Cylinder Head Assembly

Note: Install NEW cylinder head bolts.

Cylinder Head Bolt
Tighten the cylinder head bolts in sequence.
^ First Pass 30 Nm (22 ft. lbs.)
^ Final Pass 155 degrees
Cylinder Head Front Chaincase Bolt 35 Nm (26 ft. lbs.)
Cylinder Head Oil Gallery Plug 35 Nm (26 ft. lbs.)
Cam Cover to Cylinder Head Bolt 10 Nm (89 inch lbs.)
Cam Cover to Ground Cable Bolt 10 Nm (89 inch lbs.)
Cam Cover to Ground Cable Stud 10 Nm (89 inch lbs.)
Camshaft Bearing Cap Bolt
Tighten bolts in increments of 3 turns until they are seated.
Tighten bolts to 10 Nm (89 inch lbs.).
Camshaft Sprocket Bolt
^ First Pass 85 Nm (63 ft. lbs.)
^ Final Pass 30 degrees
Camshaft Timing Chain Tensioner 75 Nm (55 ft. lbs.)
Dipstick Guide to Intake Manifold Bolt 10 Nm (89 inch lbs.)
Drive Belt Tensioner Bolt 45 Nm (33 ft. lbs.)

Exhaust Manifold to Cylinder Head Nut 14 Nm (124 inch lbs.)
Exhaust Manifold to Cylinder Head Stud 10 Nm (89 inch lbs.)
Exhaust Manifold Pipe Flange Stud 16 Nm (12 ft. lbs.)
Front Cover to Block Bolt 25 Nm (18 ft. lbs.)
Intake Camshaft Rear Cap Bolt 25 Nm (18 ft. lbs.)
Intake Manifold to Cylinder Head Bolt 10 Nm (89 inch lbs.)
Intake Manifold to Cylinder Head Nut 10 Nm (89 inch lbs.)
Intake Manifold to Cylinder Head Stud 6 Nm (53 inch lbs.)
Lower Crankcase to Block Peripheral Bolt 25 Nm (18 ft. lbs.)
Thermostat Housing to Block Bolts 10 Nm (89 inch lbs.)
Throttle Body Bolt 10 Nm (89 inch lbs.)
Throttle Body Nut 10 Nm (89 inch lbs.)
Throttle Body Stud 6 Nm (53 inch lbs.)
Timing Adjustable Chain Guide Bolt 10 Nm (89 inch lbs.)
Timing Chain Oil Nozzle Bolt 10 Nm (89 inch lbs.)
Timing Fixed Chain Guide Bolt 10 Nm (89 inch lbs.)
Timing Upper Chain Guide Bolt 10 Nm (89 inch lbs.)
^ Engine Type Inline 4 Cylinder
^ Displacement 2.2 L (134 CID)
^ RPO L61
^ Liter (VIN) F
^ Bore 85.992 - 86.008 mm (3.3855 - 3.3861 in)
^ Compression Ratio 10:01
Balance Shaft
^ Bearing Clearance 0.030 - 0.063 mm (0.0012 - 0.0025 in)
^ Bearing Diameter - Inside - Carrier 20.050 - 20.063 mm (0.7894 - 0.7899 in)
^ Bearing Diameter - Outside - Carrier 41.975 - 41.995 mm (1.6526 - 1.6534 in)
^ Bearing Journal Diameter 20.000 - 20.020 mm (0.7874 - 0.7882 in)
^ Bushing Clearance 0.033 - 0.102 mm (0.0013 - 0.0040 in)
^ Bushing Diameter - Inside 36.776 - 36.825 mm (1.4479 - 1.4498 in)
^ Bushing Journal Diameter 36.723 - 36.743 mm (1.4458 - 1.4466 in)
^ End Play 0.100 - 0.300 mm (0.0020 - 0.0118 in)
Block
^ Balance Shaft Bearing Bore Diameter - Carrier 42.000 - 42.016 mm (1.6535 - 1.6542 in)
^ Balance Shaft Bushing Bore Diameter 40.763 - 40.776 mm (1.6048 - 1.6054 in)
^ Crankshaft Main Bearing Bore Diameter 64.068 - 64.082 mm (2.5224 - 2.5229 in)
^ Cylinder Bore Diameter 85.992 - 86.008 mm (3.3855 - 3.3861 in)
^ Cylinder Bore Out-of-Round - Maximum 0.010 mm (0.0004 in)
^ Cylinder Bore Taper - Maximum 0.010 mm (0.0004 in)
^ Cylinder Head Deck Surface Flatness - Transverse 0.030 mm (0.0012 in)
^ Cylinder Head Deck Surface Flatness - Longitude 0.050 mm (0.002 in)
^ Cylinder Head Deck Surface Flatness - Overall 0.08 mm (0.0031 in)
Camshaft
^ Camshaft End Play 0.040 - 0.144 mm (0.0016 - 0.0057 in)
^ Camshaft Journal Diameter 26.935 - 26.960 mm (1.0604 - 1.0614 in)
^ Camshaft Thrust Surface 21.000 - 21.052 mm (0.8268 - 0.8252 in)
Connecting Rod
^ Connecting Rod Bearing Clearance 0.029 - 0.069 mm (0.0011 - 0.0027 in)
^ Connecting Rod Bore Diameter - Bearing End 52.118 - 52.134 mm (2.0519 - 2.05252 in)
^ Connecting Rod Bore Diameter - Pin End 20.007 - 20.021 mm (0.7877 - 0.7882 in)
^ Connecting Rod Side Clearance 0.070 - 0.370 mm (0.0028 - 0.0146 in)
^ Connecting Rod Straightness - Bend - Maximum 0.021 mm (0.0083 in)
^ Connecting Rod Straightness - Twist - Maximum 0.04 mm (0.0157 in)
Crankshaft
^ Connecting Rod Journal Diameter 49.000 - 49.014 mm (1.9291 - 1.9297 in)
^ Crankshaft End Play 0.050 - 0.380 mm (0.0012 - 0.0150 in)
^ Crankshaft Main Bearing Clearance 0.031 - 0.067 mm (0.0012 - 0.0026 in)
^ Crankshaft Main Journal Diameter 55.994 - 56.008 mm (2.2045 - 2.2050 in)
Cylinder Head
^ Surface Flatness - Block Deck - Transverse 0.030 mm (0.0012 in)
^ Surface Flatness - Block Deck - Longitude 0.050 mm (0.002 in)
^ Surface Flatness - Block Deck - Overall 0.1 mm (0.004 in)
^ Valve Guide Bore - Exhaust 6.000 - 6.012 mm (0.2362 - 0.2367 in)
^ Valve Guide Bore - Intake 6.000 - 6.012 mm (0.2362 - 0.2367 in)
^ Valve Lifter Bore Diameter - Stationary Lash Adjusters 12.013 - 12.037 mm (0.4730 - 0.4739 in)
Lubrication System
^ Oil Pressure - Minimum - @1000 RPM 344.75 - 551.60 kPa (50 - 80 psi)
^ Oil Capacity - with Filter 4.8L (5.0 quarts)
^ Oil Capacity - without Filter 4.3L (4.5 quarts)
Piston Rings
^ Piston Ring End Gap - First Compression Ring 0.20 - 0.40 mm (0.008 - 0.016 in)
^ Piston Ring End Gap - Second Compression Ring 0.35 - 0.55 mm (0.014 - 0.022 in)
^ Piston Ring End Gap - Oil Control Ring - Rails 0.25 - 0.76 mm (0.010 - 0.030 in)
^ Piston Ring to Groove Clearance - First Compression Ring 0.04 - 0.08 mm (0.0015 - 0.0031 in)
^ Piston Ring to Groove Clearance - Second Compression Ring 0.030 - 0.069 mm (0.0012 - 0.0027 in)
^ Piston Ring to Groove Clearance - Oil Control Ring 0.090 - 0.106 mm (0.0035 - 0.0042 in)
^ Piston Ring Thickness - First Compression Ring 1.170 - 1.190 mm (0.0461 - 0.0469 in)
^ Piston Ring Thickness - Second Compression Ring 1.471 - 1.490 mm (0.0579 - 0.0587 in)
^ Piston Ring Thickness - Oil Control Ring - Rail - Maximum 0.43 mm (0.0169 in)
^ Piston Ring Thickness - Oil Control Ring - Spacer 1.574 - 1.651 mm (0.0620 - 0.0650 in)
Pistons and Pins
^ Piston - Piston Diameter - @14.5 mm up 85.967 - 85.982 mm (3.3845 - 3.3851 in)
^ Piston - Piston Pin Bore Diameter 20.002 - 20.007 mm (0.07875 - 0.7877 in)
^ Piston - Piston Ring Grove Width - Top 1.23 - 1.25 mm (0.0484 - 0.0492 in)
^ Piston - Piston Ring Grove Width - Second 1.52 - 1.54 mm (0.0598 - 0.0606 in)
^ Piston - Piston Ring Grove Width - Oil Control 2.52 - 2.54 mm (0.0992 - 0.1000 in)
^ Piston - Piston To Bore Clearance 0.010 - 0.041 mm (0.0004 - 0.0016 in)
^ Pin - Piston Pin Clearance to Connecting Rod Bore 0.007 - 0.026 mm (0.0003 - 0.0010 in)
^ Pin - Piston Pin Clearance to Piston Pin Bore 0.002 - 0.012 mm (0.0001 - 0.0005 in)
^ Pin - Piston Pin Diameter 19.995 - 20.000 mm (0.7872 - 0.7874 in)
^ Pin - Piston Pin End Play 0.19 - 1.16 mm (0.0075 - 0.0461 in)
Valve System
^ Valves - Valve Face Runout - Maximum 0.04 mm (0.0016 in)
^ Valves - Valve Seat Runout - Maximum 0.05 mm (0.0020 in)
^ Valves - Valve Stem Diameter - Intake 5.955 - 5.970 mm (0.2344 - 0.2355 in)
^ Valves - Valve Stem Diameter - Exhaust 5.935 - 5.950 mm (0.2337 - 0.2343 in)
^ Valves - Valve Stem to Guide Clearance - Intake 0.030 - 0.057 mm (0.0012 - 0.0022 in)
^ Valves - Valve Stem to Guide Clearance - Exhaust 0.050 - 0.077 mm (0.0020 - 0.0026 in)
^ Valve Lifters - Valve Lifter Diameter - Stationary Lash Adjuster 11.986 - 12.000 mm (0.0005 - 0.0020 in)
^ Valve Lifters - Valve Lifter-to-Bore Clearance - Stationary Lash Adjuster 0.013 - 0.051 mm (3.2210 - 3.2299 in)
^ Valve Springs - Valve Spring Load - Closed - @22.5 mm 245.0 - 271.0 N. - Eng Spec.
^ Valve Springs - Valve Spring Load - Open - @32.5 mm 525.0 - 575.0 N. - Eng Spec.