For 1990-2009 cars

# 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
· 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·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·m | 15 lb ft
A/C Compressor Bracket Bolt | 40 N·m | 30 lb ft
A/C Compressor Bracket Bolt - L81 | 40 N·m | 30 lb ft
A/C Compressor and Power Steering Pump Bracket Bolts | 40 N·m | 30 lb ft
Air Box Mount Bolt | 6 N·m | 53 lb in
Battery Terminal Bolts | 17 N·m | 13 lb ft
Belt Tensioner Bolts | 40 N·m | 30 lb ft
Brake Vacuum Line | 20 N·m | 15 lb ft
Camshaft Bearing Cap Bolt | 8 N·m | 71 lb in
Camshaft Cover Bolts | 8 N·m | 71 lb ft
Camshaft Gear Bolt

- First Pass

50 N·m

37 lb ft

- Second Pass

60 degrees

- Final Pass

15 degrees

Camshaft Sprocket Bolt

- First Pass

50 N·m

37 lb ft

- Second Pass

60 degrees

- Final Pass

15 degrees

Connecting Rod Cap Bolts

- First Pass

35 N·m

26 lb ft

- Second Pass

45 degrees

- Final Pass

15 degrees

Coolant Bridge Bolt | 30 N·m | 22 lb ft
Coolant Extension Housing Bolt | 20 N·m | 15 lb ft
Coolant Intake Housing Bolts | 20 N·m | 15 lb ft
Coolant Pipe/Engine Lift Bracket Bolt | 20 N·m | 15 lb ft
Crankshaft Balancer Bolt | 20 N·m | 15 lb ft
Crankshaft Bearing Bridge Adjusting Sleeves | 8 N·m | 71 lb in
Crankshaft Bearing Bridge Bolts | 20 N·m | 15 lb ft
Crankshaft Bearing Cap

- First Pass

50 N·m

37 lb ft

- Second Pass

60 degrees

- Final Pass

15 degrees

Crankshaft Drive Gear Bolt - L81

- First Pass

250 N·m

184 lb ft

- Second Pass

45 degrees

- Final Pass

15 degrees

Crankshaft Position Sensor Bolt | 8 N·m | 71 lb in
Crankshaft Reluctor Ring Screw | 15 N·m | 11 lb ft
Cylinder Head Bolt

- First Pass

25 N·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·m | 71 lb in
EGR Pipe Bolts | 25 N·m | 18 lb ft
Engine Control Module Bolts | 8 N·m | 71 lb in
Engine Lift Bracket Bolts | 8 N·m | 71 lb in
Engine Mount Bracket Bolt | 55 N·m | 41 lb ft
Engine Mount-to-Bracket Bolt | 55 N·m | 41 lb ft
Engine Mount-to-Frame Bolt | 55 N·m | 41 lb ft
Engine Oil Cooler Cover Bolt | 20 N·m | 15 lb ft
Engine Oil Cooler Inlet and Outlet Nut | 30 N·m | 22 lb ft
Engine Oil Pipe to Heat Exchanger
First Pass | 30 N·m | 22 lb ft
Second Pass | 15 °
Engine Ventilation Chamber Bolts | 8 N·m | 71 lb in
Exhaust Manifold Nut | 20 N·m | 15 lb ft
Exhaust Manifold Pipe-to-Exhaust Manifold Nuts | 30 N·m | 22 lb ft
Flex Plate Bolt

- First Pass

65 N·m

48 lb ft

- Second Pass

30 degrees

- Final Pass

15 degrees

Front Timing Belt Cover Bolt | 8 N·m | 71 lb in
Fuel Rail Bolts | 8 N·m | 71 lb in
Generator Mounting Bolts | 35 N·m | 26 lb ft
Idler Pulley Bolt | 40 N·m | 30 lb ft
Idler Pulley Fastener | 40 N·m | 30 lb ft
Ignition Module Bolt | 8 N·m | 71 lb in
Intake Manifold Bolt Upper to Lower | 20 N·m | 15 lb ft
Intake Manifold Runner Bolts | 8 N·m | 71 lb in
Intake Manifold Runner Bracket Bolt | 20 N·m | 15 lb ft
Intake Manifold Spacer Bolt Flange | 16N·m | 12 lb ft
Intake Plenum Bolts | 8 N·m | 71 lb in
Lower Engine-to-Transaxle Bell Housing Bolts | 65 N·m | 48 lb ft
Nose Cone Bracket-to-Oil Pan Bolts - Transaxle Nose Bracket Bolts | 40 N·m | 30 lb ft
Oil Cooler Feed and Return Lines to Engine Block | 30 N·m | 22 lb ft
Oil Drain Plug | 10N·m | 90 lb in
Oil Filter Cap | 15N·m | 11 lb ft
Oil Filter Cartridge Housing-to-Engine | 45 N·m | 33 lb ft
Oil Level Indicator Tube Bolt | 20N·m | 15 lb ft
Oil Pan Baffle Bolt - L81 | 8N·m | 71 lb in
Oil Pan Bolts | 15N·m | 11 lb ft
Oil Pickup Tube Bolts | 8N·m | 71 lb in
Oil Pump Bolts | 28N·m | 21 lb ft
Oxygen Sensors - Exhaust Manifold | 45N·m | 33 lb ft
Power Steering Pump Bolts | 20N·m | 15 lb ft
Power Steering Pump Pulley Bolt
First Pass | 20N·m | 15 lb ft
Second Pass | 30 degrees
Final Pass | 15 degrees
Rear Timing Belt Cover Bolt | 8N·m | 71 lb ft
Rear Timing Belt Cover Threaded Pin | 10 N·m | 89 lb in
Spark Plug | 25N·m | 18 lb ft
Thermostat Housing Bolts | 20N·m | 15 lb ft
Throttle Body Nut | 8N·m | 71 lb in
Timing Belt Tensioner Bracket Bolt | 40N·m | 30 lb ft
Timing Belt Tensioner Fastening Nut | 20N·m | 15 lb ft
Torque Converter Bolts | 65N·m | 48 lb ft
Transaxle Mount Through Bolt | 55N·m | 41 lb ft
Transaxle-to-Oil Pan Bolts | 65N·m | 48 lb ft
Upper Bell Housing Bolts | 65N·m | 48 lb ft
Upper Pulley Bolt | 40N·m | 30 lb ft
Ventilation Housing Bolts | 8N·m | 71 lb in
Water Pump Bolt | 25N·m | 18 lb ft
Water Pump Pulley Bolt
First Pass | 8N·m | 71 lb in
Second Pass | 30 degrees
Third Pass | 30 degrees
Wheel Bolts | 125N·m | 92 lb ft