Engine Mechanical - 2.4L: 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 62

Scheme 62: 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 63

Scheme 63: 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	18	0.709	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 64

Scheme 64: 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	0.63
2	M10 x 1.5	215	211	212	213	214	23.5	0.925	18.5	0.73
3	M12 x 1.75	865	856	857	858	859	19.5	0.768	12.5	0.49

Engine Block - Left Side View

Scheme 65

Scheme 65: 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 66

Scheme 66: 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	20.5	0.807	16.5	0.65
2	M8 x 1.25	210	206	207	208	209	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	855	856	857	858	859	33.5	1.319	26.5	1.04
6	M12 x 1.75	865	856	857	858	859	19.5	0.778	12.5	0.49

Engine Block - Right Side View

Scheme 67

Scheme 67: 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	113.3	4.461	107.3	4.22
3	M12 x 1.75	865	856	857	858	859	13.5	0.531	12.5	0.49

Engine Block - Top View

Scheme 68

Scheme 68: 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 69

Scheme 69: 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 70

Scheme 70: 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 71

Scheme 71: 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	M10 x 1.5	215	211	212	213	214	28.5	1.122	22.5	0.89

Lower Crankcase - Left View

Scheme 72

Scheme 72: 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	M8 x 1.25	210	211	212	213	214	30.5	1.201	22.5	0.886

Lower Crankcase - Right View

Scheme 73

Scheme 73: 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	24	0.945	20	0.787
2	M6 x 1	205	201	202	203	204	20	0.787	16	0.63
3	M8 x 1.25	854	206	207	208	209	THRU		THRU

Cylinder Head - Top View

Scheme 74

Scheme 74: 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

Cylinder Head - Intake Manifold Deck View

Scheme 75

Scheme 75: 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 76

Scheme 76: 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 77

Scheme 77: 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	17	0.67	14	0.551

Cylinder Head - Back View

Scheme 78

Scheme 78: Disassembled Views

Callout	Component Name
201	Exhaust Valve
202	Intake Valve
203	Timing Chain Guide Bolt Access Hole
204	Cylinder Head
205	Cylinder Head Gallery Plug
206	Hydraulic Lash Adjuster
207	Roller Finger Follower
208	Cylinder Head Bolt
209	Small Cylinder Head Bolt
210	Valve Stem Seal
211	Valve Spring
212	Valve Spring Retainer
213	Valve Keys
214	Hydraulic Lash Adjuster
215	Roller Finger Follower
216	Intake Camshaft
219	Camshaft Cap
220	Exhaust Camshaft
221	Camshaft Cap
222	Camshaft Cap Bolt
300	Coolant Air Bleed Fitting
413	Engine Oil Fill Cap
507	Fuel Injector Rotator Cup
508	Fuel Injector O-ring
509	Fuel Injector
510	Fuel Injector O-ring
511	Fuel Injector Clip
512	Fuel Rail
513	Camshaft Cover Gasket
514	Camshaft Cover
515	Camshaft Cover Bolt
707	Front Lift Bracket Bolt
708	Front Lift Bracket
709	Rear Lift Bracket
710	Rear Lift Bracket Bolt
713	Fuel Injector Wiring Harness
717	Spark Plug
718	Camshaft Position Actuator Solenoid Valve - Exhaust
719	Camshaft Position Actuator Solenoid Valve - Intake
720	Camshaft Position Actuator Solenoid Valve Bolt
721	Ignition Coil
724	Ignition Coil Bolt
725	Camshaft Position Sensor
726	Camshaft Position Sensor Bolt
727	Camshaft Position Sensor
728	Camshaft Position Sensor Bolt

Scheme 79

Callout	Component Name
408	Oil Indicator Tube O-ring
409	Oil Indicator Tube
410	Oil Indicator Tube Bolt
411	Oil Indicator O-ring
412	Oil Indicator
500	Intake Manifold Gasket
501	Intake Manifold Bolt
502	Intake Manifold
503	Throttle Body Seal
504	Throttle Body
506	Throttle Body Bolt
711	Map Sensor

Scheme 80

Callout	Component Name
600	Exhaust Manifold Stud
601	Exhaust Manifold Gasket
602	Exhaust Manifold
603	Exhaust Manifold Nut
604	Exhaust Manifold Heat Shield
605	Exhaust Manifold Heat Shield Stud
712	Oxygen Sensor

Scheme 81

Callout	Component Name
100	Engine Block
101	Crankshaft Bearing - Upper
102	Crankshaft Thrust Bearing - Upper
103	Crankshaft
104	Crankshaft Bearing - Lower
105	Crankshaft Thrust Bearing - Lower
106	Lower Crankcase
107	Lower Crankcase Perimeter Bolt
108	Lower Crankcase Main Bearing Bolt
109	Crankshaft Rear Seal
110	Flywheel - Automatic Transmission
111	Automatic Transaxle Flywheel to Crankshaft Bolt
112	Manual Transaxle Flywheel
113	Manual Transaxle Flywheel Bolt
114	Engine Block to Transaxle Alignment Pin
115	Engine Block Gallery Plug
116	Cylinder Head Alignment Pin
117	Cylinder Bore Sleeve
118	Connecting Rod Cap Bolt
119	Connecting Rod
120	Connecting Rod Bearing
121	Piston Assembly
122	Piston Ring Assembly
200	Cylinder Head Gasket
301	Thermostat Housing
302	Thermostat Housing to Block Gasket
303	Water Pipe Support Bracket Bolt
304	Water Pipe Support Bracket Bolt Stud
305	Water Pipe Support Bracket
306	Thermostat Gasket
307	Thermostat
308	Thermostat Housing Cap
309	Thermostat Housing Cap Bolt
310	Water Transfer Pipe
311	Water Transfer Pipe O-ring Seals
312	Water Pump
313	Water Pump to Engine Block Seal
400	Engine Oil Pan
401	Engine Oil Pan Alignment Pins
402	Engine Oil Pan Drain Plug
403	Engine Oil Pan Bolt
404	Engine Oil Pan Long Bolt
405	Oil Filter
406	Oil Filter Cap O-ring
407	Oil Filter Cap
433	Piston Oil Squirter
700	Oil Pressure Switch
701	Crankshaft Position Sensor Bolt
702	Crankshaft Position Sensor
703	Knock Sensor
706	Coolant Temperature Sensor

Scheme 82

Callout	Component Name
123	Balance Shaft Rear Bearing
124	Exhaust Balance Shaft
125	Intake Balance Shaft
126	Exhaust Balance Shaft Bearing Carrier
127	Intake Balance Shaft Bearing Carrier
128	Exhaust Balance Shaft Drive Sprocket
129	Intake Balance Shaft Drive Sprocket
130	Balance Shaft Drive Sprocket Bolts
223	Upper Timing Chain Guide Bolt
224	Upper Timing Chain Guide
225	Exhaust Camshaft Position Actuator
226	Intake Camshaft Position Actuator
227	Camshaft Position Actuator Bolt
228	Timing Chain Oil Nozzle
229	Timing Chain Oil Nozzle Bolt
230	Timing Chain Drive Sprocket
231	Fixed Timing Chain Guide
232	Fixed Timing Chain Guide Bolt
233	Timing Chain
234	Timing Chain Tensioner Washer
235	Timing Chain Tensioner Body
236	Timing Chain Tensioner O-ring Seal
237	Timing Chain Tensioner Plunger
238	Adjustable Timing Chain Guide
239	Adjustable Timing Chain Guide Bolt
240	Balance Shaft Drive Sprocket
241	Balance Shaft Drive Chain Guide
242	Balance Shaft Drive Chain Guide Bolt
243	Balance Shaft Drive Chain Guide
244	Balance Shaft Drive Chain Guide Bolt
245	Balance Shaft Drive Chain
246	Balance Shaft Drive Chain Tensioner Assembly
247	Balance Shaft Drive Chain Tensioner Assembly Bolt
248	Adjustable Balance Shaft Drive Chain Guide
249	Adjustable Balance Shaft Drive Chain Guide Bolt
314	Water Pump Drive Sprocket
315	Water Pump Drive Sprocket Bolt
316	Water Pump Bolt
317	Engine Front Cover Access Plate Gasket
318	Engine Front Cover Access Plate
319	Engine Front Cover Access Plate Bolt
414	Engine Front Cover Alignment Pins
415	Engine Front Cover Gasket
416	Oil Pump Cover Bolt
417	Oil Pump Cover
418	Oil Pump Outer Gerotor
419	Oil Pump Inner Gerotor
420	Engine Front Cover
421	Engine Front Cover Bolt
422	Oil Pressure Relief Valve Spring
423	Oil Pressure Relief Valve Plunger
424	Oil Pressure Relief Valve O-ring Seal
425	Oil Pressure Relief Valve Plug
426	Crankshaft Front Seal
427	Crankshaft Damper
428	Crankshaft Damper Bolt
704	Belt Tensioner
705	Belt Tensioner Bolt

Scheme 83

Scheme 83: Engine Identification

Identification can be made through the use of the Broadcast Code label on the engine front cover (1) and the use of the partial VIN etched on the oil filter bowl (2).

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

The partial VIN identifies the specific vehicle by sequence number.

Engine Mechanical - 2.4L: Maintenance Chevrolet HHR I