Saturn Engine >> CYLINDER BLOCK CAUTIONS FOR 1.9L ENGINES

Saturn Engine >> CYLINDER BLOCK CAUTIONS FOR 1.9L ENGINES

Cylinder Block Cautions For
1990-2000 GM 1.9L VIN 7, 8 &M 9 Engines

The AERA Technical Committee offers the following cylinder block cautions for 1990-2000 GM 1.9L VIN 7, 8 & 9 engines. These engines are used in Saturn vehicles and the information applies to both single and dual camshaft designs.

Cylinder block inspection:
Use extreme care and do not scratch any of the machined surfaces. It is recommended to use a plastic gasket scraper while cleaning machined surfaces of the aluminum block.

When cleaning the cylinder block, do not heat the block above 120°F (44°C) as additional heat may allow cylinder sleeve movement the cylinder head is removed.

Remove all traces of RTV sealer from all blind holes including oil pan, front cover and rear seal carrier boltholes with a 3/16 (4.76MM) drill. Doing so will reduce the likelihood of the casting cracking during assembly. (See Figure 1)

Clean the bolt holes and gasket surfaces with a chlorinated solvent such as carburetor spray clean, brake clean, or alcohol. Do not clean block with Petroleum based liquids, as they will leave a film unto which RTV sealer will not stick. (See Figure 2)

Check top of block for allowable flatness: (See Figure 3)
Width .0009 (0.24mm) to a max of .0020 (.050mm).
Length .0031 (0.80mm) to a max of .0040 (.100mm)
Liner Height should be flush +/- .0005 (.013mm).

Inspect cylinder liners for size:
Liner number?s 1,2 and 3 standard diameter is 3.2280-3.2287 (81.99-82.01mm) and the maximum standard diameter is 3.2297 (82.035mm).

Liner number 4 standard diameter is 3.2283-3.229 and the max standard diameter is 3.2301 (82.045mm).

Standard out of round and taper all .0004 (.010mm) max.
Service limit .0020 (.050mm) max.

Inspect cylinder liners for surface finish:
Deglazing can be done with a flex hone if the liners are the correct size and a 45° crosshatch is required as shown in Figure 4.
If oil consumption has occurred, honing is required with 380-450 grit stones.

If the cylinder bores require boring to an oversize diameter, remember the number 4 cylinder liner is .0004 (.010 mm) larger than the other three liners.

The AERA Technical Committee

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