GM Service Manual Online
For 1990-2009 cars only
Table 1: New Lifter Thickness

Application

Specification

Metric

English

Balanceshaft

  • Thrust Clearance - Standard

0.05-0.09 mm

0.0020-0.0035 in

  • Thrust Clearance - Maximum

0.09 mm

0.0035 in

  • Oil Clearance - Standard

0.022-0.049 mm

0.0009-0.0019 in

  • Oil Clearance - Maximum

0.049 mm

0.0019 in

Balanceshaft Housing Bolt

  • Standard Length

58.3-59.7 mm

2.295-2.350 in

  • Maximum Length

60.3 mm

2.374 in

Camshaft

Valve Clearance Standard

  • Intake

0.19-0.29 mm

0.0075-0.0114 in

  • Exhaust

0.38-0.48 mm

0.0150-0.189 in

Camshaft Thrust Clearance

  • Standard Intake

0.040-0.095 mm

0.0016-0.0037 in

  • Standard Exhaust

0.090-0.145 mm

0.0035-0.0057 in

  • Maximum Intake

0.110 mm

0.0043 in

  • Maximum Exhaust

0.150 mm

0.0059 in

Camshaft Oil Clearance Standard

  • Camshaft No. 1 Journal Bearing Mark 1

0.007-0.038 mm

0.0003-0.0015 in

  • Camshaft No. 1 Journal Bearing Mark 2

0.008-0.038 mm

0.0003-0.0015 in

  • Camshaft No. 1 Journal Bearing Mark 3

0.008-0.038 mm

0.0003-0.0015 in

  • Camshaft Other Journals

0.025-0.062 mm

0.0010-0.0024 in

  • No. 2 Camshaft No. 1 Journal

0.040-0.072 mm

0.0016-0.0028 in

  • No. 2 Camshaft No. 1 Journals

0.025-0.062 

0.0010-0.0024 in

  • Maximum - Intake

0.070 mm

0.0028 in

  • Maximum - Exhaust

0.100 mm

0.0039 in

  • Circle Runout - Maximum

0.03 mm

0.0012 in

Camshaft Lobe Height

  • Standard - Intake

47.306-47.406 mm

1.8624-1.8664 in

  • Standard - Exhaust

46.063-46.163 mm

1.8135-1.8174 in

  • Minimum - Intake

47.196 mm

1.8581 in

  • Minimum - Exhaust

45.953 mm

1.8092 in

Camshaft Journal Diameter- Standard

  • No. 1

35.971-35.985 mm

1.4162-1.4167 in

  • Other

22.959-22.975 mm

0.9039-0.9045 in

Camshaft Timing Chain Assembly

  • Maximum Elongation

114.5 mm

4.508 in

Camshaft Timing Gear Assembly

  • Minimum Diameter (with chain)

97.3 mm

3.831 in

Camshaft Timing Gear or Sprocket

  • Minimum Diameter (with chain)

97.3 mm

3.831 in

Chain Tensioner Plate

  • Maximum Wear

0.5 mm

0.020 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

  • Thrust Clearance - Standard

0.160-0.362 mm

0.0063-0.0143 in

  • Thrust Clearance - Maximum

0.362 mm

0.0143 in

  • Oil Clearance - Standard

0.024-0.048 mm

0.0009-0.0019 in

  • Oil Clearance - Maximum

0.063 mm

0.0025 in

  • Maximum Misalignment

0.05 per 100 mm

0.0020 per 3.94 in

  • Maximum Twist

0.05 per 100 mm

0.0020 per 3.94 in

Connecting Rod Bolt

  • Standard Diameter

7.2-7.3 mm

0.283-0.287 in

  • Minimum Diameter

7.0 mm

0.276 in

Crankshaft

  • Maximun Circle Runout

0.03 mm

0.0012 in

  • Standard Main Journal Diameter

54.988-55.000 mm

2.1649-2.1654 in

  • Maximum Main Journal for Taper and Distortion

0.003 mm

0.0001 in

  • Standard Crank Pin Diameter

47.990-48.000 mm

1.8894-1.8898 in

  • Maximum Crank Pin for Taper and Distortion

0.003 mm

0.0001 in

  • Thrust Clearance - Standard

0.04-0.24 mm

0.0016-0.0095 in

  • Thrust Clearance - Maximum

0.30 mm

0.0118 in

  • Oil Clearance - Standard

0.017-0.040 mm

0.0007-0.0016 in

  • Oil Clearance - Maximum

0.060 mm

0.0024 in

Crankshaft Bearing Cap Set Bolt

  • Standard Diameter

7.5-7.6 mm

0.295-0.299 in

  • Minimum Diameter

7.5 mm

0.295 in

Crankshaft Timing Gear or Sprocket

  • Minimum Diameter (with chain)

51.6 mm

2.031 in

Cylinder Block

  • Maximum Warpage

0.05 mm

0.0020 in

  • Standard Cylinder Bore Diameter

88.500-88.513 mm

3.4843-3.4847 in

  • Maximum Cylinder Bore Diameter

88.613 mm

3.4887 in

Cylinder Head

  • Cylinder Block Side - Maximun Warpage

0.08 mm

0.0031 in

  • Intake Manifold Side - Maximun Warpage

0.08 mm

0.0031 in

  • Exhaust Manifold Side - Maximun Warpage

0.08 mm

0.0031 in

Inner Compression Spring

  • Standard Length

47.43 mm

1.867 in

  • Maximum Deviation

1.6 mm

0.063 in

Intake Valve

  • Overall Standard Length

101.71 mm

4.0043 in

  • Overall Minimum Length

101.21 mm

3.9846 in

  • Standard Valve Stem Diameter

5.470-5.485 mm

0.2154-0.2159 in

  • Standard Margin Thickness

1.05-1.45 mm

0.0413-0.0571 in

  • Minimum Margin Thickness

0.50 mm

0.0197 in

Exhaust Valve

  • Overall Standard Length

101.15 mm

3.9823 in

  • Overall Minimum Length

100.70 mm

3.9646 in

  • Standard Valve Stem Diameter

5.465-5.480 mm

0.2152-0.2157 in

  • Standard Margin Thickness

1.20-1.60 mm

0.0472-0.0630 in

  • Minimum Margin Thickness

0.50 mm

0.0197 in

Intake Valve Guide Bush

  • Standard Inside Diameter

5.510-5.530 mm

0.2169-0.2177 in

  • Oil Clearance - Standard

0.025-0.060 mm

0.0010-0.0024 in

  • Oil Clearance - Maximum

0.090 mm

0.0035 in

Exhaust Valve Guide Bush

  • Standard Inside Diameter

5.510-5.530 mm

0.2169-0.2177 in

  • Oil Clearance - Standard

0.030-0.065 mm

0.0012-0.0026 in

  • Oil Clearance - Maximum

0.095 mm

0.0037 in

Valve Lifter

  • Standard Diameter

30.966-30.976 mm

1.2191-1.2195 in

  • Oil Clearance - Standard

0.033-0.059 mm

0.0013-0.0023

  • Oil Clearance - Maximum

0.079 mm

0.0031 in

  • Lifter Bore Diamter Standard

31.009-31.025 mm

1.2208-1.2215 in

Engine

Ignition Timing Standard

  • When Using Scan Tool

BTDC 8-12° at idle

  • When Not Using Scan Tool

BTDC 8-12° at idle

(Connect terminals 13 (TC) and 4 (CG))

BTDC 8-15° at idle

Remove terminals 13 (TC) and 4 (CG))

  • Engine Idling Speed Standard

600-700 rpm

Compression

  • Standard

1300 kPA (189 psi)

  • Minimum

1000 kPA (145 psi)

  • Difference between each cynlinder

100 kPA (15 psi)

Oil Pump Chain Assembly

  • Maximum Elongation

102.2 mm

4.024 in

Oil Pump Drive Gear

  • Minimum Diameter (with chain)

48.2 mm

1.898 in

Oil Pump Drive Shaft Gear

  • Minimum Diameter (with chain)

48.2 mm

1.898 in

Piston

  • Standard Diameter

88.469-88.479 mm

3.4830-3.4834 in

  • Oil Clearance - Standard

0.021-0.044 mm

0.0008-0.0017 in

  • Oil Clearance - Maximum

0.10 mm

0.0039 in

Ring Groove Clearance Standard

  • Top

0.020-0.070 mm

0.0008-0.0028 in

  • Second

0.020-0.060 mm

0.0008-0.0024 in

  • Oil

0.020-0.070 mm

0.0008-0.0028 in

Piston Pin

  • Oil Clearance - Standard (Piston pin x Piston pin bore)

0.001-0.007 mm

0.00004-0.00028 in

  • Oil Clearance - Maximum (Piston pin x Piston pin bore)

0.010 mm

0.0004 in

  • Oil Clearance - Standard (Piston pin x Connecting rod small end bore)

0.005-0.011 mm

0.0002-0.0004 in

  • Oil Clearance - Maximum (Piston pin x Connecting rod small end bore)

0.011 mm

0.0004 in

Piston Ring

End Gap Standard

  • Top

0.24-0.31 mm

0.0094-0.0122 in

  • Second

0.33-0.43 mm

0.0130-0.0169 in

  • Oil

0.10-0.30 mm

0.0040-0.0119 in

End Gap Maximum

  • Top

0.31 mm

0.0122 in

  • Second

0.43 mm

0.0169 in

  • Oil

0.30 mm

0.0118 in


New Lifter Thickness

Lifter No.

Thickness mm (in.)

Lifter No.

Thickness mm (in.)

Lifter No.

Thickness mm (in.)

06

5.060 (0.1992)

30

5.300 (0.2087)

54

5.540 (0.2181)

08

5.080 (0.2000)

32

5.320 (0.2094)

56

5.560 (0.2189)

10

5.100 (0.2008)

34

5.340 (0.2102)

58

5.580 (0.2197)

12

5.120 (0.2016)

36

5.360 (0.2110)

60

5.600 (0.2205)

14

5.140 (0.2024)

38

5.380 (0.2118)

62

5.620 (0.2213)

16

5.160 (0.2031)

40

5.400 (0.2126)

64

5.640 (0.2220)

18

5.180 (0.2039)

42

5.420 (0.2134)

66

5.660 (0.2228)

20

5.200 (0.2047)

44

5.440 (0.2142)

68

5.680 (0.2236)

22

5.220 (0.2055)

46

5.460 (0.2150)

70

5.700 (0.2244)

24

5.240 (0.2063)

48

5.480 (0.2157)

72

5.720 (0.2252)

26

5.260 (0.2071)

50

5.500 (0.2165)

74

5.740 (0.2260)

28

5.280 (0.2079)

52

5.520 (0.2173)

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