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Engine Mechanical - 2.0l - Specifications Saturn Sky I final

Mechanical 16 illustrations ~138 words

Fastener Tightening Specifications

ApplicationSpecification
MetricEnglish
A/C Compressor to Block Bolt22 N.m16 lb ft
Balance Shaft Adjustable Chain Guide Bolt10 N.m89 lb in
Balance Shaft Chain Tensioner Bolt10 N.m89 lb in
Balance Shaft Fixed Chain Guide Bolt12 N.m106 lb in
Balance Shaft Retaining Bolt10 N.m89 lb in
Block Heater Bolt10 N.m89 lb in
Cam Cover to Cylinder Head Bolt10 N.m89 lb in
Cam Cover to Ground Cable Bolt10 N.m89 lb in
Cam Cover to Ground Cable Stud10 N.m89 lb in
Camshaft
Camshaft Cap Bolt10 N.m89 lb in
Camshaft Position Actuator Solenoid Valve Bolt10 N.m89 lb in
Camshaft Position Sensor Bolt10 N.m89 lb in
Exhaust Camshaft Position Actuator30 N.m + 100 degrees22 lb ft + 100 degrees
Intake Camshaft Position Actuator30 N.m + 100 degrees22 lb ft + 100 degrees
Catalytic Converter Bolt50 N.m37 lb ft
Catalytic Converter Bracket Bolt50 N.m37 lb ft
Catalytic Converter Nut50 N.m37 lb ft
Connecting Rod Bolt
First Pass25 N.m18 lb ft
Final Pass100 degrees
Coolant Jacket Plug35 N.m26 lb ft
Crankshaft Balancer Bolt
First Pass100 N.m74 lb ft
Final Pass125 degrees
Crankshaft Bearings - Lower Crankcase to Block - Bedplate
First Pass20 N.m15 lb ft
Final Pass77 degrees
Crankshaft Position Reluctor Ring15 N.m11 lb ft
Crankshaft Position Sensor Bolt10 N.m89 lb in
Cylinder Head Bolt
First Pass30 N.m22 lb ft
Final Pass155 degrees
Cylinder Head Front Chain Case Bolt35 N.m26 lb ft
Cylinder Head Oil Gallery Plug35 N.m26 lb ft
Cylinder Head Opening Plate Bolt10 N.m89 lb in
Drive Belt Tensioner Bolt45 N.m33 lb ft
Engine Coolant Drain Plug20 N.m15 lb ft
Engine Coolant Temperature Sensor20 N.m15 lb ft
Engine Lift Bracket Front Bolt25 N.m18 lb ft
Engine Lift Bracket Rear Bolt25 N.m18 lb ft
EVAP Purge Solenoid Valve Bolt4 N.m35 lb in
Exhaust Manifold Heat Shield Bolt25 N.m18 lb ft
Exhaust Manifold to Turbocharger Stud20 N.m15 lb ft
Exhaust Manifold to Cylinder Head Nut14 N.m10 lb ft
Exhaust Manifold to Cylinder Head Stud20 N.m15 lb ft
Flywheel Bolt
First Pass53 N.m39 lb ft
Final Pass25 degrees
Front Cover to Block Bolt25 N.m18 lb ft
Fuel Pipe Bracket Bolt10 N.m89 lb in
Fuel Pressure Sensor33 N.m24 lb ft
Fuel Pump Bolt - High Pressure15 N.m11 lb ft
Fuel Pump Fuel Feed Line Bolt10 N.m89 lb in
Fuel Pump - High Pressure Line30 N.m22 lb ft
Fuel Pump - Low Pressure Line30 N.m22 lb ft
Fuel Pump Cover10 N.m89 lb in
Fuel Rail Bolts22 N.m16 lb ft
Generator to Block Bolt22 N.m16 lb ft
Ignition Coil Bolt10 N.m89 lb in
Intake Manifold Brace Bolt22 N.m16 lb ft
Intake Manifold Brace and Vacuum Pump Nut25 N.m18 lb ft
Intake Manifold Brace Stud15 N.m11 lb ft
Intake Manifold to Cylinder Head Bolt25 N.m18 lb ft
Intake Manifold to Cylinder Head Nut25 N.m18 lb ft
Intake Manifold to Cylinder Head Stud15 N.m11 lb ft
Knock Sensor Bolt25 N.m18 lb ft
Lower Crankcase to Block Perimeter Bolt25 N.m18 lb ft
MAP Sensor Bolt4 N.m35 lb in
Oil Cooler Bolt25 N.m18 lb ft
Oil Filter Adapter Cover22 N.m16 lb ft
Oil Gallery Gerotor Cover - Rear Bolt6 N.m53 lb in
Oil Gallery Plug - Cylinder Head35 N.m26 lb ft
Oil Gallery Plug - Rear - Block60 N.m44 lb ft
Oil Level Indicator Tube Bolt10 N.m89 lb in
Oil Pan Baffle Bolt14 N.m10 lb ft
Oil Pan Bolts25 N.m18 lb ft
Oil Pan Drain Plug25 N.m18 lb ft
Oil Pressure Switch26 N.m19 lb ft
Oil Pump Gerotor Cover Bolt6 N.m53 lb in
Oil Pump Pressure Relief Valve Plug40 N.m30 lb ft
Oxygen Sensor42 N.m31 lb ft
Piston Oil Nozzle15 N.m11 lb ft
Power Steering Pump Bolt25 N.m18 lb ft
Power Steering Tensioner Bolt22 N.m16 lb ft
Spark Plug20 N.m15 lb ft
Starter Motor to Block Bolt53 N.m39 lb ft
Thermostat Housing to Block Bolts10 N.m89 lb in
Throttle Body Bolt10 N.m89 lb in
Throttle Body Nut10 N.m89 lb in
Timing Chain Adjustable Guide Bolt10 N.m89 lb in
Timing Chain Fixed Guide Bolt12 N.m106 lb in
Timing Chain Guide Bolt Access Hole Plug75 N.m55 lb ft
Timing Chain Oil Nozzle Bolt10 N.m89 lb in
Timing Chain Tensioner75 N.m55 lb ft
Timing Chain Tensioner Bolt10 N.m89 lb in
Timing Chain Upper Guide Bolt10 N.m89 lb in
Turbocharger Air Bypass Valve Cover Bolt/Screw10 N.m89 lb in
Turbocharger Air Cooler Outlet Pipe Bolts25 N.m18 lb ft
Turbocharger Brace Nut50 N.m37 lb ft
Turbocharger Coolant Feed Pipe Bolt35 N.m26 lb ft
Turbocharger Coolant Feed Pipe Mounting Bolt10 N.m89 lb in
Turbocharger Coolant Return Pipe Bolt35 N.m26 lb ft
Turbocharger Heat Shield Bolt10 N.m89 lb in
Turbocharger Nut30 N.m22 lb ft
Turbocharger Oil Feed Pipe Bolt40 N.m30 lb ft
Turbocharger Oil Return Pipe Bolt10 N.m89 lb in
Turbocharger Wastegate Regulator Solenoid Valve Bracket Bolt/Screw10 N.m89 lb in
Vacuum Pump Bolt10 N.m89 lb in
Vacuum Pump Bracket Bolt25 N.m18 lb ft
Vacuum Pump Bracket Nut25 N.m18 lb ft
Vent Tube to Cylinder Head15 N.m11 lb ft
Water Pipe Support Bracket Bolt10 N.m89 lb in
Water Pump Access Cover Bolt10 N.m89 lb in
Water Pump Cover Stud10 N.m89 lb in
Water Pump Bolts25 N.m18 lb ft
Water Pump Drain Plug20 N.m15 lb ft
Water Pump Sprocket Bolt10 N.m89 lb in

Engine Mechanical Specifications

ApplicationSpecification
MetricEnglish
General Data
Engine TypeInline 4 Cylinder
Displacement2.0 L122 CID
RPOLNF
Liter (VIN)A, M
Bore85.992-86.008 mm3.3880-3.3887 in
Stroke86 mm3.388 in
Compression Ratio9.2:1
Balance Shaft
Bearing Clearance0.030-0.060 mm0.0012-0.0024 in
Bearing Diameter - Inside - Carrier20.050-20.063 mm0.7894-0.7899 in
Bearing Diameter - Outside - Carrier41.975-41.995 mm1.6526-1.6534 in
Bearing Journal Diameter20.000-20.020 mm0.7874-0.7882 in
Bushing Clearance0.033-0.102 mm0.0013-0.0040 in
Bushing Diameter - Inside36.775-36.835 mm1.4489-1.4512 in
Bushing Journal Diameter36.723-36.743 mm1.4458-1.4466 in
End Play0.050-0.300 mm0.0020-0.0118 in
Block
Balance Shaft Bearing Bore Diameter - Carrier42.000-42.016 mm1.6535-1.6542 in
Balance Shaft Bushing Bore Diameter40.763-40.776 mm1.6048-1.6054 in
Crankshaft Main Bearing Bore Diameter64.068-64.082 mm2.5224-2.5229 in
Cylinder Bore Diameter85.992-86.008 mm3.3880-3.3887 in
Cylinder Bore Out-of-Round - Maximum0.010 mm0.0004 in
Cylinder Bore Taper - Maximum0.010 mm0.0004 in
Cylinder Head Deck Surface Flatness - Longitude0.050 mm0.002 in
Cylinder Head Deck Surface Flatness - Overall0.10 mm0.0039 in
Cylinder Head Deck Surface Flatness - Transverse0.030 mm0.0012 in
Camshaft
Camshaft End Play0.040-0.307 mm0.0016-0.0121 in
Camshaft Journal Diameter26.935-26.960 mm1.0604-1.0614 in
Camshaft Journal Diameter - Front34.960-34.935 mm1.3774-1.3764 in
Camshaft Thrust Surface - with Camshaft Actuator Installed30.020-30.175 mm1.1828-1.1889 in
Connecting Rod
Connecting Rod Bearing Clearance0.029-0.073 mm0.0011-0.0029 in
Connecting Rod Bore Diameter - Bearing End52.118-52.134 mm2.0519-2.05252 in
Connecting Rod Bore Diameter - Pin End23.007-23.017 mm0.9058-0.9062 in
Connecting Rod Side Clearance0.070-0.370 mm0.0028-0.0146 in
Connecting Rod Straightness - Bend - Maximum0.021 mm0.0083 in
Connecting Rod Straightness - Twist - Maximum0.04 mm0.0157 in
Crankshaft
Connecting Rod Journal Diameter49.000-49.014 mm1.9291-1.9297 in
Crankshaft End Play0.050-0.380 mm0.0012-0.0150 in
Crankshaft Main Bearing Clearance0.031-0.067 mm0.0012-0.0026 in
Crankshaft Main Journal Diameter55.994-56.008 mm2.2045-2.2050 in
Cylinder Head
Overall Height - Minimum128.9 mm5.07 in
Deck Straightness - in 150 mm (5.91 in)0.05 mm0.0019 in
Deck Straightness - in 25 mm (0.985 in)0.025 mm0.0009 in
Between Head Bolt Holes0.030 mm0.0011 in
Surface Flatness - Block Deck - Longitude0.050 mm0.002 in
Surface Flatness - Block Deck - Overall0.1 mm0.004 in
Surface Flatness - Block Deck - Transverse0.030 mm0.0012 in
Valve Guide Bore - Exhaust6.000-6.012 mm0.2362-0.2367 in
Valve Guide Bore - Intake6.000-6.012 mm0.2362-0.2367 in
Valve Lifter Bore Diameter - Stationary Lash Adjusters12.013-12.037 mm0.4730-0.4739 in
Valve Seat Angle - Relief Surface30 Degrees
Valve Seat Angle - Seating Surface45 Degrees
Valve Seat Angle - Undercut Surface60 Degrees
Valve Seat Roundness - Maximum0.025 mm0.0010 in
Valve Seat Runout - Maximum0.080 mm0.0031 in
Valve Seat Width - Exhaust Seating Surface1.600 mm0.0630 in
Valve Seat Width - Intake Seating Surface1.200 mm0.0472 in
Lubrication System
Oil Pressure - Minimum - @1000 RPM @ 90°C (194°F)206.84-482.63 kPa30-70 psi
Oil Capacity4.8L5.0 quarts
Piston Rings
Piston Ring End Gap - First Compression Ring0.20-0.35 mm0.0078-0.0138 in
Piston Ring End Gap - Second Compression Ring0.35-0.55 mm0.014-0.022 in
Piston Ring End Gap - Oil Control Ring - Rails0.25-0.75 mm0.010-0.030 in
Piston Ring to Groove Clearance - First Compression Ring0.040-0.080 mm0.0016-0.0031 in
Piston Ring to Groove Clearance - Second Compression Ring0.003-0.068 mm0.0001-0.0027 in
Piston Ring to Groove Clearance - Oil Control Ring0.024-0.176 mm0.0009-0.0069 in
Piston Ring Thickness - First Compression Ring1.170-1.190 mm0.0461-0.0469 in
Piston Ring Thickness - Second Compression Ring1.471-1.490 mm0.0579-0.0587 in
Piston Ring Thickness - Oil Control Ring - Rail - Maximum0.473 mm0.0186 in
Piston Ring Thickness - Oil Control Ring - Spacer0.96-1.04 mm0.0378-0.0409 in
Pistons and Pins
Pin - Piston Pin Clearance to Connecting Rod Bore0.009-0.023 mm0.0004-0.0009 in
Pin - Piston Pin Clearance to Piston Pin Bore0.005-0.015 mm0.0002-0.0006 in
Pin - Piston Pin Diameter22.995-23.000 mm0.9053-0.9055 in
Pin - Piston Pin End Play0.320-1.278 mm0.0126-0.0503 in
Piston - Piston Diameter - @14.5 mm up85.967-85.982 mm3.3845-3.3851 in
Piston - Piston Pin Bore Diameter23.005-23.010 mm0.9057-0.9059 in
Piston - Piston Ring Groove Width - Oil Control2.001-2.003 mm0.0788-0.0789 in
Piston - Piston Ring Groove Width - Second1.52-1.54 mm0.0598-0.0606 in
Piston - Piston Ring Groove Width - Top1.23-1.25 mm0.0484-0.0492 in
Piston - Piston To Bore Clearance0.010-0.041 mm0.0004-0.0016 in
Valve System
Valves - Valve Face Angle45 Degrees
Valves - Valve Face Runout - Maximum0.04 mm0.0016 in
Valves - Valve Seat Runout - Maximum0.080 mm0.0031 in
Valves - Valve Face Seat Width - Exhaust1.6000 mm0.06299 in
Valves - Valve Face Seat Width - Intake1.2000 mm0.04724 in
Valves - Valve Head Diameter - Exhaust29.950-30.250 mm1.1791-1.1909 in
Valves - Valve Head Diameter - Intake34.950-35.250 mm1.3760-1.4154 in
Valves - Valve Head O.D. and Chamfer Height - Exhaust1.1174 mm0.04399 in
Valves - Valve Head O.D. and Chamfer Height - Intake1.0526 mm0.04144 in
Valves - Valve Stem Diameter - Exhaust5.935-5.950 mm0.2337-0.2343 in
Valves - Valve Stem Diameter - Intake5.955-5.970 mm0.2344-0.2355 in
Valves - Valve Stem Height - Closed32.500 mm1.2795 in
Valves - Valve Stem to Guide Clearance - Exhaust0.050-0.077 mm0.0020-0.0026 in
Valves - Valve Stem to Guide Clearance - Intake0.030-0.057 mm0.0012-0.0022 in
Valve Lifters - Valve Lifter Diameter - Stationary Lash Adjuster11.986-12.000 mm0.0005-0.0020 in
Valve Lifters - Valve Lifter-to-Bore Clearance - Stationary Lash Adjuster0.013-0.051 mm3.2210-3.2299 in
Valve Rocker Arms - Rocker Arm Ratio1.68 to 1
Valve Rocker Arms - Rocker Arm Roller Diameter17.740-17.800 mm0.6987-0.7008 in
Valve Springs - Valve Spring Free Length41.400-44.200 mm1.6299-1.7402 in
Valve Springs - Valve Spring Installed Height - Closed32.500 mm1.2795 in
Valve Springs - Valve Spring Installed Height - Open22.500 mm0.8858 in
Valve Springs - Valve Spring Load - Open - @22.5 mm525.0-575.0 N118-129 lb
Valve Springs - Valve Spring Load - Closed - @32.5 mm245.0-271.0 N55-61 lb

Engine Mechanical Specifications

Adhesives, Fluids, Lubricants, and Sealers

ApplicationType of MaterialGM Part Number
United StatesCanada
# 6 Intake Rear Camshaft CapSealant1237852188901148
Balance Shaft BearingsEngine Oil1234618410953495
Cam LobesEngine Oil1234618410953495
CamshaftsLubricant12345501992704
Crank Sensor O-ringEngine Oil1234618410953495
Cylinder BoresEngine Oil1234618410953495
Cylinder Head PlugsSealant1234538210953489
Engine Block Threaded PlugsSealant1234600410953480
Engine Block to BedplateSealant1237852188901148
Engine OilEngine Oil1234618410953495
Engine Oil Level Indicator Tube O-RingLubricant12345501992704
Fuel Injector O-ringsEngine Oil1234618410953495
Fuel Injector Tip InsulatorsEngine Oil1234618410953495
Hydraulic Lash AdjustersLubricant12345501992704
Intake and Exhaust Valve StemsLubricant12345501992704
Main BearingsLubricant12345501992704
Oil Filter Cap - Threads and O-ring Lead-in ChamfersEngine Oil1234618410953495
Oil Pan to Bedplate JointSealant1237852188901148
Oil Pump - Pump ElementsEngine Oil1234618410953495
Oxygen Sensor ThreadsAnti-seize12397953
Piston Pin to Piston/Rod - Pin Bores of Piston and RodEngine Oil1234618410953495
Rod Bearings - Rod Pins of CrankshaftEngine Oil1234618410953495
Thread RepairCutting Fluid1052864992881
Cleaner1234613910953463
12377981
Timing Chain Guide Bolt Access Hole PlugSealant1234538210953489
ValvesParts Immersion Solvent1234536810953514
Valve Rocker Arm/Valve TipLubricant12345501992704
Water Feed Tube O-ringsLubricant123455791974984
Water Pump Drain PlugSealant1234600410953480

Scheme 31

Scheme 31: Engine Block - Front View
Service Call OutThread SizeInsertDrillCounterbore ToolTapDriverDrill Depth MaximumTap Depth Maximum
J 42385-850MMINMMIN
1M8 x 1.2521020620720820923.50.9318.50.73
2M12 x 1.7585585685785885933.51.3226.51.04
3M10 x 1.521521121221321424.50.9619.50.77
4M6 x 1205201202203204200.787160.63

Engine Block - Front View

Scheme 32

Scheme 32: Engine Block - Back View
Service Call OutThread SizeInsertDrillCounterbore ToolTapDriverDrill Depth MaximumTap Depth Maximum
J 42385-850MMINMMIN
1M8 x 1.25210206207208209240.945THRU
2M10 x 1.5215211212213214291.161THRU
3M12 x 1.75855856857858859391.53533.51.32
4M16 x 1.5860861862863864210.827150.59

Engine Block - Back View

Scheme 33

Scheme 33: Engine Block - Right Side View
Service Call OutThread SizeInsertDrillCounterbore ToolTapDriverDrill Depth MaximumTap Depth Maximum
J 42385-850MMINMMIN
1M6 x 120520120220320422.50.886160.63
2M10 x 1.5215211212213214341.339271.063
3M12 x 1.7586585685785885919.50.76812.50.49

Engine Block - Right Side View

Scheme 34

Scheme 34: Engine Block - Bottom View
Service Call OutThread SizeInsertDrillCounterbore ToolTapDriverDrill Depth MaximumTap Depth Maximum
J 42385-850MMINMMIN
1M8 x 1.25210206207208209281.102220.87
2M10 x 1.5514511N/A512513602.36253.52.11

Engine Block - Bottom View

Scheme 35

Scheme 35: Engine Block - Left Side View
Service Call OutThread SizeInsertDrillCounterbore ToolTapDriverDrill Depth MaximumTap Depth Maximum
J 42385-850MMINMMIN
1M6 x 120520120220320420.50.80716.50.65
2M10 x 1.521521121221321423.50.925180.71
3M8 x 1.2521020620720820930.51.20122.50.89
4M12 x 1.7586585685785885915.50.6112.50.49
5M12 x 1.7586585685785885919.50.77812.50.49

Engine Block - Left Side View

Scheme 36

Scheme 36: Engine Block - Top View
Service Call OutThread SizeInsertDrillCounterbore ToolTapDriverDrill Depth MaximumTap Depth Maximum
J 42385-850MMINMMIN
1M8 x 1.2521020620720820923.50.92518.50.73
2M11 x 1.5507504N/A50550677.53.053702.758
3M12 x 1.7586585685785885913.50.53112.50.49

Engine Block - Top View

Scheme 37

Scheme 37: Lower Crankcase - Front View
Service Call OutThread SizeInsertDrillCounterbore ToolTapDriverDrill Depth MaximumTap Depth Maximum
J 42385-850MMINMMIN
1M8 x 1.2521020620720820923.50.92518.50.73
2M8 x 1.2521020620720820930.51.20125.51.00

Lower Crankcase - Front View

Scheme 38

Scheme 38: Lower Crankcase - Back View
Service Call OutThread SizeInsertDrillCounterbore ToolTapDriverDrill Depth MaximumTap Depth Maximum
J 42385-850MMINMMIN
1M10 x 1.521521121221321429.51.161THRU

Lower Crankcase - Back View

Scheme 39

Scheme 39: Lower Crankcase - Bottom View
Service Call OutThread SizeInsertDrillCounterbore ToolTapDriverDrill Depth MaximumTap Depth Maximum
J 42385-850MMINMMIN
1M8 x 1.2521020620720820923.50.92518.50.73

Lower Crankcase - Bottom View

Scheme 40

Scheme 40: Lower Crankcase - Right View
Service Call OutThread SizeInsertDrillCounterbore ToolTapDriverDrill Depth MaximumTap Depth Maximum
J 42385-850MMINMMIN
1M10 x 1.5215211212213214341.339271.063

Lower Crankcase - Right View

Scheme 41

Scheme 41: Lower Crankcase - Left View
Service Call OutThread SizeInsertDrillCounterbore ToolTapDriverDrill Depth MaximumTap Depth Maximum
J 42385-850MMINMMIN
1M8 x 1.25210211212213214341.339271.063

Lower Crankcase - Left View

Scheme 42

Scheme 42: Cylinder Head - Top View
Service Call OutThread SizeInsertDrillCounterbore ToolTapDriverDrill Depth MaximumTap Depth Maximum
J 42385-850MMINMMIN
1M6 x 1205852N/A203204230.906190.748
2M6 x 1205201202203204200.787160.63
3M14 x 1.75856857N/A858859THRUTHRU
4M8 x 1.25854853N/A208209301.182271.063

Cylinder Head - Top View

Scheme 43

Scheme 43: Cylinder Head - Intake Manifold Deck View
Service Call OutThread SizeInsertDrillCounterbore ToolTapDriverDrill Depth MaximumTap Depth Maximum
J 42385-850MMINMMIN
1M6 x 1205201202203204200.787160.63
2M8 x 1.25210206207208209200.787160.63
3M8 x 1.25205201202203204160.630120.473

Cylinder Head - Intake Manifold Deck View

Scheme 44

Scheme 44: Cylinder Head - Exhaust Manifold Deck View
Service Call OutThread SizeInsertDrillCounterbore ToolTapDriverDrill Depth MaximumTap Depth Maximum
J 42385-850MMINMMIN
1M6 x 1205201202203204200.78160.63
2M8 x 1.25210206207208209250.984200.78

Cylinder Head - Exhaust Manifold Deck View

Scheme 45

Scheme 45: Cylinder Head - Front View
Service Call OutThread SizeInsertDrillCounterbore ToolTapDriverDrill Depth MaximumTap Depth Maximum
J 42385-850MMINMMIN
1M6 x 1205201202203204200.787160.63
2M8 x 1.25210206207208209250.984200.787

Cylinder Head - Front View

Scheme 46

Scheme 46: Cylinder Head - Back View
Service Call OutThread SizeInsertDrillCounterbore ToolTapDriverDrill Depth MaximumTap Depth Maximum
J 42385-850MMINMMIN
1M8 x 1.25210206207208209250.984200.787
2M12 x 1.75865856857858859180.709140.551
3M6 x 1205201202203204200.787160.63

Cylinder Head - Back View