GM Service Manual Online
For 1990-2009 cars only

Application

Specification

Metric

English

Camshaft Intake

  • Maximum Circle Runout

0.04 mm

0.0016 in

  • Standard Cam Lobe Height

42.816-42.916 mm

1.6857-1.6896 in

  • Maximum Can Lobe Height

42.666 mm

1.6798 in

  • No. 1 Journal Diameter

34.449-34.465 mm

1.3563-1.3569 in

  • Other Journal Diameter

22.949-22.965 mm

0.9035-0.9041 in

  • Standard Thrust Clearance - Intake

0.06-0.155 mm

0.0024-0.0061 in

  • Maximum Thrust Clearance - Intake

0.17 mm

0.0067 in

Standard Oil Clearance

  • Camshaft No. 1 Journal

0.03-0.063 mm

0.0012-0.0025 in

  • Camshaft Other Journals

0.035-0.072 mm

0.0014-0.0028 in

  • Maximum Oil Clearance Camshaft No. 1 Journal

0.085 mm

0.0033 in

  • Maximum Oil Clearance Camshaft Other Journals

0.09 mm

0.0035 in

Camshaft Exhaust

  • Maximum Circle Runout

0.04 mm

0.0016 in

  • Standard Cam Lobe Height

44.336-44.436 mm

1.7455-1.7494 in

  • Minimum Can Lobe Height

44.186 mm

1.7396 in

  • No. 1 Journal Diameter

34.449-34.465 mm

1.3563-1.3569 in

  • Other Journal Diameter

22.949-22.965 mm

0.9035-0.9041 in

  • Standard Thrust Clearance - Exhaust

0.06-0.155 mm

0.0024-0.0061 in

  • Standard Thrust Clearance - Exhaust

0.17 mm

0.0067 in

Standard Oil Clearance

  • Camshaft No. 1 Journal

0.03-0.079 mm

0.0012-0.0031 in

  • Camshaft Other Journals

0.035-0.072 mm

0.0014-0.0028 in

  • Maximum Oil Clearance Camshaft No. 1 Journal

0.085 mm

0.0033 in

  • Maximum Oil Clearance Camshaft Other Journal

0.09 mm

0.0035 in

  • Exhaust Manifold - Maximum Warpage

0.70 mm

0.028 in

Camshaft Housing - Seal Diameter

3.5-4.0 mm

0.138-0.158 in

Camshaft Timing Chain Assembly - Maximum Chain Elongation

115.2 mm

4.535 in

Camshaft Timing Exhaust Gear Assembly - Minimum Gear or Sprocket Diameter (With Chain)

96.8 mm

3.811 in

Camshaft Timing Gear Assembly - Minimum Gear or Sprocket Diameter (With Chain)

96.8 mm

3.811 in

Chain Tensioner Plate - Maximum Wear

1.0 mm

0.039 in

Chain Tensioner Slipper - Maximum Wear

1.0 mm

0.039 in

Chain Vibration Damper - Maximum Wear

1.0 mm

0.039 in

Connecting Rod

  • Standard Oil Clearance

0.03-0.062 mm

0.0012-0.0024 in

  • Maximum Oil Clearance

0.07 mm

0.0028 in

  • Standard Oil Clearance

0.016-0.039 mm

0.0006-0.0015 in

  • Maximum Oil Clearance

0.05 mm

0.0020 in

Connecting Rod Bearing Thickness

  • Mark 1

1.489-1.493 mm

0.0586-0.0588 in

  • Mark 2

1.494-1.497 mm

0.0588-0.0589 in

  • Mark 3

1.498-1.501 mm

0.0590-0.0591 in

  • Connecting Rod Small End Bore Diameter

20.012-20.021 mm

0.7879-0.7882 in

Connecting Rod Bolt

  • Standard Diameter

6.6-6.7 mm

0.2598-0.2638 in

  • Minimum Diameter

6.4 mm

0.252 in

Connecting Rod Large End Bore Diameter

  • Mark A

20.012-20.015 mm

0.7879-0.7880 in

  • Mark B

20.016-20.018 mm

0.7880-0.7881 in

  • Mark C

20.019-20.021 mm

0.7881-0.7882 in

Connecting Rod Small End Bore Diameter

  • Mark 1

47.000-47.008 mm

1.8504-1.8507 in

  • Mark 2

47.009-47.016 mm

1.8507-1.8510 in

  • Mark 3

47.017-47.024 mm

1.8510-1.8513 in

Crankshaft

  • Standard Thrust Clearance

0.04-0.14 mm

0.0016-0.0055 in

  • Maximum Thrust Clearance

0.18 mm

0.0071 in

  • Thrust Washer Thickness

2.43-2.48 mm

0.0957-0.0976 in

Cylinder Block Main Journal Bore Diameter

  • Mark 0

52.000-52.003 mm

2.0472-2.0474 in

  • Mark 1

52.003-52.005 mm

2.0474-2.0474 in

  • Mark 2

52.005-52.007 mm

2.0474-2.0475 in

  • Mark 3

52.007-52.010 mm

2.0475-2.0476 in

  • Mark 4

52.010-52.012 mm

2.0476-2.0477 in

  • Mark 5

52.012-52.014 mm

2.0477-2.0478 in

  • Mark 6

52.014-52.016 mm

2.0478-2.0479 in

Main Journal Diameter

47.988-48.000 mm

1.8893-1.8898 in

  • Maximum Taper and Distortion

0.004 mm

0.0002 in

Main Journal Diameter

  • Mark 0

47.999-48.000 mm

1.8897-1.8898 in

  • Mark 1

47.997-47.998 mm

1.8896-1.8897 in

  • Mark 2

47.995-47.996 mm

1.8896-1.8896 in

  • Mark 3

47.993-47.994 mm

1.8895-1.8895 in

  • Mark 4

47.991-47.992 mm

1.8894-1.8894 in

  • Mark 5

47.988-47.990 mm

1.8893-1.8894 in

Crankshaft Journal Diameter

  • Mark 0

47.999-48.000 mm

1.8897-1.8898 in

  • Mark 1

47.997-47.998 mm

1.8896-1.8897 in

  • Mark 2

47.995-47.996 mm

1.8896-1.8896 in

  • Mark 3

47.993-47.994 mm

1.8895-1.8895 in

  • Mark 4

47.991-47.992 mm

1.8894-1.8894 in

  • Mark 5

47.988-47.990 mm

1.8893-1.8894 in

Standard Main Bearing Center Wall Thickness

  • Mark 1

1.994-1.997 mm

0.0785-0.0786 in

  • Mark 2

1.998-2.000 mm

0.0787-0.0787 in

  • Mark 3

2.001-2.003 mm

0.0788-0.0789 in

  • Mark 4

2.004-2.006 mm

0.0789-0.0790 in

  • Maximum Circle Runout

0.03 mm

0.0012 in

  • Standard Oil Clearance

0.016-0.039 mm

0.0006-0.0015 in

  • Maximum Oil Clearance

0.050 mm

0.0020 in

  • Crank Pin Diameter

43.992-44.000 mm

1.7320-1.7323 in

  • Maximum Taper and Distortion

0.004 mm

0.0002 in

Crankshaft Bearing

  • Dimension A

0.5-1.0 mm

0.020-0.039 in

  • Dimension A-B

0.5 mm or less

0.0197 in or less

Crankshaft Bearing Cap Set Bolt

  • Standard Diameter

84.3-85.7 mm

3.3189-3.3740 in

  • Minimum Diameter

86.7 mm

3.4134 in

Crankshaft Pin Diameter

  • Mark 1

43.992-44.000 mm

1.7320-1.7323 in

  • Mark 2

43.992-44.000 mm

1.7320-1.7323 in

  • Mark 3

43.992-44.000 mm

1.7320-1.7323 in

  • Standard Oil Clearance

0.005-0.011 mm

0.0002-0.0004 in

  • Maximum Oil Clearance

0.014 mm

0.0006 in

  • Maximum Rod Out-of-Alignment per 100 mm (3.94 in)

0.05 mm

0.0020 in

  • Maximum Rod twist per 100 mm (3.94 in)

0.15 mm

0.0059 in

Crankshaft Timing Sprocket - Minimum Sprocket Diameter (With Chain)

51.1 mm

2.012 in

Cylinder Block

  • Maximum Warpage

0.05 mm

0.0020 in

  • Standard Cylinder Bore Diameter

80.500-80.513 mm

3.1693-3.1698 in

  • Maximum Cylinder Bore Diameter

80.633 mm

3.1745 in

Cylinder Head

  • Cylinder Block Side - Maximum Warpage

0.05 mm

0.0020 in

  • Intake Manifold Side -- Maximum Warpage

0.10 mm

0.0039 in

  • Exhaust Manifold Side -- Maximum Warpage

0.10 mm

0.0039 in

Inner Compression Spring

  • Free Length

53.36 mm

2.1008 in

  • Maximum Deviation

1.0 mm

0.0394 in

Intake Valve

  • Standard Overall Length

109.34 mm

4.3047 in

  • Minimum Overall Length

108.84 mm

4.2850 in

  • Valve Stem Diameter

5.470-5.485 mm

0.2154-0.2159 in

  • Standard Margin Thickness

1.0 mm

0.0394 in

  • Minimum Margin Thickness

0.50 mm

0.0197 in

  • Valve Seat Width

1.0-1.4 mm

0.039-0.055 in

Exhaust Valve

  • Standard Overall Length

108.25 mm

4.2618 in

  • Minimum Overall Length

107.75 mm

4.2421 in

  • Valve Stem Diameter

5.465-5.480 mm

0.2152-0.2157 in

  • Standard Margin Thickness

1.01 mm

0.0398 in

  • Minimum Margin Thickness

0.50 mm

0.0197 in

  • Valve Seat Width

1.0-1.4 mm

0.039-0.55 in

Intake Valve Guide Bush

  • Bush Inside Diameter

5.510-5.530 mm

0.2169-0.2177 in

  • Standard Bush Oil Clearance

0.025-0.060 mm

0.0010-0.0024 in

  • Maximum Bush Oil Clearance

0.080 mm

0.0031 in

Bush Bore Diameter

  • Use STD

10.285-10.306 mm

0.4049-0.4057 in

  • Use O/S 0.05

10.335-10.356 mm

0.4069-0.4077 in

  • Protrusion Height (Bush)

9.9-10.3 mm

0.3898-0.4055 in

  • Standard Oil Clearance

0.025-0.060 mm

0.0010-0.0024 in

Exhaust Valve Guide Bush

  • Bush Inside Diameter

5.510-5.530 mm

0.2169-0.2177 in

  • Standard Oil Clearance

0.030-0.065 mm

0.0012-0.0026 in

  • Maximum Oil Clearance

0.085 mm

0.0033 in

Bush Bore Diameter

  • Use STD

10.285-10.306 mm

0.4049-0.4057 in

  • Use O/S 0.05

10.335-10.356 mm

0.4069-0.4077 in

  • Protrusion Height

11.15-11.55 mm

0.4390-0.4547 in

  • Standard Oil Clearance

0.030-0.065 mm

0.0012-0.0026 in

  • Protrusion Height (Ring Pin)

6.5-7.5 mm

0.26-0.30 in

  • Valve Seat Width

1.0-1.4 mm

0.039-0.055 in

Cylinder Head Set Bolt

  • Standard Bolt Length

146.8-148.2 mm

5.7795-5.8346 in

  • Maximum Bolt Length

149.2 mm

5.874 in

  • Standard Outside Diameter

9.77-9.96 mm

0.3846-0.3921 in

  • Minimum Outside Diameter

9.4 mm

0.3701 in

Engine Idle Speed

600-700 rpm

Engine Ignition Timing - With terminals TC and CG of DLC3 connected

8-12° BTDC at idle

Compression

  • Compression Pressure

1373 kPa

199 psi

  • Minimum Pressure

1079 kPa

157 psi

  • Difference between each cylinder

98 kPa

14 psi

No. 1 Camshaft Bearing - Dimension A-B

0.7 mm or less

0.0276 in or less

No. 2 Camshaft Bearing - Dimension A

1.05-1.75 mm

0.0413-0.0689 in

Oil Pump Chain Assembly - Maximum Chain Elongation

102.1 mm

4.019 in

Oil Pump Drive Shaft Socket - Minimum Sprocket Diameter (With Chain)

48.8 mm

1.921 in

Oil Pump Drive Socket - Minimum Sprocket Diameter (With Chain)

48.2 mm

1.898 in

Piston

  • Standard Piston Diameter

80.461-80.471 mm

3.1677-3.1681 in

  • Standard Piston Oil Clearance

0.029-0.052 mm

0.0011-0.0020 in

  • Maximum Piston Oil Clearance

0.09 mm

0.0035 in

  • Piston Pin Bore Diameter

20.006-20.015 mm

0.7876-0.7880 in

Piston Pin Bore Diameter

  • Mark A

20.006-20.009 mm

0.7876-0.7878 in

  • Mark B

20.010-20.012 mm

0.7878-0.7879 in

  • Mark C

20.013-20.015 mm

0.7879-0.7880 in

Piston Ring

Ring Groove Clearance

  • Top Ring

0.020-0.070 mm

0.0008-0.0028 in

  • Second Ring

0.020-0.060 mm

0.0008-0.0024 in

  • Oil Ring

0.020-0.065 mm

0.0008-0.0026 in

Standard End Gap

  • Top Ring

0.2-0.3 mm

0.0079-0.0118 in

  • Second Ring

0.3-0.5 mm

0.0118-0.0197 in

  • Oil Ring

0.1-0.4 mm

0.0039-0.0157 in

Maximum End Gap

  • Top Ring

0.5 mm

0.0197 in

  • Second Ring

0.7 mm

0.0276 in

  • Oil Ring

0.7 mm

0.0276 in

Piston Pin

  • Piston Pin Diameter

20.004-20.013 mm

0.7876-0.7879 in

Piston Pin Diameter

  • Mark A

20.004-20.007 mm

0.7876-0.7877 in

  • Mark B

20.008-20.010 mm

0.7877-0.7878 in

  • Mark C

20.011-20.013 mm

0.7878-0.7879 in

  • Standard Oil Clearance

-0.001-0.005 mm

-0.00004-0.0002 in

  • Maximum Oil Clearance

0.010 mm

0.0004 in

V-Belt Deflection

  • New Belt

7.5-8.6 mm

0.30-0.34 in

  • Used Belt

8.0-10.0 mm

0.32-0.39 in

V-Belt Tension

  • New Belt

637-735 N·m

143-165 lb ft

  • Used Belt

392-588 N·m

88-132 lb ft