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Engine Specifications Saturn SL II

Mechanical
ApplicationSpecification
Displacement1.9L (116 Cu. In)
Bore3.2" (82 mm)
Stroke3.5" (90 mm)
Compression Ratio
DOHC9.5:1
SOHC9.3:1
Fuel SystemMFI

GENERAL SPECIFICATIONS

ApplicationIn. (mm)
Crankshaft
End Play
Standard.002-.008 (.05-.20)
Maximum.010 (.25)
Runout.002 (.05)
Main Bearings
Journal Diameter
Standard2.2438-2.2444 (56.993-57.007)
Minimum2.2437 (56.990)
Journal Out-Of-Round.0004 (.010)
Journal Taper.0004 (.010)
Oil Clearance
Standard.0002-.0020 (.006-.050)
Maximum.0024 (.060)
Connecting Rod Bearings
Journal Diameter1.8500-1.8508 (46.990-47.010)
Journal Out-Of-Round.0004 (.010)
Journal Taper.0004 (.010)
Oil Clearance
Standard.0004-.0025 (.010-.065)
Maximum.0029 (.074)

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

ApplicationIn. (mm)
Pin Bore Diameter (Bushing)
Standard
1998.7679-.7685 (19.506-19.520)
1999.7679-.7683 (19.505-19.517)
Maximum
1998.7687 (19.526)
1999.7685 (19.520)
Crankpin Bore Diameter1.9761-1.9767 (50.193-50.207)
Maximum Bend (1).0126 (.320)
Maximum Twist (1)
1998.0110 (.279)
1999.0063 (.160)
Side Clearance
Standard.0065-.0171 (.165-.435)
Maximum.0185 (.470)
(1) Per 4" of rod length.
(1)Per 4" of rod length.

CONNECTING RODS

ApplicationIn. (mm)
Pistons
Diameter(1) 3.2270-3.2277 (81.966-81.984)
Oil Clearance
Cylinders No. 1, 2 & 3
Standard.0002-.0017 (.006-.044)
Maximum.0028 (.070)
Cylinder No. 4
Standard.0006-.0021 (.016-.054)
Maximum.0028 (.070)
Pin Bore Diameter.7678-.7680 (19.502-19.507)
Pins
Diameter.7676-.7677 (19.496-19.500)
Oil Clearance
Pin-To-Piston.0001-.0004 (.002-.011)
Pin-To-Rod.002-.009 (.006-.024)
Rings
No. 1
End Gap
Standard.0098-.0157 (.250-.400)
Maximum.0197 (.500)
Side Clearance.0016-.0032 (.040-.080)
No. 2
End Gap
Standard.0098-.0197 (.250-.500)
Maximum.0236 (.600)
Side Clearance.0012-.0031 (.030-.080)
No. 3 (Oil)
End Gap
Standard.0098-.0492 (0.250-1.250)
Maximum.0551 (1.400)
(1) Measured at right angle to piston pin hole, .20" (5 mm) from bottom of piston.
(1)Measured at right angle to piston pin hole, .20" (5 mm) from bottom of piston.

PISTONS, PINS & RINGS (1998)

ApplicationIn. (mm)
Pistons
Diameter(1) 3.2270-3.2280 (81.966-81.992)
Oil Clearance
Cylinders No. 2 & 3
Standard.0000-.0017 (.000-.044)
Maximum.0028 (.070)
Cylinders No. 1 & 4
Standard.0003-.0021 (.008-.054)
Maximum.0028 (.070)
Pin Bore Diameter.7678-.7680 (19.502-19.507)
Pins
Diameter.7676-.7677 (19.496-19.500)
Oil Clearance
Pin-To-Piston.0001-.0004 (.002-.011)
Pin-To-Rod.002-.008 (.006-.021)
Rings
No. 1
End Gap
Standard.0071-.0130 (.180-.330)
Maximum.0177 (.450)
Side Clearance.0016-.0028 (.040-.070)
No. 2
End Gap
Standard.0138-.0216 (.350-.550)
Maximum.0256 (.650)
Side Clearance.0012-.0031 (.030-.080)
No. 3 (Oil)
End Gap
Standard.0039-.0197 (0.100-.500)
Maximum.0256 (.650)
(1) Measured at right angle to piston pin hole, .20" (5 mm) from bottom of piston.
(1)Measured at right angle to piston pin hole, .20" (5 mm) from bottom of piston.

PISTONS, PINS & RINGS (1999)

ApplicationIn. (mm)
Cylinder Bore
Diameter
Cylinders No. 1, 2 & 3
Standard3.2280-3.2287 (81.990-82.010)
Maximum Wear3.2297 (82.035)
Cylinder No. 4
Standard3.2283-3.2291 (82.000-82.020)
Maximum Wear3.2301 (82.045)
Maximum Taper.0020 (.050)
Maximum Out-Of-Round.0020 (.050)
Cylinder Liner Protrusion
StandardFlush With Deck
Maximum(1) .0005 (.013)
Piston Protrusion
Above Deck Surface
Standard.0118 (.300)
Maximum.0149 (.379)
Below Deck Surface
Standard.0026 (.066)
Maximum.0057 (.145)
Minimum Deck Height (2)7.4512 (189.26)
Maximum Deck Warpage
Longitudinal (Lengthwise)
Standard.0031 (.080)
Maximum.0040 (.100)
Transverse (Across)
Standard.0009 (.024)
Maximum.0020 (.050)
(1) Above or below deck surface. (2) Distance between top of main bearing bore and deck surface.
(1)Above or below deck surface.
(2)Distance between top of main bearing bore and deck surface.

CYLINDER BLOCK

ApplicationSpecification
Valve Face Angle45.0-45.5°
Valve Head Minimum Margin.030" (.75 mm)
Valve Installed Height
Standard1.612-1.636" (40.95-41.55 mm)
Minimum1.612" (40.95 mm)
Maximum1.638" (41.60 mm)
Valve Length
Intake
Standard3.965-3.983" (100.72-101.18 mm)
Minimum3.962" (100.64 mm)
Maximum3.987" (101.26 mm)
Exhaust
Standard3.938-3.956" (100.02-100.48 mm)
Minimum3.935" (99.94 mm)
Maximum3.959" (100.56 mm)
Valve Stem Diameter
Intake
Standard.2736-.2741" (6.949-6.962 mm)
Minimum.2730" (6.935 mm)
Exhaust
Standard.2726-2736" (6.931-6.950 mm)
Minimum.2724" (6.919 mm)
Valve Springs
Free Length1.65" (41.8 mm)
Out-Of-Square
Standard.08" (2.0 mm)
Maximum.10" (2.5 mm)
Lbs. @ In. (kg @ mm)
Pressure (Minimum)
Valve Closed63 @ 1.39 (28 @ 35.3)
Valve Open155 @ .98 (69 @ 26.3)

VALVES & VALVE SPRINGS (1998 DOHC)

ApplicationSpecification
Valve Face Angle44.5-45°
Valve Head Minimum Margin.030" (.75 mm)
Valve Installed Height
Standard1.548-1.567" (39.31-39.98 mm)
Minimum1.548" (39.31 mm)
Maximum1.586" (40.28 mm)
Valve Length
Intake
Standard3.793-3.817 (96.28-96.74 mm)
Minimum3.787" (96.20 mm)
Maximum3.812" (96.74 mm)
Exhaust
Standard3.766-3.784" (95.58-96.04 mm)
Minimum3.760" (95.50 mm)
Maximum3.784" (96.04 mm)
Valve Stem Diameter
Intake
Standard.2347-.2363" (5.958-5.977 mm)
Minimum.2342" (5.945 mm)
Exhaust
Standard.2342-2349" (5.944-5.963 mm)
Minimum.2336" (5.930 mm)
Valve Springs
Free Length1.56" (40.1 mm)
Out-Of-Square
Standard.08" (2.0 mm)
Maximum.10" (2.5 mm)
Lbs. @ In. (kg @ mm)
Pressure (Minimum)
Valve Closed40 @ 1.22 (18 @ 31.0)
Valve Open94 @ .85 (42 @ 21.5)

VALVES & VALVE SPRINGS (1999 DOHC)

ApplicationSpecification
Valve Face Angle44.75-45.25°
Valve Length
Intake
Standard5.4539-5.4744" (138.53-139.05 mm)
Minimum5.4520" (138.48 mm)
Maximum5.4764" (139.10 mm)
Exhaust
Standard5.4618-5.4823" (138.73-139.25 mm)
Minimum5.4598" (138.68 mm)
Maximum5.4843" (139.30 mm)
Valve Stem Diameter
Intake
Standard.2736-.2741" (6.949-6.962 mm)
Minimum.2730" (6.935 mm)
Exhaust
Standard.2726-.2736" (6.931-6.950 mm)
Minimum.2722" (6.919 mm)
Valve Head Margin
Intake
Standard.038-.050" (0.96-1.11 mm)
Minimum.035" (0.90 mm)
Exhaust
Standard.044-.056" (1.12-1.27 mm)
Minimum.039" (1.00 mm)
Valve Installed Height
Standard1.900-1.919" (48.25-48.75 mm)
Maximum1.921" (48.80 mm)
Valve Springs
Free Length1.89-1.91" (48.0-48.6 mm)
Out-Of-Square
Standard.08" (2.0 mm)
Maximum.10" (2.5 mm)
Lbs. @ In. (kg @ mm)
Pressure (Minimum)
Valve Closed75 @ 1.61 (33 @ 41.0)
Valve Open196 @ 1.28 (87 @ 30.0)

VALVES & VALVE SPRINGS (SOHC)

ApplicationSpecification
Maximum Warpage
Head Gasket Surface
Longitudinal (Lengthwise).0028" (.07 mm)
Transverse (Across).0012" (.03 mm)
Manifold Surfaces.004" (.10 mm)
Valve Seat Angle44.5-45.0°
Valve Seat Width
Intake
Standard.031-.048" (1.0-1.3 mm)
Maximum.065" (1.66 mm)
Exhaust
Standard.051-.063 (1.05-1.49 mm)
Maximum.076" (1.92 mm)
Valve Seat Bore Diameter
Intake1.315-1.316" (33.40-33.42 mm)
Exhaust1.118-1.119" (28.40-28.42 mm)
Valve Seat Insert Diameter
Intake1.319" (33.50 mm)
Exhaust1.122" (28.50 mm)
Valve Guides
Cylinder Head Bore Diameter
Standard.4463-.4474" (11.337-11.363 mm)
Maximum.4476" (11.368 mm)
Guide Inside Diameter
1998
Standard.2751-.2761" (6.987-7.013 mm)
Maximum.2775" (7.050 mm)
1999
Standard.2364-.2372 (6.000-6.020)
Maximum.239 (6.06)
Guide Installed Height.327-.357" (8.30-8.55 mm)
Valve Stem-To-Guide Oil Clearance
Intake
Standard.0010-.0025" (.023-.064 mm)
Maximum.0045" (.113 mm)
Exhaust
Standard.0015-.0032" (.037-.082 mm)
Maximum.0052" (.131 mm)

CYLINDER HEAD (DOHC)

ApplicationSpecification
Maximum Warpage
Head Gasket Surface
Longitudinal (Lengthwise).0028" (.07 mm)
Transverse (Across).0012" (.03 mm)
Manifold Surfaces.004" (.10 mm)
Valve Seat Angle44.5-45.5°
Valve Seat Width
Intake
Standard.039-.051" (1.00-1.30 mm)
Maximum.063" (1.60 mm)
Exhaust
Standard.051-.063" (1.30-1.60 mm)
Maximum.075" (1.90 mm)
Valve Seat Bore Diameter
Intake1.6333-1.6344" (41.487-41.513 mm)
Exhaust1.377-1.3785" (34.987-35.013 mm)
Valve Seat Insert Diameter
Intake1.6367-1.6378" (41.573-41.599 mm)
Exhaust1.3808-1.3819" (35.073-35.099 mm)
Valve Guides
Cylinder Head Bore Diameter
Factory Size Guide
Standard.4463-.4474" (11.337-11.363 mm)
Maximum.4476" (11.368 mm)
Oversize Guide.4562-.4572" (11.587-11.613 mm)
Guide Inside Diameter
Standard.2751-.2761" (6.987-7.013 mm)
Maximum.2776" (7.050 mm)
Guide Installed Height.404-.413" (10.25-10.50 mm)
Valve Stem-To-Guide Oil Clearance
Intake
Standard.0010-.0025" (.025-.064 mm)
Maximum.0045" (.115 mm)
Exhaust
Standard.0015-.0032" (.037-.082 mm)
Maximum.0053" (.135 mm)

CYLINDER HEAD (SOHC)

ApplicationIn. (mm)
Bore Diameter
Standard1.1417-1.1428 (29.000-29.026)
Maximum1.1437 (29.050)
Bore Warpage (1)
Standard.0020 (.050)
Maximum.0025 (.064)
End Play
Standard.002-.008 (.05-.20)
Maximum.010 (.25)
Camshaft Runout
Standard.002 (.05)
Maximum.004 (.10)
Journal Diameter
Standard1.1398-1.1406 (28.950-28.970)
Minimum1.1388 (28.925)
Lobe Lift
Intake
Standard.3528-.3559 (8.960-9.040)
Minimum.3508 (8.910)
Exhaust
Standard.3409-.3441 (8.660-8.740)
Minimum.3390 (8.610)
Oil Clearance
Standard.0012-.0030 (.030-.076)
Maximum.0049 (.125)
Timing Chain
Maximum Inner Diameter23.15 (588.0)
Chain Tensioner Plunger Travel (2)
Standard.059-.374 (1.5-9.5)
Maximum.863 (21.00)
(1) To measure bore warpage, place straightedge in bearing saddle. Slide a feeler gauge between straightedge and each bearing. (2) With timing chain and guides installed.
(1)To measure bore warpage, place straightedge in bearing saddle. Slide a feeler gauge between straightedge and each bearing.
(2)With timing chain and guides installed.

CAMSHAFT & CAMSHAFT DRIVE (1998 DOHC)

ApplicationIn. (mm)
Bore Diameter
Standard1.0638-1.0648 (27.000-27.026)
Maximum1.0658 (27.050)
Bore Warpage (1)
Standard.0020 (.050)
Maximum.0025 (.064)
End Play
Standard.0002-.0156 (.006-.396
Maximum.018 (.45)
Camshaft Runout
Standard.003 (.080
Maximum.0047 (.120)
Journal Diameter
Standard1.0618-1.0626 (268.950-26.970)
Minimum1.0608 (26.925)
Lobe Lift
Intake
Standard.2042-.2074 (5.183-5.263)
Minimum.2020 (5.133)
Exhaust
Standard.2042-.2074 (5.183-5.263)
Minimum.2020 (5.133)
Oil Clearance
Standard.0012-.0030 (.030-.076)
Maximum.0049 (.125)
Timing Chain
Maximum Inner Diameter(2)
Chain Tensioner Plunger Travel (3)
Standard.045-.388 (1.16-9.85)
Maximum.709 (18.00)
(1) To measure bore warpage, place straightedge in bearing saddle. Slide a feeler gauge between straightedge and each bearing. (2) Information is not available from manufacturer. (3) With timing chain and guides installed.
(1)To measure bore warpage, place straightedge in bearing saddle. Slide a feeler gauge between straightedge and each bearing.
(2)Information is not available from manufacturer.
(3)With timing chain and guides installed.

CAMSHAFT & CAMSHAFT DRIVE (1999 DOHC)

ApplicationIn. (mm)
Bore Diameter
Standard1.7510-1.7520 (44.475-44.500)
Maximum1.7525 (44.513)
Bore Warpage (1)
Standard.0020 (.050)
Maximum.0025 (.064)
End Play
Standard.003-.008 (.07-.20)
Maximum.010 (.25)
Camshaft Runout
Standard.002 (.05)
Maximum.003 (.07)
Journal Diameter
Standard1.7480-1.7490 (44.399-44.424)
Minimum1.7470 (44.375)
Lobe Lift
Standard.2531-.2556 (6.428-6.493)
Minimum.2520 (6.400)
Journal Oil Clearance
Standard.0020-.0040 (.051-.101)
Maximum.0054 (.138)
Timing Chain
Inner Diameter (2)
Standard16.50-16.61 (419.0-422.0)
Maximum16.73 (425.0)
Chain Tensioner Plunger Travel (3)
1998
Standard.059-.413 (1.5-10.5)
Maximum.863 (21.00)
1999
Standard.045-.388 1.16-9.85)
Maximum.7092 (18.0)
(1) To measure bore warpage, insert a straightedge into camshaft bearing bores. Slide a feeler gauge between straightedge and bearing at each end of head. (2) No information available for 1999 model. (3) With timing chain and guides installed.
(1)To measure bore warpage, insert a straightedge into camshaft bearing bores. Slide a feeler gauge between straightedge and bearing at each end of head.
(2)No information available for 1999 model.
(3)With timing chain and guides installed.

CAMSHAFT & CAMSHAFT DRIVE (SOHC)

ApplicationIn. (mm)
Bore Diameter
Standard1.2992-1.3002 (33.000-33.025)
Maximum1.3004 (33.030)
Lifter Diameter
Standard1.2976-1.2982 (32.959-32.975)
Maximum1.2971 (32.947)
Oil Clearance
Standard.0010-.0026 (.025-.066)
Maximum.0033 (.083)

VALVE LIFTERS (1998 DOHC)

ApplicationIn. (mm)
Bore Diameter
Standard.4727-.4736 (12.008-12.030)
Maximum.4744 (12.040)
Lash Adjuster Body Diameter
Standard.4719-.4724 (11.986-12.000)
Minimum.4716 (11.980)
Oil Clearance
Standard.003-.0017 (.008-.044)
Maximum.0024 (.060)

VALVE LASH ADJUSTERS (1999 DOHC)

ApplicationIn. (mm)
Bore Diameter
Standard.8434-.8444 (21.422-21.448)
Maximum.8445 (21.450)
Lifter Diameter
Standard.8420-.8427 (21.387-21.405)
Minimum.8417 (21.380)
Oil Clearance
Standard.0007-.0024 (.017-.061)
Maximum.0028 (.070)
Lifter Length
Standard2.0563-2.0697 (52.230-52.570)
Minimum2.0531 (52.150)
Lifter Width (At Flats)
Standard.7551-.7598 (19.180-19.300)
Minimum.7539 (19.150)
Lifter Guide Plate Width
Standard.7634-.7685 (19.390-19.520)
Maximum.7632 (19.385)

VALVE LIFTERS (SOHC)