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HOMESERVICE MANUALSSATURN2000SW2 AUTOMATICREPAIR AND DIAGNOSISENGINE MECHANICALMECHANICAL1.9L 4-CYLINDERENGINE SPECIFICATIONS

2000 Saturn SW2 Automatic

Engine Specifications

2000 Saturn SW2 AutomaticSECTION Engine Specifications

GENERAL SPECIFICATIONS

Application		Specification
Displacement		1.9L (116 Cu. In)
Bore		3.2" (82 mm)
Stroke		3.5" (90 mm)
Compression Ratio
DOHC		9.5:1
SOHC		9.3:1
Fuel System		MFI

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

Application			In. (mm)
Crankshaft
End Play
Standard			.002-.008 (.05-.20)
Maximum			.010 (.25)
Runout			.002 (.05)
Main Bearings
Journal Diameter
Standard			2.2438-2.2444 (56.993-57.007)
Minimum			2.2437 (56.990)
Journal Out-Of-Round			.0004 (.010)
Journal Taper			.0004 (.010)
Oil Clearance
Standard			.0002-.0020 (.006-.050)
Maximum			.0022 (.055)
Connecting Rod Bearings
Journal Diameter			1.8500-1.8508 (46.990-47.010)
Journal Out-Of-Round			.0004 (.010)
Journal Taper			.0004 (.010)
Oil Clearance
Standard			.0001-.0021 (.003-.053)
Maximum			.0022 (.055)

CONNECTING RODS

Application

In. (mm)

Pin Bore Diameter (Bushing)

Standard

.7679-.7683 (19.505-19.517)

Maximum

.7685 (19.520)

Crankpin Bore Diameter

1.9761-1.9767 (50.193-50.207)

Maximum Bend ⁽¹⁾

.0126 (.320)

Maximum Twist ⁽¹⁾

.0063 (.160)

Side Clearance

Standard

.0065-.0171 (.165-.435)

Maximum

.0185 (.470)

⁽¹⁾	Per 4" of rod length.

PISTONS, PINS & RINGS

Application

In. (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.

CYLINDER BLOCK

Application

In. (mm)

Cylinder Bore

Diameter

Cylinders No. 2 & 3

Standard

3.2280-3.2287 (81.990-82.010)

Maximum Wear

3.2297 (82.035)

Cylinder No. 1 & 4

Standard

3.2283-3.2291 (82.000-82.020)

Maximum Wear

3.2301 (82.045)

Maximum Taper

.0020 (.050)

Maximum Out-Of-Round

.0020 (.050)

Cylinder Liner Protrusion

Standard

Flush 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.

VALVES & VALVE SPRINGS (DOHC)

Application			Specification
Valve Face Angle			45-45.5°
Valve Head Minimum Margin			.030" (.75 mm)
Valve Installed Height
Standard			1.548-1.567" (39.31-39.98 mm)
Minimum			1.548" (39.31 mm)
Maximum			1.586" (40.28 mm)
Valve Length
Intake
Standard			3.793-3.817 (96.28-96.74 mm)
Minimum			3.787" (96.20 mm)
Maximum			3.812" (96.74 mm)
Exhaust
Standard			3.766-3.784" (95.58-96.04 mm)
Minimum			3.760" (95.50 mm)
Maximum			3.784" (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 Length			1.56" (40.1 mm)
Out-Of-Square
Standard			.08" (2.0 mm)
Maximum			.10" (2.5 mm)
Lbs. @ In. (kg @ mm)
Pressure (Minimum)
Valve Closed			40 @ 1.22 (18 @ 31.0)
Valve Open			94 @ .85 (42 @ 21.5)

VALVES & VALVE SPRINGS (SOHC)

Application			Specification
Valve Face Angle			45.0-45.5°
Valve Length
Intake
Standard			5.4539-5.4744" (138.53-139.05 mm)
Minimum			5.4520" (138.48 mm)
Maximum			5.4764" (139.10 mm)
Exhaust
Standard			5.4618-5.4823" (138.73-139.25 mm)
Minimum			5.4598" (138.68 mm)
Maximum			5.4843" (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
Standard			1.900-1.919" (48.25-48.75 mm)
Maximum			1.921" (48.80 mm)
Valve Springs
Free Length			1.89-1.91" (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 Closed			75 @ 1.61 (33 @ 41.0)
Valve Open			196 @ 1.28 (87 @ 30.0)

CYLINDER HEAD (DOHC)

Application				Specification
Maximum Warpage
Head Gasket Surface
Longitudinal (Lengthwise)				.0028" (.07 mm)
Transverse (Across)				.0012" (.03 mm)
Manifold Surfaces				.004" (.10 mm)
Valve Seat Angle				44.5-45.0°
Valve Seat Width
Intake
Standard				.031-.048" (.79-1.23 mm)
Maximum				.065" (1.66 mm)
Exhaust
Standard				.041-.058 (1.05-1.49 mm)
Maximum				.076" (1.92 mm)
Valve Seat Bore Diameter
Intake				1.315-1.316" (33.40-33.42 mm)
Exhaust				1.118-1.119" (28.40-28.42 mm)
Valve Seat Insert Diameter
Intake				1.319" (33.50 mm)
Exhaust				1.122" (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
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-.0030" (.037-.076 mm)
Maximum				.0052" (.131 mm)

CYLINDER HEAD (SOHC)

Application				Specification
Maximum Warpage
Head Gasket Surface
Longitudinal (Lengthwise)				.0028" (.07 mm)
Transverse (Across)				.0012" (.03 mm)
Manifold Surfaces				.004" (.10 mm)
Valve Seat Angle				44.5-45.5°
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
Intake				1.6333-1.6344" (41.487-41.513 mm)
Exhaust				1.377-1.3785" (34.987-35.013 mm)
Valve Seat Insert Diameter
Intake				1.6367-1.6378" (41.573-41.599 mm)
Exhaust				1.3808-1.3819" (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)

CAMSHAFT & CAMSHAFT DRIVE (DOHC)

Application

In. (mm)

Bore Diameter

Standard

1.0638-1.0648 (27.000-27.026)

Maximum

1.0658 (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

Standard

1.0618-1.0626 (268.950-26.970)

Minimum

1.0608 (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

.0021-.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.

CAMSHAFT & CAMSHAFT DRIVE (SOHC)

Application

In. (mm)

Bore Diameter

Standard

1.7510-1.7520 (44.475-44.500)

Maximum

1.7525 (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

Standard

1.7480-1.7490 (44.399-44.424)

Minimum

1.7470 (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⁾

Standard

16.50-16.61 (419.0-422.0)

Maximum

16.73 (425.0)

Chain Tensioner Plunger Travel ⁽³⁾

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⁾	Information unavailable from manufacturer.

⁽³⁾	With timing chain and guides installed.

VALVE LASH ADJUSTERS (DOHC)

Application		In. (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 LIFTERS (SOHC)

Application		In. (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
Standard		2.0563-2.0697 (52.230-52.570)
Minimum		2.0531 (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)

RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

• You smell fuel, burning insulation, or see smoke.
• Brakes feel soft, pull hard to one side, or make grinding noises.
• The engine overheats, stalls repeatedly, or misfires under load.
• You are missing required tools, torque specs, or safe lifting equipment.
• You are not confident in the next step or safety outcome.