GM Service Manual Online
For 1990-2009 cars only

Application

Specification

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

Application

Specification

Metric

English

General Data

  • Engine Type

V8

  • Regular Production Option (RPO)

L18

  • Displacement

8.1 Liter

496 CID

  • 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

Lubrication System

Oil Filter Type

PF454

Oil Type

5W-30

Oil Capacity

  • With Filter Change

6.1 Liters

6.5 Quarts

  • Without Filter Change

5.7 Liters

6.0 Quarts

Oil Pressure - Hot

  • Minimum

34 kPa @ 1,000 RPM

5 psi @ 1,000 RPM

  • Minimum

69 kPa @ 2,000 RPM

10 psi @ 2,000 RPM