest four-cylinder GM has
produced, and one of the most compact anywhere).

The 2.4L also introduced cam phasing to the Ecotec line in North America. Cam phasing
changes the timing of valve operation as conditions such as rpm and engine load vary. It
allows an outstanding balance of smooth torque delivery over a broad rpm range, higher
specific output (horsepower per liter of displacement) and lower specific fuel
consumption. Cam phasing also provides another effective tool for controlling exhaust
emissions.

Like all Ecotec engines, the 2.4L I-4 VVT has undergone the toughest and most
comprehensive validation process in GM history, passing all of the dynamometer and
vehicle tests traditionally run by various GM organizations worldwide. Validation included
extensive dynamometer testing and millions of miles of real-world road testing in an
extreme range of climates, and most recently, since the Ecotec 2.4L I-4 VVT ( LE5 ) has
now been added to our marine engine portfolio for 2008, the engine has completed the
Global Engine Durability (GED), test as a requirement to release a product to our outside
sales marine customers.

The 2.4L I-4 VVT features durability enhancements and technology familiar in premium
V-type engines, including low-friction hydraulic roller finger valve operation and
electronic “drive-by-wire” throttle in all applications. A hydraulic tensioner keeps the
timing chain adjusted for life, and extended-life spark plugs deliver 100,000 miles of
service. Routine maintenance is limited to oil and filter changes, and even those are
made as easy as possible with a paper filter replacement cartridge and GM’s industry-
leading Oil Life Monitoring System, which determines oil-change intervals according to
real-world operation rather than a predetermined mileage interval. Every engine in the
Ecotec line has aluminum-intensive construction and:

1 • Dual overhead camshafts (DOHC) with four valves per

cylinder
2 • Twin counter-rotating balance shafts to cancel the
second-order vibration typical in four-cylinder inline
engines
3 • Direct mounting of accessories like the alternator and
compressor to eliminate common sources of noise,
vibration and harshness
• Full circle transmission attachment and a structural oil
pan that bolts to both the engine block and transmission
bell housing.

For all its design and production efficiencies and multitude of applications, the Ecotec
2.4L I-4 VVT succeeds for one reason. It’s a world-class four cylinder engine that
delivers excellent performance without sacrificing durability, economy or smooth, quiet
operation.

The Ecotec 2.4L VVT is built at GM Powertrain’s Spring Hill, Tenn., Engine
Manufacturing facility.