Engine Mechanical - 2.0L: Maintenance — Chevrolet HHR I (2005-2011)

Adhesives, Fluids, Lubricants, and Sealers

Application	Type of Material	GM Part Number
Application	Type of Material	United States	Canada
# 6 Intake Rear Camshaft Cap	Sealant	12378521	88901148
Balance Shaft Bearings	Engine Oil	12345610	993193
Cam Lobes	Engine Oil	12345610	993193
Crank Sensor O-ring	Engine Oil	12345610	993193
Cylinder Bores	Engine Oil	12345610	993193
Cylinder Head Plugs	Sealant	12345382	10953489
Engine Block Threaded Plugs	Sealant	12346004	10953480
Engine Block to Bedplate	Sealant	12378521	88901148
Engine Oil Level Indicator Tube O-ring	Lubricant	12345501	992704
Fuel Injector O-rings	Engine Oil	12345610	993193
Fuel Injector Tip Insulators	Engine Oil	12345610	993193
Intake and Exhaust Valve Stems	Lubricant	12345501	992704
Main Bearings	Lubricant	12345501	992704
Oil Filter Cap - Threads and O-ring Lead-in Chamfers	Engine Oil	12345610	993193
Oil Pan to Bedplate Joint	Sealant	12378521	88901148
Oil Pump - Pump Elements	Engine Oil	12345610	993193
Oxygen Sensor Threads	Anti-seize	12397953
Piston Pin to Piston/Rod - Pin Bores of Piston and Rod	Engine Oil	12345610	993193
Rod Bearings - Rod Pins of Crankshaft	Engine Oil	12345610	993193
Stationary Hydraulic Lash Adjusters	Lubricant	12345501	992704
Timing Chain Guide Bolt Access Hole Plug	Sealant	12345382	10953489
Valve Rocker Arm/Valve Tip	Lubricant	12345501	992704
Water Feed Tube O-rings	Lubricant	12345579	1974984
Water Pump Drain Plug	Sealant	12346004	10953480

Scheme 120

Scheme 120: Engine Block - Front View

Service Call Out	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth Maximum		Tap Depth Maximum
J 42385-850							MM	IN	MM	IN
1	M8 x 1.25	210	206	207	208	209	23.5	0.93	18.5	0.73
2	M12 x 1.75	855	856	857	858	859	33.5	1.32	26.5	1.04
3	M10 x 1.5	215	211	212	213	214	24.5	0.96	19.5	0.77
4	M6 x 1	205	201	202	203	204	20	0.787	16	0.63

Engine Block - Front View

Scheme 121

Scheme 121: Engine Block - Back View

Service Call Out	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth Maximum		Tap Depth Maximum
J 42385-850							MM	IN	MM	IN
1	M8 x 1.25	210	206	207	208	209	24	0.945	THRU
2	M10 x 1.5	215	211	212	213	214	29	1.161	THRU
3	M12 x 1.75	855	856	857	858	859	39	1.535	33.5	1.32
4	M16 x 1.5	860	861	862	863	864	21	0.827	15	0.59

Engine Block - Back View

Scheme 122

Scheme 122: Engine Block - Right Side View

Service Call Out	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth Maximum		Tap Depth Maximum
J 42385-850							MM	IN	MM	IN
1	M6 x 1	205	201	202	203	204	22.5	0.886	16	0.63
2	M10 x 1.5	215	211	212	213	214	34	1.339	27	1.063
3	M12 x 1.75	865	856	857	858	859	19.5	0.768	12.5	0.49

Engine Block - Right Side View

Scheme 123

Scheme 123: Engine Block - Bottom View

Service Call Out	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth Maximum		Tap Depth Maximum
J 42385-850							MM	IN	MM	IN
1	M8 x 1.25	210	206	207	208	209	28	1.102	22	0.87
2	M10 x 1.5	514	511	N/A	512	513	60	2.362	53.5	2.11

Engine Block - Bottom View

Scheme 124

Scheme 124: Engine Block - Left Side View

Service Call Out	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth Maximum		Tap Depth Maximum
J 42385-850							MM	IN	MM	IN
1	M6 x 1	205	201	202	203	204	20.5	0.807	16.5	0.65
2	M10 x 1.5	215	211	212	213	214	23.5	0.925	18	0.71
3	M8 x 1.25	210	206	207	208	209	30.5	1.201	22.5	0.89
4	M12 x 1.75	865	856	857	858	859	15.5	0.61	12.5	0.49
5	M12 x 1.75	865	856	857	858	859	19.5	0.778	12.5	0.49

Engine Block - Left Side View

Scheme 125

Scheme 125: Engine Block - Top View

Service Call Out	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth Maximum		Tap Depth Maximum
J 42385-850							MM	IN	MM	IN
1	M8 x 1.25	210	206	207	208	209	23.5	0.925	18.5	0.73
2	M11 x 1.5	507	504	N/A	505	506	77.5	3.053	70	2.758
3	M12 x 1.75	865	856	857	858	859	13.5	0.531	12.5	0.49

Engine Block - Top View

Scheme 126

Scheme 126: Lower Crankcase - Front View

Service Call Out	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth Maximum		Tap Depth Maximum
J 42385-850							MM	IN	MM	IN
1	M8 x 1.25	210	206	207	208	209	23.5	0.925	18.5	0.73
2	M8 x 1.25	210	206	207	208	209	30.5	1.201	25.5	1.00

Lower Crankcase - Front View

Scheme 127

Scheme 127: Lower Crankcase - Back View

Service Call Out	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth Maximum		Tap Depth Maximum
J 42385-850							MM	IN	MM	IN
1	M10 x 1.5	215	211	212	213	214	29.5	1.161	THRU

Lower Crankcase - Back View

Scheme 128

Scheme 128: Lower Crankcase - Bottom View

Service Call Out	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth Maximum		Tap Depth Maximum
J 42385-850							MM	IN	MM	IN
1	M8 x 1.25	210	206	207	208	209	23.5	0.925	18.5	0.73

Lower Crankcase - Bottom View

Scheme 129

Scheme 129: Lower Crankcase - Right View

Service Call Out	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth Maximum		Tap Depth Maximum
J 42385-850							MM	IN	MM	IN
1	M10 x 1.5	215	211	212	213	214	34	1.339	27	1.063

Lower Crankcase - Right View

Scheme 130

Scheme 130: Lower Crankcase - Left View

Service Call Out	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth Maximum		Tap Depth Maximum
J 42385-850							MM	IN	MM	IN
1	M8 x 1.25	210	211	212	213	214	34	1.339	27	1.063

Lower Crankcase - Left View

Scheme 131

Scheme 131: Cylinder Head - Top View

Service Call Out	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth Maximum		Tap Depth Maximum
J 42385-850							MM	IN	MM	IN
1	M6 x 1	205	852	N/A	203	204	23	0.906	19	0.748
2	M6 x 1	205	201	202	203	204	20	0.787	16	0.63
3	M14 x 1.75	856	857	N/A	858	859	THRU		THRU
4	M8 x 1.25	854	853	N/A	208	209	30	1.182	27	1.063

Cylinder Head - Top View

Scheme 132

Scheme 132: Cylinder Head - Intake Manifold Deck View

Service Call Out	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth Maximum		Tap Depth Maximum
J 42385-850							MM	IN	MM	IN
1	M6 x 1	205	201	202	203	204	20	0.787	16	0.63
2	M8 x 1.25	210	206	207	208	209	20	0.787	16	0.63
3	M8 x 1.25	205	201	202	203	204	16	0.630	12	0.473

Cylinder Head - Intake Manifold Deck View

Scheme 133

Scheme 133: Cylinder Head - Exhaust Manifold Deck View

Service Call Out	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth Maximum		Tap Depth Maximum
J 42385-850							MM	IN	MM	IN
1	M6 x 1	205	201	202	203	204	20	0.78	16	0.63
2	M8 x 1.25	210	206	207	208	209	25	0.984	20	0.78

Cylinder Head - Exhaust Manifold Deck View

Scheme 134

Scheme 134: Cylinder Head - Front View

Service Call Out	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth Maximum		Tap Depth Maximum
J 42385-850							MM	IN	MM	IN
1	M6 x 1	205	201	202	203	204	20	0.787	16	0.63
2	M8 x 1.25	210	206	207	208	209	25	0.984	20	0.787

Cylinder Head - Front View

Scheme 135

Scheme 135: Cylinder Head - Back View

Service Call Out	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth Maximum		Tap Depth Maximum
J 42385-850							MM	IN	MM	IN
1	M8 x 1.25	210	206	207	208	209	25	0.984	20	0.787
2	M12 x 1.75	865	856	857	858	859	18	0.709	14	0.551
3	M6 x 1	205	201	202	203	204	20	0.787	16	0.63

Cylinder Head - Back View

Scheme 136

Scheme 136: Disassembled Views

Callout	Component Name
1	Camshaft Position Actuator Solenoid Valve - Intake
2	Camshaft Position Actuator Solenoid Valve Bolt
3	Camshaft Position Actuator Solenoid Valve Bolt
4	Camshaft Position Actuator Solenoid Valve - Exhaust
5	Upper Intake Manifold Sight Shield Grommet
6	Ball Stud
7	Upper Intake Manifold Sight Shield Grommet
8	Turbocharger Coolant Feed Pipe Fitting
9	Turbocharger Coolant Feed Hose Gasket
10	Turbocharger Coolant Feed Hose Clamp
11	Turbocharger Coolant Feed Hose
12	Turbocharger Coolant Feed Hose Bolt
13	Turbocharger Coolant Feed Hose Gasket
14	Turbocharger Coolant Feed Hose Clamp
15	Upper Intake Manifold Sight Shield Grommet
16	Ball Stud
17	Ignition Coil Bolt
18	Ignition Coil Bolt Retainer
19	Ignition Coil
20	Spark Plug
21	Camshaft Cover Bolt
22	Camshaft Cover Bolt Retainer
23	Oil Fill Cap
24	Oil Fill Cap Seal
25	Camshaft Cover
26	Camshaft Cover Seal
27	Camshaft Cover Seal
28	Camshaft Cap Bolt
29	Camshaft Cap
30	Camshaft Cap
31	Camshaft Cap
32	Exhaust Camshaft
33	Intake Camshaft
34	Camshaft Position Sensor Bolt
35	Camshaft Position Sensor
36	Camshaft Position Sensor O-Ring
37	Roller Finger Follower
38	Hydraulic Lash Adjuster
39	Roller Finger Follower
40	Hydraulic Lash Adjuster
41	Cylinder Head Bolt
42	Coolant Air Bleed Fitting
43	Valve Keys
44	Valve Spring Retainer
45	Valve Spring
46	Valve Stem Seal
47	Small Cylinder Head Bolt
48	Cylinder Head
49	Timing Chain Guide Bolt Access Hole
50	Exhaust Valve
51	Intake Valve
52	Camshaft Position Sensor Bolt
53	Camshaft Position Sensor - Intake
54	Camshaft Position Sensor O-Ring
55	Cylinder Head Gallery Plug
56	Rear Lift Bracket
57	Rear Lift Bracket Bolt
58	Cylinder Head Cover Plate Seal
59	Cylinder Head Cover Plate
60	Cylinder Head Cover Plate Bolt
61	Fuel Injector Seal
62	Fuel Injector
63	Fuel Injector O-Ring
64	Fuel Injector Hold Down Clamp
65	Fuel Rail
66	Fuel Rail Pressure Sensor
67	Fuel Injector Wiring Harness
68	Fuel Rail Bolt

Scheme 137

Callout	Component Name
1	Evaporative (EVAP) Emission Purge Solenoid Valve Bolt
2	EVAP Purge Solenoid Valve
3	Manifold Absolute Pressure (MAP) Sensor Bolt
4	MAP Sensor
5	Fuel Pump Lifter
6	High Pressure Fuel Pump Gasket
7	High Pressure Fuel Pump O-Ring
8	High Pressure Fuel Pump
9	High Pressure Fuel Pump Bolt
10	Fuel Feed Line
11	Fuel Feed Line Bolt
12	High Pressure Fuel Pump Insulator
13	High Pressure Fuel Pump Cover
14	High Pressure Fuel Line
15	Fuel Injector Insulator
16	Oil Indicator Tube
17	Oil Indicator
18	Intake Manifold Brace
19	Intake Manifold Brace Bolt
20	Oil Indicator O-Ring
21	AIR Bypass Valve Solenoid Bolt
22	AIR Bypass Valve Solenoid
23	Throttle Body Bolt
24	Throttle Body
25	Throttle Body Seal
26	Power Brake Booster Fitting
27	Intake Manifold
28	Intake Manifold Gasket

Scheme 138

Callout	Component Name
1	Turbocharger Wastegate Regulator Solenoid Hose
2	Turbocharger Wastegate Regulator Solenoid Hose Clamp
3	Turbocharger Wastegate Regulator Solenoid Hose
4	Turbocharger Wastegate Regulator Solenoid Valve Assembly
5	Turbocharger Wastegate Regulator Solenoid Valve Bracket
6	Turbocharger Wastegate Regulator Solenoid Valve Bracket Bolt/Screw
7	Turbocharger Wastegate Regulator Solenoid Hose
8	Turbocharger Wastegate Regulator Solenoid Hose Clamp
9	Turbocharger Oil Feed Pipe
10	Turbocharger Oil Feed Pipe Bolt
11	Turbocharger Oil Feed Pipe Gasket
12	Turbocharger Oil Feed Pipe Gasket
13	Turbocharger Oil Feed Pipe Bolt
14	Turbocharger Coolant Return Pipe Gasket
15	Turbocharger Coolant Return Pipe Bolt
16	Turbocharger Coolant Return Pipe
17	Turbocharger Coolant Return Pipe Bolt
18	Turbocharger Coolant Return Pipe Gasket
19	Turbocharger Coolant Feed Pipe
20	Turbocharger Coolant Feed Pipe Gasket
21	Turbocharger Coolant Feed Pipe Bolt
22	Engine Coolant Heater
23	Engine Coolant Heater Bolt
24	Exhaust Manifold Heat Shield Bolt
25	Exhaust Manifold Heat Shield Bolt
26	Exhaust Manifold Heat Shield
27	Exhaust Manifold Nut
28	Exhaust Manifold
29	Exhaust Manifold Gasket
30	Exhaust Manifold Stud
31	Oxygen Sensor Fastener
32	Oxygen Sensor
33	Oxygen Sensor Gasket
34	Catalytic Converter Nut
35	Catalytic Converter
36	Catalytic Converter Seal
37	Catalytic Converter Stud
38	Catalytic Converter Bracket Bolts
39	Catalytic Converter Bracket
40	Catalytic Converter Stud
41	Turbocharger Air Cooler Outlet Pipe
42	Turbocharger Air Cooler Outlet Pipe Bolt
43	Turbocharger Heat Shield
44	Turbocharger Heat Shield Bolts
45	Turbocharger Air Cooler Outlet Pipe Seal
46	Turbocharger Gasket
47	Turbocharger
48	Turbocharger Air Bypass Diaphragm Assembly
49	Turbocharger Air Bypass Valve Spring
50	Turbocharger Air Bypass Valve Cover
51	Turbocharger Air Bypass Valve Cover Bolt/Screw
52	Turbocharger Oil Return Pipe Gasket
53	Turbocharger Oil Return Pipe Bolt
54	Turbocharger Oil Return Pipe
55	Turbocharger Oil Return Pipe O-Ring
56	Turbocharger Brace

Scheme 139

Callout	Component Name
1	Water Pump to Engine Block Seal
2	Water Pump Seal
3	Water Pump
4	Water Pump Bolt
5	Outlet Pipe O-rings
6	Outlet Pipe
7	Coolant Thermostat Housing Bolt
8	Coolant Thermostat Housing
9	Thermostat Housing to Block Gasket
10	Coolant Thermostat Housing Seal
11	Coolant Temperature Sensor
12	Thermostat
13	Coolant Inlet
14	Coolant Inlet Bolt
15	Water Pipe Support Bracket
16	Water Pipe Support Bracket Bolt
17	Water Pipe Support Bracket Bolt Stud
18	Piston Ring Assembly
19	Piston Assembly
20	Connecting Rod Bushing
21	Connecting Rod
22	Connecting Rod Bearing
23	Connecting Rod Cap Bolt
24	Oil Cooler O-ring
25	Oil Cooler
26	Oil Cooler Bolt
27	Front Lift Bracket
28	Front Lift Bracket Bolt
29	Cylinder Head Gasket
30	Cylinder Bore Liner
31	Cylinder Head Alignment Pin
32	Oil Filter Cap
33	Oil Filter Cap O-ring
34	Oil Filter
35	Engine Block Gallery Plug
36	Engine Block to Transaxle Alignment Pin
37	Crankshaft Position Sensor
38	Crankshaft Position Sensor Bolt
39	Oil Pressure Switch
40	Oil Squirter
41	Manual Transaxle Flywheel to Crankshaft Bolt
42	Flywheel - Manual Transaxle
43	Automatic Transaxle Flywheel to Crankshaft Bolt
44	Flywheel - Automatic Transaxle
45	Crankshaft Rear Seal
46	Engine Block
47	Crankshaft Thrust Bearing - Upper
48	Crankshaft Bearing - Upper
49	Crankshaft
50	Crankshaft Thrust Bearing - Lower
51	Crankshaft Bearing - Lower
52	Lower Crankcase Main Bearing Bolt
53	Lower Crankcase Perimeter Bolt
54	Engine Oil Pan
55	Engine Oil Pan Alignment Pins
56	Lower Crankcase Main Bearing Bolt
57	Engine Oil Pan Drain Plug
58	Engine Oil Pan Bolt
59	Engine Oil Pan Long Bolt
60	Knock Sensor - Rear
61	Knock Sensor - Front
62	Vacuum Pump Bracket
63	Vacuum Pump Bracket Bolt
64	Starter Bolt
65	Starter

Scheme 140

Callout	Component Name
1	Timing Chain Tensioner Body
2	Timing Chain Tensioner Seal
3	Adjustable Timing Chain Guide
4	Adjustable Timing Chain Guide Bolt
5	Timing Chain
6	Fixed Timing Chain Guide Bolt
7	Fixed Timing Chain Guide
8	Timing Chain Drive Sprocket
9	Friction Washers
10	Timing Chain Oil Nozzle Bolt
11	Timing Chain Oil Nozzle
12	Camshaft Position Actuator Bolt
13	Intake Camshaft Position Actuator
14	Camshaft Position Actuator Bolt
15	Exhaust Camshaft Position Actuator
16	Upper Timing Chain Guide
17	Upper Timing Chain Guide Bolt
18	Balance Shaft Drive Sprocket Bolts
19	Exhaust Balance Shaft Drive Sprocket
20	Intake Balance Shaft Drive Sprocket
21	Exhaust Balance Shaft Bearing Carrier
22	Intake Balance Shaft Bearing Carrier
23	Exhaust Balance Shaft
24	Intake Balance Shaft
25	Balance Shaft Rear Bearing
26	Water Pump Drive Sprocket Bolt
27	Water Pump Drive Sprocket
28	Balance Shaft Drive Chain Tensioner Assembly Bolt
29	Balance Shaft Drive Chain Tensioner Assembly
30	Adjustable Balance Shaft Drive Chain Guide Bolt
31	Adjustable Balance Shaft Drive Chain Guide
32	Balance Shaft Drive Chain
33	Balance Shaft Drive Chain Guide Bolt
34	Balance Shaft Drive Chain Guide
35	Balance Shaft Drive Sprocket
36	Balance Shaft Drive Chain Guide
37	Balance Shaft Drive Chain Guide Bolt
38	Engine Front Cover Alignment Pins
39	Engine Front Cover Gasket
40	Oil Pump Cover Bolt
41	Oil Pump Cover
42	Oil Pump Gear
43	Oil Pump Inner Rotor
44	Engine Front Cover
45	Engine Front Cover Bolt
46	Crankshaft Front Oil Seal
47	Crankshaft Balancer
48	Crankshaft Balancer Bolt
49	Engine Front Cover Bolt
50	Oil Pressure Relief Valve
51	Oil Pressure Relief Valve O-Ring
52	Water Pump Sprocket Access Cover Bolt
53	Water Pump Sprocket Access Cover
54	Water Pump Sprocket Access Cover Gasket
55	Belt Tensioner Bolt
56	Belt Tensioner
57	Belt Tensioner Bolt
58	Belt Tensioner Pulley Bolt
59	Belt Tensioner
60	Power Steering Pump Pulley
61	Power Steering Pump Bolt
62	Power Steering Pump Bracket
63	Power Steering Pump Bracket Bolt

Scheme 141

Scheme 141: Engine Identification

Identification can be made through the use of the broadcast code label (1) on the engine front cover and the use of the partial vehicle identification number (VIN) etched on the oil filter bowl (2).

Scheme 142

Callout	Component Name
1	Barcode
2	Sequence Number
3	Day
4	Month
5	Year
6	Engine Assembly Plant
7	Broadcast Code
8	Part Designation
9	Engine Assembly Number
10	Broadcast Code

The partial VIN identifies the specific vehicle by sequence number.

Engine Mechanical - 2.0L: Maintenance Chevrolet HHR I