Engine Engine Mechanical - 4.8L, 5.3L, and 6.0L 6-1 Engine ...
Engine
Engine Mechanical - 4.8L, 5.3L, and 6.0L
Engine Mechanical - 4.8L, 5.3L, and 6.0L
Specifications
SIE-ID = 890258
LMD = 07-jun-2002
Fastener Tightening Specifications
Specification
Application
Air Cleaner Outlet Duct Clamp
Metric
English
7 Nm
62 lb in
Air Conditioning Belt Tensioner Bolt
50 Nm
37 lb ft
Battery Cable Channel Bolt
12 Nm
106 lb in
Camshaft Retainer Bolts
25 Nm
18 lb ft
Camshaft Sensor Bolt
25 Nm
18 lb ft
Camshaft Sprocket Bolts
35 Nm
26 lb ft
Connecting Rod Bolts C First Pass
20 Nm
15 lb ft
Connecting Rod Bolts C Final Pass
75 degrees
Coolant Temperature Gage Sensor
20 Nm
15 lb ft
Crankshaft Balancer Bolt C Installation Pass C to Ensure the Balancer is
Completely Installed
330 Nm
240 lb ft
Crankshaft Balancer Bolt C First Pass C Install a NEW Bolt After the
Installation Pass and Tighten as Described in the First and Final Passes
50 Nm
37 lb ft
Crankshaft Balancer Bolt C Final Pass
Crankshaft Bearing Cap Bolts C Inner Bolts C First Pass in Sequence
140 degrees
20 Nm
Crankshaft Bearing Cap Bolts C Inner Bolts C Final Pass in Sequence
Crankshaft Bearing Cap Bolts C Outer Bolts C First Pass in Sequence
15 lb ft
80 degrees
20 Nm
Crankshaft Bearing Cap Bolts C Outer Bolts C Final Pass in Sequence
15 lb ft
51 degrees
Crankshaft Bearing Cap Side Bolts
25 Nm
18 lb ft
Crankshaft Oil Deflector Nuts
25 Nm
18 lb ft
Crankshaft Position Sensor Bolt
25 Nm
18 lb ft
Crossbar Bolt
100 Nm
74 lb ft
Cylinder Head Bolts C First Pass all M11 Bolts in Sequence
30 Nm
22 lb ft
Cylinder Head Bolts C Second Pass all M11 Bolts in Sequence
90 degrees
Cylinder Head Bolts C Final Pass all M11 Bolts in Sequence C
Excluding the Medium Length Bolts at the Front and Rear of Each
Cylinder Head
90 degrees
Cylinder Head Bolts C Final Pass M11 Medium Length Bolts at the
Front and Rear of Each Cylinder Head in Sequence
50 degrees
Cylinder Head Bolts C M8 Inner Bolts in Sequence
30 Nm
22 lb ft
Cylinder Head Coolant Plug
20 Nm
15 lb ft
Differential Carrier Lower Mounting Bolt/Nut
100 Nm
74 lb ft
Drive Belt Idler Pulley Bolt
50 Nm
37 lb ft
Drive Belt Tensioner Bolt
50 Nm
37 lb ft
Engine Block Coolant Drain Plugs
60 Nm
44 lb ft
Engine Block Heater
40 Nm
30 lb ft
Engine Block Oil Gallery Plugs
60 Nm
44 lb ft
Engine Coolant Air Bleed Pipe and Cover Bolts
12 Nm
106 lb in
Engine Flywheel Bolts C First Pass
20 Nm
15 lb ft
Engine Flywheel Bolts C Second Pass
50 Nm
37 lb ft
Engine Flywheel Bolts C Final Pass
100 Nm
74 lb ft
Engine Front Cover Bolts
25 Nm
18 lb ft
Engine Harness Ground Bolt C Right Rear
16 Nm
12 lb ft
2003 - C/K 800 Utility (June 11, 2002)
6-1
6-2
Engine Mechanical - 4.8L, 5.3L, and 6.0L
Engine
Fastener Tightening Specifications (contd)
Specification
Application
Metric
English
Engine Harness Ground Bolt to Block
25 Nm
18 lb ft
Engine Rear Cover Bolts
25 Nm
18 lb ft
Engine Service Lift Bracket M10 Bolts
50 Nm
37 lb ft
Engine Service Lift Bracket M8 Bolt
25 Nm
18 lb ft
Engine Shield Bolt
20 Nm
15 lb ft
Engine Valley Cover Bolts
25 Nm
18 lb ft
Engine Wiring Harness Bracket Nut
5 Nm
44 lb in
Evaporative Emission (EVAP) Purge Solenoid Bolt
10 Nm
89 lb in
Exhaust Manifold Bolts C First Pass
15 Nm
11 lb ft
Exhaust Manifold Bolts C Final Pass
25 Nm
18 lb ft
Exhaust Manifold Heat Shield Bolts
9 Nm
80 lb in
Fuel Rail Bolts
10 Nm
89 lb in
9 Nm
80 lb in
3.8 Nm
34 lb in
Fuel Rail Cover Bolt
Fuel Rail Crossover Tube Bolts
Fuel Rail Stop Bracket Bolt
50 Nm
37 lb ft
Generator Bracket Bolt
50 Nm
37 lb ft
Generator Cable Nut
9 Nm
80 lb in
Heater Hose Bracket Nut
9 Nm
80 lb in
Hood Hinge Bolt
25 Nm
18 lb ft
Ignition Coil-to-Bracket Bolts
8 Nm
71 lb in
Ignition Coil Bracket-to-Valve Rocker Arm Cover Bolts
12 Nm
106 lb in
Inner Axle Housing Nut
100 Nm
74 lb ft
Intake Manifold Bolts C First Pass in Sequence
5 Nm
44 lb in
Intake Manifold Bolts C Final Pass in Sequence
10 Nm
89 lb in
Intake Manifold Sight Shield Bolts
10 Nm
89 lb in
Intake Manifold Sight Shield Bracket Bolts
5 Nm
45 lb in
Intake Manifold Sight Shield Retainer Bolt
5 Nm
44 lb in
Intake Manifold Wiring Harness Stud
10 Nm
89 lb in
Knock Sensors
20 Nm
15 lb ft
Oil Filter
30 Nm
22 lb ft
Oil Filter Fitting
55 Nm
40 lb ft
Oil Level Indicator Tube Bolt
25 Nm
18 lb ft
Oil Level Sensor
13 Nm
115 lb in
Oil Pan Baffle Bolts
12 Nm
106 lb in
Oil Pan Closeout Cover Bolt C Left Side
9 Nm
80 lb in
Oil Pan Closeout Cover Bolt C Right Side
9 Nm
80 lb in
Oil Pan Cover Bolts
12 Nm
106 lb in
Oil Pan Drain Plug
25 Nm
18 lb ft
Oil Pan M8 Bolts C Oil Pan-to-Engine Block and Oil Pan-to-Front Cover
25 Nm
18 lb ft
Oil Pan M6 Bolts C Oil Pan-to-Rear Cover
12 Nm
106 lb in
Oil Pan Skid Plate Bolt
20 Nm
15 lb ft
Oil Pressure Sensor
20 Nm
15 lb ft
Oil Pump-to-Engine Block Bolts
25 Nm
18 lb ft
Oil Pump Cover Bolts
12 Nm
106 lb in
Oil Pump Relief Valve Plug
12 Nm
106 lb in
Oil Pump Screen Nuts
25 Nm
18 lb ft
Oil Pump Screen-to-Oil Pump Bolt
12 Nm
106 lb in
2003 - C/K 800 Utility (June 11, 2002)
Engine
Engine Mechanical - 4.8L, 5.3L, and 6.0L
Fastener Tightening Specifications (contd)
Specification
Application
Metric
English
Positive Battery Cable Clip Bolt
9 Nm
80 lb in
Power Steering Pump Rear Bolt
50 Nm
37 lb ft
Spark Plugs C New Cylinder Heads
20 Nm
15 lb ft
Spark Plugs C All Subsequent Installations
15 Nm
11 lb ft
Throttle Body Nuts
10 Nm
89 lb in
Throttle Body Studs
6 Nm
53 lb in
Torque Converter Bolt C 4L60-E/4L65-E
63 Nm
47 lb ft
Torque Converter Bolt C 4L80-E/4L85-E
60 Nm
44 lb ft
Transmission Bolt/Stud
50 Nm
37 lb ft
Transmission Cover Bolt
12 Nm
106 lb in
Transmission Oil Level Indicator Tube Nut
18 Nm
13 lb ft
Valve Lifter Guide Bolts
12 Nm
106 lb in
Valve Rocker Arm Bolts
30 Nm
22 lb ft
Valve Rocker Arm Cover Bolts
12 Nm
106 lb in
Water Inlet Housing Bolts
15 Nm
11 lb ft
Water Pump Bolts C First Pass
15 Nm
11 lb ft
Water Pump Bolts C Final Pass
30 Nm
22 lb ft
Water Pump Cover Bolts
15 Nm
11 lb ft
SIE-ID = 823792
LMD = 03-jun-2002
Engine Mechanical Specifications (LR4 VIN V)
Specification
Application
Metric
English
General
Engine Type
Displacement
V8
4.8L
293 CID
RPO
LR4
VIN
Bore
Stroke
V
96.0C96.018 mm
83.0 mm
Compression Ratio
Firing Order
Spark Plug Gap
3.779C3.78 in
3.268 in
9.47:1
1C8C7C2C6C5C4C3
1.524 mm
0.06 in
Camshaft Bearing Bore Diameter
55.063C55.088 mm
2.168C2.169 in
Crankshaft Main Bearing Bore Diameter
69.871C69.889 mm
2.75C2.751 in
0.006 mm
0.0002 in
96.0C96.018 mm
3.779C3.78 in
0.018 mm
0.0007 in
234.57C234.82 mm
9.235C9.245 in
Cylinder Head Deck Surface Flatness C Measured Within a 152.4 mm
(6.0 in) Area
0.11 mm
0.004 in
Cylinder Head Deck Surface Flatness C Measuring the Overall Length
of the Block Deck
0.22 mm
0.008 in
21.417C21.443 mm
0.843C0.844 in
0.025C0.305 mm
0.001C0.012 in
Block
Crankshaft Main Bearing Bore Out-of-Round
Cylinder Bore Diameter
Cylinder Bore Taper C Thrust Side
Cylinder Head Deck Height C Measuring from the Centerline of
Crankshaft to the Deck Face
Valve Lifter Bore Diameter
Camshaft
Camshaft End Play
2003 - C/K 800 Utility (June 11, 2002)
6-3
6-4
Engine Mechanical - 4.8L, 5.3L, and 6.0L
Engine
Engine Mechanical Specifications (LR4 VIN V) (contd)
Specification
Application
Camshaft Journal Diameter
Metric
English
54.99C55.04 mm
2.164C2.166 in
Camshaft Journal Out-of-Round
0.025 mm
0.001 in
Camshaft Lobe Lift C Exhaust
6.96 mm
0.274 in
Camshaft Lobe Lift C Intake
6.82 mm
0.268 in
Camshaft Runout C Measured at the Intermediate Journals
0.05 mm
0.002 in
0.023C0.065 mm
0.0009C0.0025 in
Connecting Rod Bearing Clearance C Service
0.023C0.076 mm
0.0009C0.003 in
Connecting Rod Bore Diameter C Bearing End
56.505C56.525 mm
2.224C2.225 in
Connecting Rod Bore Out-of-Round C Bearing End C Production
0.004C0.008 mm
0.00015C0.0003 in
Connecting Rod Bore Out-of-Round C Bearing End C Service
0.004C0.008 mm
0.00015C0.0003 in
0.11C0.51 mm
0.00433C0.02 in
53.318C53.338 mm
2.0991C2.0999 in
Connecting Rod Journal Diameter C Service
53.308 mm
2.0987 in
Connecting Rod Journal Out-of-Round C Production
0.005 mm
0.0002 in
Connecting Rod Journal Out-of-Round C Service
0.01 mm
0.0004 in
Connecting Rod Journal Taper C Maximum for 1/2 of Journal Length
C Production
0.005 mm
0.0002 in
Connecting Rod Journal Taper C Maximum for 1/2 of Journal Length
C Service
0.02 mm
0.00078 in
0.04C0.2 mm
0.0015C0.0078 in
Connecting Rod
Connecting Rod Bearing Clearance C Production
Connecting Rod Side Clearance
Crankshaft
Connecting Rod Journal Diameter C Production
Crankshaft End Play
Crankshaft Main Bearing Clearance C Production
0.02C0.052 mm
0.0008C0.0021 in
Crankshaft Main Bearing Clearance C Service
0.02C0.065 mm
0.0008C0.0025 in
64.993C65.007 mm
2.558C2.559 in
Crankshaft Main Journal Diameter C Production
Crankshaft Main Journal Diameter C Service
64.993 mm
2.558 in
Crankshaft Main Journal Out-of-Round C Production
0.003 mm
0.000118 in
Crankshaft Main Journal Out-of-Round C Service
0.008 mm
0.0003 in
Crankshaft Main Journal Taper C Production
0.01 mm
0.0004 in
Crankshaft Main Journal Taper C Service
0.02 mm
0.00078 in
Crankshaft Rear Flange Runout
0.05 mm
0.002 in
Crankshaft Reluctor Ring Runout C Measured 1.0 mm (0.04 in) Below
Tooth Diameter
0.7 mm
0.028 in
26.14C26.22 mm
1.029C1.0315 in
Crankshaft Thrust Surface C Service
26.22 mm
1.0315 in
Crankshaft Thrust Surface Runout
0.025 mm
0.001 in
Cylinder Head Height/Thickness C Measured from the Cylinder Head
Deck to the Valve Rocker Arm Cover Seal Surface
120.2 mm
4.732 in
Surface Flatness C Block Deck C Measured Within a 152.4 mm
(6.0 in) Area
0.08 mm
0.003 in
Surface Flatness C Block Deck C Measuring the Overall Length of the
Cylinder Head
0.1 mm
0.004 in
Surface Flatness C Exhaust Manifold Deck
0.13 mm
0.005 in
Surface Flatness C Intake Manifold Deck
0.08 mm
0.0031 in
Valve Guide Installed Height C Measured from the Spring Seat
Surface to the Top of the Guide
17.32 mm
0.682 in
Crankshaft Thrust Surface C Production
Cylinder Head
Intake Manifold
2003 - C/K 800 Utility (June 11, 2002)
Engine
Engine Mechanical - 4.8L, 5.3L, and 6.0L
6-5
Engine Mechanical Specifications (LR4 VIN V) (contd)
Specification
Application
Metric
English
Surface Flatness C Measured at Gasket Sealing Surfaces and
Measured Within a 200 mm (7.87 in) Area that Includes Two Runner
Port Openings
0.3 mm
0.118 in
Oil Capacity C with Filter
5.68 Liters
6.0 Quarts
Oil Capacity C without Filter
4.73 Liters
5.0 Quarts
41 kPa at 1,000
engine RPM
124 kPa at 2,000
engine RPM
165 kPa at 4,000
engine RPM
6 psig at 1,000
engine RPM
18 psig at 2,000
engine RPM
24 psig at 4,000
engine RPM
Front Cover Alignment C at Oil Pan Surface
0.0C0.5 mm
0.0C0.02 in
Rear Cover Alignment C at Oil Pan Surface
0.0C0.5 mm
0.0C0.02 in
Oil Pan Alignment C to Rear of Engine Block at Transmission Bell
Housing Mounting Surface
0.0C0.25 mm
0.0C0.01 in
Piston Ring End Gap C First Compression Ring C Measured in
Cylinder Bore C Production
0.23C0.44 mm
0.009C0.017 in
Piston Ring End Gap C First Compression Ring C Measured in
Cylinder Bore C Service
0.23C0.5 mm
0.009C0.0196 in
Piston Ring End Gap C Second Compression Ring C Measured in
Cylinder Bore C Production
0.44C0.7 mm
0.017C0.027 in
Piston Ring End Gap C Second Compression Ring C Measured in
Cylinder Bore C Service
0.44C0.76 mm
0.0173C0.03 in
Piston Ring End Gap C Oil Control Ring C Measured in Cylinder Bore
C Production
0.18C0.75 mm
0.007C0.029 in
Piston Ring End Gap C Oil Control Ring C Measured in Cylinder Bore
C Service
0.18C0.81 mm
0.007C0.032 in
Piston Ring to Groove Clearance C First Compression Ring C
Production
0.04C0.085 mm
0.00157C0.00335 in
Piston Ring to Groove Clearance C First Compression Ring C Service
0.04C0.085 mm
0.00157C0.00335 in
Piston Ring to Groove Clearance C Second Compression Ring C
Production
0.04C0.078 mm
0.00157C0.0031 in
Piston Ring to Groove Clearance C Second Compression Ring C
Service
0.04C0.078 mm
0.00157C0.0031 in
Piston Ring to Groove Clearance C Oil Control Ring C Production
0.012C0.2 mm
0.0005C0.0078 in
Piston Ring to Groove Clearance C Oil Control Ring C Service
0.012C0.2 mm
0.0005C0.0078 in
Piston C Piston Diameter C Measured Over Skirt Coating
96.002C96.036 mm
3.779C3.78 in
Piston C Piston to Bore Clearance C Production
?0.036 to 0.016 mm
?0.0014 to 0.0006 in
0.071 mm
0.0028 in
0.02C0.043 mm C
interference
0.00078C0.00169 in C
interference
Pin C Piston Pin Clearance to Piston Pin Bore C Production
0.007C0.02 mm
0.00027C0.00078 in
Pin C Piston Pin Clearance to Piston Pin Bore C Service
0.007C0.021 mm
0.00027C0.00082 in
Pin C Piston Pin Diameter
23.997C24.0 mm
0.9447C0.9448 in
Lubrication System
Oil Pressure C Minimum C Hot
Oil Pan
Piston Rings
Pistons and Pins
Piston C Piston to Bore Clearance C Service Limit with Skirt Coating
Worn Off
Pin C Piston Pin Fit in Connecting Rod Bore
Valve System
Valves C Valve Face Angle
Valves C Valve Face Width
2003 - C/K 800 Utility (June 11, 2002)
45 degrees
1.25 mm
0.05 in
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