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Service Manual Update for Engine Block Clearance, Cylinder Head Clearance and Fastener Torque Specifications

Subject:Service Manual Update for Engine Block Clearance, Cylinder Head Clearance and Fastener Torque Specifications

Models:2000-2004 Saturn L-Series
2002-2003 Saturn VUE Vehicles
with RPO L81 engine

Attention: Technician


Purpose

The purpose of this bulletin is to provide updated torque and clearance specifications for all 2000 - 2004 L-Series and 2002 - 2003 VUE Engine Service Manuals at your location.

Please make copies of the Engine Block Clearance, Cylinder Head Clearance and Fastener Torque Specification Charts in this bulletin and reference when performing engine mechanical repairs.

The SI website will be updated immediately and future Service Stall System SI CD releases will include this and other Service Manual updates.

Engine Block Clearance Specifications

Application

Service Limit

Metric

English

Cylinder Bore - Select Fit Designation Stamped on Block

(8)

85.975-85.985 mm

3.3848-3.3852 in

(99)

85.985-85.995 mm

3.3852-3.3856 in

(00)

85.995-86.005 mm

3.3856-3.3860 in

(01)

86.005-86.015 mm

3.3860-3.3864 in

(02)

86.015-86.025 mm

3.3864-3.3868 in

(7 + 0.5) Oversize

86.465-86.475 mm

3.4041-3.4045 in

Maximum (Out-of-Round/Taper) Cylindricity

0.0065 mm

0.0003 in

Piston - Select Fit Designation Stamped on Top of Piston

(8)

85.940-85.950 mm

3.3834-3.3828 in

(99)

85.950-85.960 mm

3.3838-3.3842 in

(00)

85.960-85.970 mm

3.3842-3.3846 in

(01)

85.970-85.980 mm

3.3846-3.3850 in

(02)

85.980-85.990 mm

3.3850-3.3854 in

(7 + 0.5) Oversize

86.430-86.440 mm

3.4027-3.4031 in

Piston Bore Clearance

0.025-0.045 mm

0.0010-0.0018 in

Piston Pin Diameter

21 mm

0.8267 in

路 Clearance in Piston

0.001-0.015 mm

0.0001-0.0005 in

Piston Ring - Compression

Thickness

1.5 mm

0.0590 in

Ring Groove Clearance

0.02-0.04 mm

0.0008-0.0015 in

Ring Gap

0.30-0.50 mm

0.0118-0.0196 in

Piston Ring - Oil

Thickness

3.0 mm

0.1181 in

Ring Groove Clearance

0.01-0.03 mm

0.0004-0.0012 in

Ring Gap

0.40-1.40 mm

0.0157-0.0551 in

Crankshaft - Main Journal

Standard Size - Green

67.980-67.988 mm

2.6763-2.6766 in

Standard Size - Brown

67.988-67.996 mm

2.6766-2.6770 in

Undersize - 0.25 - Green/Blue

67.730-67.738 mm

2.6656-2.6668 in

Undersize - 0.25 - Brown/Blue

67.738-67.746 mm

2.668-2.6671 in

Undersize - 0.50 - Green/White

67.480-67.488 mm

2.666-2.6570 in

Undersize - 0.50 - Brown/Blue

67.488-67.496 mm

2.6570-2.6573 in

Main Journal Maximum Out-of-Round (Roundness)

0.003 mm

0.00012 in

Crankshaft Bearing Clearance

0.014-0.043 mm

0.0006-0.0017 in

Standard Size - Crankshaft Main Bearing Thrust Dimension

24.552-24.500 mm

0.9666-0.9646 in

Undersize - 0.25 Crankshaft Main Bearing Thrust Dimension

24.752-24.700 mm

0.9745-0.9724 in

Undersize - 0.50 Crankshaft Main Bearing Thrust Dimension

24.952-24.900 mm

0.9824-0.9803 in

Crankshaft End Play

0.010-0.76 mm

0.0004-0.0300 in

Connecting Rod Journal Diameter

48.971-48.990 mm

1.927-1.928 in

Undersize - 0.25

48.721-48.740 mm

1.918-1.919 in

Undersize - 0.50

48.471-48.490 mm

1.908-1.909 in

Connecting Rod

Side Clearance

0.07-0.282 mm

0.0027-0.0110 in

Big End Diameter (without shells)

52.000-52.012 mm

2.0472-2.0477 mm

Cylinder Head Specifications

Measurement

Standard

Service Limit

Metric

English

Metric

English

Compression (Hot)

250 RPM (Open Throttle)

1310 kPa

190 psi min

1,241 kPa

180 psi min

Cylinder Leakage (Hot)

689 kPa (100 psi) Input

69 kPa 10% max

10 psi max

138 kPa 15% max

20 psi max

Cylinder Head

Total Height

134.0 mm

5.276 in

133.9-134.1 mm

5.272-5.280 in

Maximum Distortion (Length)

--

--

0.05/100 mm

0.0020/3.937 in

Valve

Lifter

--

--

--

--

Face Angle

--

--

--

45 degrees

Seat Angle

--

--

--

45 degrees

Seat Width

--

--

--

--

Intake

1.0-1.4 mm

0.0394-0.0551 in

--

--

Exhaust

1.4-1.8 mm

0.0551-0.0709 in

--

--

Valve Length - Production

Intake

102.1 mm

4.016 in

--

--

Exhaust

92.25 mm

3.6141 in

--

--

Valve Length - Service

Intake

101.7 mm

4.0039 in

--

--

Exhaust

91.8 mm

3.6141 in

--

--

Valve Stem Diameter

Standard (K) Intake

5.955-5.970 mm

0.2344-0.2350 in

--

--

Standard (K) Exhaust

5.945-5.960 mm

0.2341-0.2346 in

--

--

Oversize (K 1-0.075) Intake

6.030 mm

0.2374 in

--

--

Oversize (K 1-0.075) Exhaust

6.020 mm

0.2370 in

--

--

Valve Guide Diameter

Standard (K)

6.000-6.012 mm

0.2362-0.2367 in

--

--

Oversize (K 1-0.075)

6.075-6.090 mm

0.2392-0.2398 in

--

--

Stem Clearance

Intake

0.030-0.057 mm

0.0012-0.0022 in

--

--

Exhaust

0.040-0.067 mm

0.0016-0.0026 in

--

--

Valve Height

Intake

39.2 mm

1.543 in

--

--

Exhaust

39.2 mm

1.543 in

--

--

Intake and Exhaust Compressed at 252 N (56.6 lbs)

34 mm

1.338 in

--

--

Camshaft

Exhaust Cam Lobe Lift Rise

9.2 mm +/- 0.1

0.358-0.366 in

8.61 mm

0.339 in min

Lifter Body Diameter

32.959-32.975 mm

1.2976-1.282 in

32.947 mm

1.297 in min

Lifter Body Clearance

0.025-0.066 mm

0.0010-0.0026 in

0.083 mm

0.003 in max

Journal Diameter

27.939-27.960 mm

1.099-1.10 in

--

--

Bearing Clearance

0.040-0.082 mm

0.0016-0.0032 in

--

--

End Play

0.04-0.144 mm

0.0016-0.0057 in

--

--

Spark Plug

Type

Bosch FLR-LTE (GM P/N 90541059)

--

Gap

0.9-1.1 mm

0.035-0.043 in

--

--

Torque

--

--

25 N路m

19 ft-lbs.

Oil Pressure - Minimum

Engine Idle - at Normal Operating Temperature

--

--

110 kPa

16 psi

Fastener Torque Specifications

Application

Specification

Metric

English

A/C Compressor Bolts

20 N路m

15 lb ft

A/C Compressor Bracket Bolt

40 N路m

30 lb ft

A/C Compressor Bracket Bolt - L81

40 N路m

30 lb ft

A/C Compressor and Power Steering Pump Bracket Bolts

40 N路m

30 lb ft

Air Box Mount Bolt

6 N路m

53 lb in

Battery Terminal Bolts

17 N路m

13 lb ft

Belt Tensioner Bolts

40 N路m

30 lb ft

Brake Vacuum Line

20 N路m

15 lb ft

Camshaft Bearing Cap Bolt

8 N路m

71 lb in

Camshaft Cover Bolts

8 N路m

71 lb ft

Camshaft Gear Bolt

  • First Pass

50 N路m

37 lb ft

  • Second Pass

60 degrees

  • Final Pass

15 degrees

Camshaft Sprocket Bolt

  • First Pass

50 N路m

37 lb ft

  • Second Pass

60 degrees

  • Final Pass

15 degrees

Connecting Rod Cap Bolts

  • First Pass

35 N路m

26 lb ft

  • Second Pass

45 degrees

  • Final Pass

15 degrees

Coolant Bridge Bolt

30 N路m

22 lb ft

Coolant Extension Housing Bolt

20 N路m

15 lb ft

Coolant Intake Housing Bolts

20 N路m

15 lb ft

Coolant Pipe/Engine Lift Bracket Bolt

20 N路m

15 lb ft

Crankshaft Balancer Bolt

20 N路m

15 lb ft

Crankshaft Bearing Bridge Adjusting Sleeves

8 N路m

71 lb in

Crankshaft Bearing Bridge Bolts

20 N路m

15 lb ft

Crankshaft Bearing Cap

  • First Pass

50 N路m

37 lb ft

  • Second Pass

60 degrees

  • Final Pass

15 degrees

Crankshaft Drive Gear Bolt - L81

  • First Pass

250 N路m

184 lb ft

  • Second Pass

45 degrees

  • Final Pass

15 degrees

Crankshaft Position Sensor Bolt

8 N路m

71 lb in

Crankshaft Reluctor Ring Screw

15 N路m

11 lb ft

Cylinder Head Bolt

  • First Pass

25 N路m

18 lb ft

  • Second Pass

90 degrees

  • Third Pass

90 degrees

  • Fourth Pass

90 degrees

  • Final Pass

15 degrees

EGR Manifold Bolt

8 N路m

71 lb in

EGR Pipe Bolts

25 N路m

18 lb ft

Engine Control Module Bolts

8 N路m

71 lb in

Engine Lift Bracket Bolts

8 N路m

71 lb in

Engine Mount Bracket Bolt

55 N路m

41 lb ft

Engine Mount-to-Bracket Bolt

55 N路m

41 lb ft

Engine Mount-to-Frame Bolt

55 N路m

41 lb ft

Engine Oil Cooler Cover Bolt

20 N路m

15 lb ft

Engine Oil Cooler Inlet and Outlet Nut

30 N路m

22 lb ft

Engine Oil Pipe to Heat Exchanger

First Pass

30 N路m

22 lb ft

Second Pass

15 掳

Engine Ventilation Chamber Bolts

8 N路m

71 lb in

Exhaust Manifold Nut

20 N路m

15 lb ft

Exhaust Manifold Pipe-to-Exhaust Manifold Nuts

30 N路m

22 lb ft

Flex Plate Bolt

  • First Pass

65 N路m

48 lb ft

  • Second Pass

30 degrees

  • Final Pass

15 degrees

Front Timing Belt Cover Bolt

8 N路m

71 lb in

Fuel Rail Bolts

8 N路m

71 lb in

Generator Mounting Bolts

35 N路m

26 lb ft

Idler Pulley Bolt

40 N路m

30 lb ft

Idler Pulley Fastener

40 N路m

30 lb ft

Ignition Module Bolt

8 N路m

71 lb in

Intake Manifold Bolt Upper to Lower

20 N路m

15 lb ft

Intake Manifold Runner Bolts

8 N路m

71 lb in

Intake Manifold Runner Bracket Bolt

20 N路m

15 lb ft

Intake Manifold Spacer Bolt Flange

16N路m

12 lb ft

Intake Plenum Bolts

8 N路m

71 lb in

Lower Engine-to-Transaxle Bell Housing Bolts

65 N路m

48 lb ft

Nose Cone Bracket-to-Oil Pan Bolts - Transaxle Nose Bracket Bolts

40 N路m

30 lb ft

Oil Cooler Feed and Return Lines to Engine Block

30 N路m

22 lb ft

Oil Drain Plug

10N路m

90 lb in

Oil Filter Cap

15N路m

11 lb ft

Oil Filter Cartridge Housing-to-Engine

45 N路m

33 lb ft

Oil Level Indicator Tube Bolt

20N路m

15 lb ft

Oil Pan Baffle Bolt - L81

8N路m

71 lb in

Oil Pan Bolts

15N路m

11 lb ft

Oil Pickup Tube Bolts

8N路m

71 lb in

Oil Pump Bolts

28N路m

21 lb ft

Oxygen Sensors - Exhaust Manifold

45N路m

33 lb ft

Power Steering Pump Bolts

20N路m

15 lb ft

Power Steering Pump Pulley Bolt

First Pass

20N路m

15 lb ft

Second Pass

30 degrees

Final Pass

15 degrees

Rear Timing Belt Cover Bolt

8N路m

71 lb ft

Rear Timing Belt Cover Threaded Pin

10 N路m

89 lb in

Spark Plug

25N路m

18 lb ft

Thermostat Housing Bolts

20N路m

15 lb ft

Throttle Body Nut

8N路m

71 lb in

Timing Belt Tensioner Bracket Bolt

40N路m

30 lb ft

Timing Belt Tensioner Fastening Nut

20N路m

15 lb ft

Torque Converter Bolts

65N路m

48 lb ft

Transaxle Mount Through Bolt

55N路m

41 lb ft

Transaxle-to-Oil Pan Bolts

65N路m

48 lb ft

Upper Bell Housing Bolts

65N路m

48 lb ft

Upper Pulley Bolt

40N路m

30 lb ft

Ventilation Housing Bolts

8N路m

71 lb in

Water Pump Bolt

25N路m

18 lb ft

Water Pump Pulley Bolt

First Pass

8N路m

71 lb in

Second Pass

30 degrees

Third Pass

30 degrees

Wheel Bolts

125N路m

92 lb ft