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Engine Mechanical - 8.1L (Unit Repair): Specifications Chevrolet Silverado 2500

Mechanical 8 illustrations ~254 words

Fastener Tightening Specifications

Application	Specification
Application	Metric	English
Camshaft Position Sensor Bolt	12 N.m	106 lb in
Camshaft Retainer Bolt	12 N.m	106 lb in
Camshaft Sprocket Bolt	30 N.m	22 lb ft
Connecting Rod Nut	30 N.m +90 Degrees	22 lb ft +90 Degrees
Coolant Drain Hole Plug
Left Front	60 N.m	44 lb ft
Sides	30 N.m	22 lb ft
Crankshaft Balancer Bolt	255 N.m	189 lb ft
Crankshaft Bearing Cap Inner Bolts
First Pass	30 N.m	22 lb ft
Final Pass	90 Degrees
Crankshaft Bearing Cap Outer Studs
First Pass	30 N.m	22 lb ft
Final Pass	80 Degrees
Crankshaft Oil Deflector Nut	50 N.m	37 lb ft
Crankshaft Position Sensor Bolt	12 N.m	106 lb in
Cylinder Head Bolt (In Sequence)
First Pass	30 N.m	22 lb ft
Second Pass	30 N.m+120 Degrees	22 lb ft +120 Degrees
Final Pass - Long Bolts #1, 2, 3, 6, 7, 8, 9, 10, 11, 14, 16, 17	60 Degrees
Final Pass - Medium Bolts #15, 18	45 Degrees
Final Pass - Short Bolts #4, 5, 12, 13	30 Degrees
Cylinder Head Coolant Hole Plug	23 N.m	17 lb ft
Drive Belt Tensioner Bolt	50 N.m	37 lb ft
EGR Adapter Nut	22 N.m	16 lb ft
EGR Valve Nut	22 N.m	16 lb ft
EGR Valve Pipe Bolt	25 N.m	19 lb ft
EGR Valve Pipe Bracket Bolt	50 N.m	37 lb ft
EGR Valve Pipe Nut	25 N.m	19 lb ft
EGR Valve Pipe Stud in Exhaust Manifold	12 N.m	106 lb in
Engine Block Heater	50 N.m	37 lb ft
Engine Coolant Temperature (ECT) Sensor	20 N.m	15 lb ft
Engine Coolant Temperature (ECT) Sensor Bracket Bolt	50 N.m	37 lb ft
Exhaust Manifold
Center Bolt	35 N.m	26 lb ft
Nut	16 N.m	12 lb ft
Stud	20 N.m	15 lb ft
Exhaust Manifold Heat Shield
Bolt	25 N.m	19 lb ft
Nut	25 N.m	19 lb ft
Flywheel Bolt
First Pass	40 N.m	30 lb ft
Second Pass	80 N.m	59 lb ft
Final Pass	100 N.m	74 lb ft
Flywheel Cover Bolt	12 N.m	106 lb in
Flywheel Housing
Hex Head Bolt	67 N.m	50 lb ft
Countersunk Bolt	60 N.m	44 lb ft
Front Cover Bolt
First Pass	6 N.m	54 lb in
Final Pass	12 N.m	106 lb in
Fuel Rail Stud	12 N.m	106 lb in
Ignition Coil Bolt	12 N.m	106 lb in
Ignition Coil Wiring Harness Bolt	12 N.m	106 lb in
Intake Manifold Bolt (In Sequence)
First Pass	5 N.m	44 lb in
Second Pass	5 N.m	44 lb in
Third Pass	10 N.m	89 lb in
Final Pass	12 N.m	106 lb in
Knock Sensor	20 N.m	15 lb ft
Knock Sensor Heat Shield Bolt - C/K/G/C3500HD	12 N.m	106 lb in
Knock Sensor Heat Shield Bolt - Medium Duty	50 N.m	37 lb ft
MAP Sensor Bolt	12 N.m	106 lb in
Oil Cooler Hose Fittings	23 N.m	17 lb ft
Oil Fill Tube Bolt	12 N.m	106 lb in
Oil Filter	38 N.m	28 lb ft
Oil Filter Fitting	66 N.m	49 lb ft
Oil Gallery Plug
Front	30 N.m	22 lb ft
Left	30 N.m	22 lb ft
Rear	30 N.m	22 lb ft
Top	20 N.m	15 lb ft
Oil Level Indicator Tube Bracket Nut	18 N.m	13 lb ft
Oil Level Switch	20 N.m	15 lb ft
Oil Pan Bolt
First Pass	10 N.m	89 lb in
Final Pass	25 N.m	19 lb ft
Oil Pan Drain Plug	28 N.m	21 lb ft
Oil Pressure Gauge Sensor	30 N.m	22 lb ft
Oil Pump Bolt	75 N.m	56 lb ft
Oil Pump Cover Bolt	12 N.m	106 lb in
Oil Pump Drive Bolt	25 N.m	19 lb ft
Purge Solenoid Bolt	10 N.m	88 lb in
Spark Plug	20 N.m	15 lb ft
Thermostat Housing Bolt	30 N.m	22 lb ft
Throttle Body
Nut	10 N.m	88 lb in
Stud	12 N.m	106 lb in
Transmission Converter Cover Bolts	12 N.m	106 lb in
Valve Lifter Guide Retainer Bolt	25 N.m	19 lb ft
Valve Rocker Arm Cover Bolt
First Pass	6 N.m	53 lb in
Final Pass	12 N.m	106 lb in
Valve Rocker Arm Nut	25 N.m	19 lb ft
Valve Rocker Arm Stud	50 N.m	37 lb ft
Water Crossover Pipe Bolt	50 N.m	37 lb ft
Water Pump Bolt
First Pass	25 N.m	18 lb ft
Final Pass	50 N.m	37 lb ft
Water Pump Pulley Bolt	25 N.m	19 lb ft

FASTENER TIGHTENING SPECIFICATIONS

Engine Mechanical Specifications

Application		Specification
Application		Metric	English
General Data
	Engine Type	V-8
	Displacement	8.1 L	496 CID
	RPO	L18
	VIN C/K/G/C3500HD	G
	VIN Medium Duty	E
	Bore	107.950 mm	4.250 in
	Stroke	111.00 mm	4.370 in
	Compression Ratio	9.1:1
	Firing Order	1-8-7-2-6-5-4-3
	Spark Plug Gap	1.52 mm	0.060 in
Cylinder Head
	Surface Flatness	0.050 mm	0.002 in
	Maximum Cylinder Head Block Deck Resurfacing	0.3048 mm	0.012 in
Exhaust Manifold
	Surface Flatness	0.254 mm	0.010 in
Lubrication System
	Oil Capacity without Filter Change	5.7 L	6 Qts
	Oil Pressure (Minimum)	34 kPa @ 1,000 RPM	5 psi @ 1,000 RPM
	Oil Pressure (Minimum)	69 kPa @ 2,000 RPM	10 psi @ 2,000 RPM
	Oil Filter System	Full Flow
	Oil Pump Type	Gear Driven
Cylinder Bore
	Diameter - Production	107.950-107.968 mm	4.2500-4.2507 in
	Diameter - Service	107.940-107.990 mm	4.2496-4.2516 in
	Out-of-Round Production (Maximum Minus Minimum Bore Diameter)	0.0180 mm (max.)	0.0007 in (max.)
	Out-of-Round Service (Maximum Minus Minimum Bore Diameter)	0.050 mm (max.)	0.002 in (max.)
	Taper Production	0.0180 mm (max.)	0.0007 in (max.)
	Taper Service - Thrust Axis	0.050 mm (max.)	0.002 in (max.)
	Taper Service - Pin Axis	0.050 mm (max.)	0.002 in (max.)
Engine Block (Production Specifications)
	Main Bearing Bore Diameter	74.6060-74.6220 mm	2.9372-2.9379 in
	Lifter Bore Diameter	21.417-21.443 mm	0.843-0.844 in
	Deck Height from Crankshaft Bore	259.875-260.125 mm	10.231-10.241 in
	Head Deck Surface Flatness (entire face)	0.100 mm	0.004 in
	Head Deck Surface Flatness within 150 mm (6 in)	0.050 mm	0.002 in
Piston
	Piston Diameter (Coated Piston)	Not Measurable	Not Measurable
	Clearance Production	Interference Fit (coated piston)	Interference Fit (coated piston)
Piston Ring Compression
	Top Groove Clearance	0.031-0.074 mm	0.0012-0.0029 in
	Second Groove Clearance	0.031-0.074 mm	0.0012-0.0029 in
	Top Ring Production Gap	0.300-0.450 mm	0.012-0.018 in
	Top Ring Service Limit Gap	0.450-0.675 mm	0.018-0.027 in
	Second Ring Production Gap	0.450-0.650 mm	0.017-0.025 in
	Second Ring Service Limit Gap	0.675-0.975 mm	0.026-0.039 in
Piston Ring Oil Control
	Ring Groove Clearance	0.051-0.203 mm	0.002-0.008 in
	Production Gap	0.249-0.759 mm	0.0098-0.0299 in
	Service Limit Gap	0.373-1.138 mm	0.015-0.045 in
Piston Pin
	Diameter	26.416-26.419 mm	1.0400-1.0401 in
	Fit in Connecting Rod	0.049-0.020 mm Interference	0.00019-0.0007 in Interference
Crankshaft
	Crankshaft Main Journal Runout - Production	0.0380 mm (max.)	0.0015 in (max.)
	Crankshaft Main Journal Runout - Service	0.0510 mm (max.)	0.0020 in (max.)
	Crankshaft Journal Diameter #1, #2, #3, #4, #5	69.805-69.822 mm	2.7482-2.7489 in
	Crankshaft Journal Taper Production	0.0102 mm (max.)	0.0004 in
	Crankshaft Journal Out-of-Round Production	0.0102 mm (max.)	0.0004 in
	Crankshaft Bearing Clearance #1, #2, #3, #4 Production	0.022-0.052 mm	0.0008-0.0020 in
	Crankshaft Bearing Clearance #5 Production	0.035-0.067 mm	0.0014-0.0026 in
	Crankshaft Bearing Clearance #1, #2, #3, #4 Service Limit	0.022-0.089 mm	0.0008-0.0035 in
	Crankshaft Bearing Clearance #5 Service Limit	0.035-0.102 mm	0.0014-0.0040 in
	Crankshaft End Play	0.127-0.279 mm	0.0050-0.0110 in
	Crankpin Diameter	55.854-55.870 mm	2.1990-2.1996 in
	Crankpin Taper Production	0.0102 mm (max.)	0.0004 in
	Crankpin Out-of-Round Production	0.0102 mm (max.)	0.0004 in
	Rod Bearing Clearance Production	0.021-0.064 mm	0.0008-0.0025 in
	Rod Bearing Clearance Service Limit	0.021-0.081 mm	0.0008-0.0032 in
	Connecting Rod Side Clearance	0.384-0.686 mm	0.0151-0.0270 in
Camshaft
	Camshaft Runout - Production	0.051 mm (Maximum)	0.002 in (Maximum)
	Camshaft Runout - Service	0.076 mm	0.003 in
	Lobe Lift Intake	6.924-7.026 mm	0.2726-0.2766 in
	Lobe Lift Exhaust	6.973-7.075 mm	0.2745-0.2785 in
	Journal Diameter	49.4720-49.5220 mm	1.9477-1.9497 in
	Camshaft Bearing Inside Diameter	49.5480-49.5730 mm	1.9507-1.9517 in
Valve System
	Lifter	Hydraulic, Roller Followers
	Rocker Arm Ratio	1.70:1
	Valve Lash Intake	Net Lash
	Valve Lash Exhaust	Net Lash
	Face Angle (Intake/Exhaust)	45 degrees
	Seat Angle (Intake/Exhaust)	46 degrees
	Seat Runout (Intake/Exhaust)	0.0500 mm (Maximum)	0.002 in (Maximum)
	Seat Width Intake	0.800-1.200 mm	0.030-0.060 in
	Seat Width Exhaust	1.651-2.159 mm	0.060-0.095 in
	Stem Clearance Production Intake	0.025-0.074 mm	0.0010-0.0029 in
	Stem Clearance Production Exhaust	0.030-0.079 mm	0.0012-0.0031 in
	Stem Clearance Service Intake	0.025-0.088 mm	0.0010-0.0034 in
	Stem Clearance Service Exhaust	0.030-0.091 mm	0.0012-0.0036 in
	Valve Spring Pressure Closed	381-419 N @ 45.923 mm	86-94 lb @ 1.808 in
	Valve Spring Pressure Open	962-1058 N @ 33.985 mm	216-236 lb @ 1.338 in
	Valve Spring Installed Height	45.923-46.685 mm	1.808-1.838 in
	Valve Spring Free Length	56.35 mm	2.218 in
	Valve Head Diameter - Intake	55.63 mm	2.19 in
	Valve Head Diameter - Exhaust	43.69 mm	1.72 in
	Valve Stem Diameter - Intake	9.436-9.454 mm	0.3715-0.3722 in
	Valve Stem Diameter - Exhaust	9.431-9.449 mm	0.3713-0.3720 in
	Maximum Valve Spring Installed Height Shim (Service Only)	0.726 mm	0.030 in
	Maximum Valve Spring Tension Shim (Service Only)	0.726 mm	0.030 in
	Maximum Combined Valve Spring Installed Height and Valve Spring Tension Shim (Service Only - Shim Placed Under Valve Rotator Only)	1.524 mm	0.060 in

ENGINE MECHANICAL SPECIFICATIONS

Scheme 1159

Scheme 1159: Sealers, Adhesives & Lubricants

Scheme 1160

Scheme 1160: Disassembled Views

Scheme 1161

Scheme 1162

Scheme 1163

Scheme 1164

Scheme 1165

Scheme 1165: Engine Identification

The engine identification number is located on three locations. There is a label on the front of the right rocker arm cover (1), the rear of the left rocker arm cover (2), and a label on the right side of the engine oil pan (3). The engine identification number is used to track and distinguish the engine prior to installation in a vehicle.

The Vehicle Identification Number (VIN) Derivative is located on the left rear side of the engine block and is a nine digit number stamped or laser etched onto the engine at the vehicle assembly plant. If reading the identification number from the left, the following information can be obtained

The first digit identifies the division.
The second digit identifies the model year.
The third digit identifies the assembly plant.
The fourth through ninth digits are the last six digits of the Vehicle Identification Number (VIN).

Scheme 1166

Scheme 1166: Draining Fluids & Oil Filter Removal

Remove the oil pan drain plug.
Drain the engine oil.
Remove the oil filter (2).
Remove the left engine coolant drain hole plug (1) and the right engine coolant drain hole plug.
Drain the engine coolant.

Torque Values And/Or Fastener Tightening Strategies

No torque or fastener tightening changes from the previous year. Refer to Fastener Tightening Specifications .

Changed Engine Specifications

No changed engine specifications. Refer to Engine Mechanical Specifications .