GM Service Manual Online
For 1990-2009 cars only

Application

Specification

Metric

English

Engine Performance

Engine

4-Cylinder/In-Line

Bore x Stroke

87.5 x 100 mm

3.44 x 3.94 in

Displacement

2,405 cm³

147 in³

Ignition Sequence

1-3-4-2

Compression Ratio

9.6 : 1

Maximum Power

T.B.D

Maximum Torque

T.B.D

Idle Speed

Air Conditioning System (ON/OFF)

690 RPM

Engine Part

Ignition Type

Direct Ignition System (DIS)

Starter

  • Type
  • Capacity

PG 260D (M/T, A/T)

1.4 kW (M/T, A/T)

Spark-Plug

  • Type

FLR8LDCU (Bosch)

  • Cap

0.9-1.1 mm

0.035-0.043 in

Fuel Injection Type

MPI

Fuel Pump Type

Electric Motor Pump

Fuel Filter Type

Cartridge

Lubricating Type

Forced Feed Type

Oil Pump Type

Rotary (Trochoid) Pump

Cooling Type

Forced Water Circulation

Radiator Type

Cross - Flow

Water Pump Type

Centrifugal

Thermostat Type

Pellet Type

Battery

  • Type
  • Rating (V-AH)
  • Cold Cranking Ampere (CCA)

MF

12V-60AH

650

Generator

  • Type
  • Rating (V-AH)

AD 237

14.6±0.25 V - 120AH

Engine Oil

  • Type

API SL (ILSAC GF-III) grade SAE 5W-30 * Hot area : SAE 10W-30

  • Engine Disassembly

4.5 L

4.7 qt

  • Oil Change (Including Oil Filter)

4.5 L

4.75 qt

  • Oil Change (Excluding Oil Filter)

4.3 L

4.54 qt

Coolant

  • Type

Dexcool

  • Capacity

9 L

9.51 qt

Fuel Tank Capacity

65 L

17.2 gal

General Data

Engine Type

4 Cylinder (In-Line)

Displacement

2,405 cm³

Bore Stroke

87.5 X 100 mm

3.44 X 3.94 in

Compression Ratio

9.6:1

Firing Order

1-3-4-2

Maximum Power

hp

kw

Maximum Torque

N·m

lb ft

Cylinder Bore

Diameter

8.75485-87.505 mm

3.444-3.445 in

Out Of Round (MAX)

0.013 mm

0.0005 in

Taper (MAX)

0.013 mm

0.0005 in

Piston Protrusion

0 mm

0 in

Oversize (Measure Replacement Piston Before Reboring

available in 0.50 mm (0.019 in) to suit bore

Block Face Distortion

0.01 mm MAX

0.00039 in

Piston

Diameter

87.465-87.485 mm

3.443-3.445 in

Clearance To Bore

0.010-0.030 mm

0.00039-0.0020 in

Ring Groove Width

  • Top
  • Second
  • Oil

TBD

TBD

Ring Groove Inner Diameter

  • Top
  • Second
  • Oil

TBD

TBD

Piston Rings

Top Compression Ring End Gap

0.3-0.5 mm

0.011-0.019 in

Second Compression Ring End Gap

0.3-0.5 mm

0.011-0.019 in

Oil Ring End Gap

0.4-1.4 mm

0.0015-0.055 in

Piston Ring With

  • Top
  • Second
  • Oil

TBD

TBD

Piston Ring Thickness

  • Top
  • Second
  • Oil

TBD

TBD

Ring Groove Clearance

  • Top
  • Second
  • Oil

TBD

TBD

Piston Pin

Diameter

20.9910-20.9970 mm

0.82641-0.82665 in

Pin Offset

0.7-0.9 mm

0.275-0.0354 in toward thrust side

Clearance: In Piston

0.011-0.014 mm

0.00043-0.00055 in

Clearance: In Rod

interference fit in rod

Length

61.5 mm

2.42 in

Camshaft

Valve Lift

  • Intake
  • Exhaust

9.2 mm

9.2 mm

0.36 in

0.36 in

Camshaft Cap To Bearing Journal Clearance

0.04-0.144 mm

0.0015-0.0056 in

Bearing Journal OD

42.455-43.470 mm

1.6714-1.7114 in

Crankshaft

Main Journal - Diameter (All)

57.982-57.995 mm

2.2788-2.2833 in

Main Journal - Radial Runout (Shaft Support On No. 1 And No. 5 Bearings Measured At No.3 Journal)

0.03 mm

0.00118 in

Main Bearing Clearance (All)

0.015-0.040 mm

0.00059-0.00157 in

End Play

0.070-0.302 mm

0.0027-0.0118 in

Service Oversize (Available In 2 Sizes)

0.25 and 0.5 mm

0.00098 and 0.019 in

Connecting Rod Journal

Diameter (All)

48.970-48.988 mm

1.9279-1.9287 in

Out Of Round (Max)

0.004 mm

0.00015 in

Rod Bearing Play

0.006-0.031 mm

0.00023-0.00122 in

Rod Bearing Clearance

0.013~0.041 mm

0.0005-0.0016 in

Cylinder Head

Valve Stem Protrusion

39.2 mm MAX

1.544 in

Valve Guide Height

13.7-14.0 mm

0.53-0.55 in

Overall Height

133.975-134.025 mm

5.2741-5.2759 in

Minimum Overall Height After Machining

133.9 mm

5.271 in

Valve System

Valve Lash Compensators

Hydraulic

Seat Runout (MAX, All)

0.03 mm

0.0018 in

Face Runout (MAX, All)

0.03 mm

0.0018 in

Valve Diameter

  • Intake
  • Exhaust

32±0.1 mm

29± 0.1 mm

1.2598± 0.0039 in

1.1417±0.00039 in

Valve Stem Diameter

  • Intake
  • Exhaust

5.955-5.970 mm

5.945-5.960 mm

0.234-0.235 in

0.2346-0.2360 in

Valve Seat Width

  • Intake
  • Exhaust

1.0-1.5 mm

1.7-2. mm

0.039-0.059 in

0.066-0.086 in

Valve Face Angle

44°

Valve Seat Angle

45°

Valve Guide Inside Diameter

6.000-6.012 mm

0.2362-0.2367 in

Oil Pump

Type

Rotary (Trochoild)

Gear Lash

0.10-0.20 mm

0.0040-0.008 in

Outer Gear to Body

0.11-0.19 mm

0.0043-0.0074 in

Outer Gear to Crescent

0.11-0.24 mm

0.0043-0.009 in

Inner Gear to Crescent

0.18-0.26 mm

0.007-0.010 in

End Clearance

0.03-0.10 mm

0.001-0.004 in