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