Chevrolet 5.7L Corvette 2004 Install guide

2004 ENGINE PERFORMANCE
Engine Mechanical (Introduction) - 5.7L - Corvette
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Fastener Tightening Specifications
Application Specification Metric English
Accessory Drive Belt Idler Pulley Bolt 50 N.m 37 lb ft
Accessory Drive Belt Tensioner Bolt 50 N.m 37 lb ft
Air Conditioning (A/C) Compressor and Condenser Hose Bolt 27 N.m 20 lb ft
A/C Drive Belt Idler Pulley Bolt 50 N.m 37 lb ft
A/C Drive Belt Tensioner Bolt 25 N.m 18 lb ft
Air Injection Reaction (AIR) Pipe-to-Exhaust Manifold Bolts 20 N.m 15 lb ft
AIR Right Side Pipe Bracket-to-Cylinder Head Bolt 20 N.m 15 lb ft
Automatic Transmission Fluid Cooler Line Clamp Bolt - at Oil Pan 12 N.m 106 lb
in
Automatic Transmission Fluid Cooler Line Clamp Bolt - at Right Transmission Cover 2.2
N.m 19 lb in
Automatic Transmission Fluid Cooler Pipe 25 N.m 18 lb ft
Camshaft Retainer Bolts 25 N.m 18 lb ft
Camshaft Sensor Bolt 25 N.m 18 lb ft
Camshaft Sprocket Bolts 35 N.m 26 lb ft
Connecting Rod Bolts - First Pass 20 N.m 15 lb ft
Connecting Rod Bolts - Final Pass 75 degrees
Coolant Temperature Gage Sensor 20 N.m 15 lb ft
Crankshaft Balancer Bolt - Installation Pass-to Ensure the Balancer is Completely
Installed 330 N.m 240 lb ft
Crankshaft Balancer Bolt - First Pass - Install a NEW Bolt After the Installation Pass
and Tighten as Described in the First and Final Passes 50 N.m 37 lb ft
Crankshaft Balancer Bolt - Final Pass 140 degrees
Crankshaft Bearing Cap Bolts - Inner Bolts - First Pass in Sequence 20 N.m 15 lb ft
Crankshaft Bearing Cap Bolts - Inner Bolts - Final Pass in Sequence 80 degrees
Crankshaft Bearing Cap Side Bolts 25 N.m 18 lb ft
Crankshaft Bearing Cap Studs - Outer Studs - First Pass in Sequence 20 N.m 15 lb ft
Crankshaft Bearing Cap Studs - Outer Studs - Final Pass in Sequence 53 degrees
Crankshaft Oil Deflector Nuts 25 N.m 18 lb ft
Crankshaft Position Sensor Bolt 25 N.m 18 lb ft
Crossmember Nut 110 81 lb ft
2004 Chevrolet Corvette
2004 ENGINE PERFORMANCE Engine Mechanical (Introduction) - 5.7L - Corvette
2004 Chevrolet Corvette
2004 ENGINE PERFORMANCE Engine Mechanical (Introduction) - 5.7L - Corvette
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December-24-07 10:50:06 AM Page 1 © 2005 Mitchell Repair Information Company, LLC.
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N.m
Cylinder Head Bolts - First Design - First Pass all M11 Bolts in Sequence 30 N.m 22 lb ft
Cylinder Head Bolts - First Design - Second Pass all M11 Bolts in Sequence 90 degrees
Cylinder Head Bolts - First Design - Final Pass all M11 Bolts in Sequence - Excluding
the Medium Length Bolts at the Front and Rear of Each Cylinder Head 90 degrees
Cylinder Head Bolts - First Design - Final Pass M11 Medium Length Bolts at the
Front and Rear of Each Cylinder Head 50 degrees
Cylinder Head Bolts - Second Design - First Pass all M11 Bolts in Sequence 30 N.m 22 lb ft
Cylinder Head Bolts - Second Design - Second Pass all M11 Bolts in Sequence 90 degrees
Cylinder Head Bolts - Second Design - Final Pass all M11 Bolts in Sequence 70 degrees
Cylinder Head Bolts - M8 Inner Bolts in Sequence 30 N.m 22 lb ft
Cylinder Head Coolant Plug 20 N.m 15 lb ft
Cylinder Head Core Hole Plug 20 N.m 15 lb ft
Driveline Close-Out Panel Bolt 12 N.m 106 lb
in
Driveline Support Bolt 50 N.m 37 lb ft
Driveline Support Plug 50 N.m 37 lb ft
Engine Block Coolant Drain Plugs 60 N.m 44 lb ft
Engine Block Heater 40 N.m 30 lb ft
Engine Block Oil Gallery Plugs 60 N.m 44 lb ft
Engine Coolant Air Bleed Pipe and Cover Bolts and Studs 12 N.m 106 lb
in
Engine Flywheel Bolts - First Pass 20 N.m 15 lb ft
Engine Flywheel Bolts - Second Pass 50 N.m 37 lb ft
Engine Flywheel Bolts - Final Pass 100
N.m 74 lb ft
Engine Flywheel Hub Collar Bolt - Automatic Transmission 130
N.m 96 lb ft
Engine Front Cover Bolts 25 N.m 18 lb ft
Engine Mount Bracket Bolt 50 N.m 37 lb ft
Engine Mount Nut 65 N.m 48 lb ft
Engine Mount-to-Engine Mount Bracket Nut 65 N.m 48 lb ft
Engine Oil Filter 30 N.m 22 lb ft
Engine Rear Cover Bolts 25 N.m 18 lb ft
Engine Service Lift Bracket M8 Bolt 25 N.m 18 lb ft
Engine Service Lift Bracket M10 Bolts 50 N.m 37 lb ft
Engine Valley Cover Baffle Cover Bolts - LS6 5 N.m 44 lb in
Engine Valley Cover Bolts 25 N.m 18 lb ft
Engine Wiring Harness Generator Lead Nut 13 N.m 115 lb
in
Engine Wiring Harness Ground Strap Bolt 32 N.m 24 lb ft
Exhaust Manifold Bolts - First Pass 15 N.m 11 lb ft
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2004 ENGINE PERFORMANCE Engine Mechanical (Introduction) - 5.7L - Corvette
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Exhaust Manifold Bolts - Final Pass 25 N.m 18 lb ft
Exhaust Manifold Heat Shield Bolts 9 N.m 80 lb in
Flywheel Housing Bolt 50 N.m 37 lb ft
Fuel Injection Fuel Rail Bolts 10 N.m 89 lb in
Generator Bracket Bolt 50 N.m 37 lb ft
Ignition Coil Bracket-to-Valve Rocker Arm Cover Bolts 12 N.m 106 lb
in
Ignition Coil-to-Bracket Bolts 12 N.m 106 lb
in
Intake Manifold Bolts - First Pass in Sequence 5 N.m 44 lb in
Intake Manifold Bolts - Final Pass in Sequence 10 N.m 89 lb in
Intermediate Steering Shaft Bolt 48 N.m 35 lb ft
Knock Sensors 20 N.m 15 lb ft
Oil Filter 30 N.m 22 lb ft
Oil Filter Fitting 55 N.m 40 lb ft
Oil Level Indicator Tube Bolt 16 N.m 12 lb ft
Oil Level Sensor 13 N.m 115 lb
in
Oil Pan Closeout Cover Bolt - Left Side 12 N.m 106 lb
in
Oil Pan Closeout Cover Bolt - Right Side 12 N.m 106 lb
in
Oil Pan Cover Bolts 12 N.m 106 lb
in
Oil Pan Drain Plug 25 N.m 18 lb ft
Oil Pan - Lower - Bolts 12 N.m 106 lb
in
Oil Pan M8 Bolts - Oil Pan-to-Engine Block and Oil Pan-to-Front Cover 25 N.m 18 lb ft
Oil Pan M6 Bolts - Oil Pan-to-Rear Cover 12 N.m 106 lb
in
Oil Pressure Sensor 20 N.m 15 lb ft
Oil Pump Cover Bolts 12 N.m 106 lb
in
Oil Pump Relief Valve Plug 12 N.m 106 lb
in
Oil Pump Screen Nuts 25 N.m 18 lb ft
Oil Pump Screen-to-Oil Pump Bolt 12 N.m 106 lb
in
Oil Pump-to-Engine Block Bolts 25 N.m 18 lb ft
Oil Temperature Sensor 20 N.m 15 lb ft
Power Steering Pump Bolt 25 N.m 18 lb ft
Propeller Shaft Hub Collar Bolt 125 92 lb ft
2004 Chevrolet Corvette
2004 ENGINE PERFORMANCE Engine Mechanical (Introduction) - 5.7L - Corvette
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ENGINE MECHANICAL SPECIFICATIONS (LS1)
Engine Mechanical Specifications (LS1)
N.m
Spark Plugs - Cylinder Heads - New 20 N.m 15 lb ft
Spark Plugs - all Subsequent Installations 15 N.m 11 lb ft
Steering Knuckle Nut - First Pass 20 N.m 15 lb ft
Steering Knuckle Nut - Second Pass 50 degrees
Steering Knuckle Nut - Final Pass 55 N.m 41 lb ft
Throttle Body Bolts 12 N.m 106 lb
in
Timing Chain Guide Bolts 35 N.m 26 lb ft
Transmission Cover Bolt 12 N.m 106 lb
in
Transmission Wiring Harness Bracket Bolt 50 N.m 37 lb ft
Transmission Wiring Harness Clip Bolt - near the Harness Ground 32 N.m 23 lb ft
Transmission Wiring Harness Clip Bolt - near the Oil Pan 25 N.m 18 lb ft
Valve Lifter Guide Bolts 12 N.m 106 lb
in
Valve Rocker Arm Bolts 30 N.m 22 lb ft
Valve Rocker Arm Cover Bolts 12 N.m 106 lb
in
Water Inlet Housing Bolts 15 N.m 11 lb ft
Water Pump Bolts - First Pass 15 N.m 11 lb ft
Water Pump Bolts - Final Pass 30 N.m 22 lb ft
Water Pump Cover Bolts 15 N.m 11 lb ft
Application Specification Metric English
General
zEngine Type V 8
zDisplacement 5.7L - 5665 cc 346 CID
zRPO LS1
zVIN G
zBore 99.0 -99.018 mm 3.897-3.898 in
zStroke 92.0 mm 3.622 in
zCompression Ratio 10.1 :1
zFiring Order 1-8-7-2-6-5-4-3
zSpark Plug Gap 1.016 mm 0.04 in
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2004 ENGINE PERFORMANCE Engine Mechanical (Introduction) - 5.7L - Corvette
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Block
zCamshaft Bearing Bore 1 and 5 Diameter - First Design 59.08-59.13 mm 2.325-2.327 in
zCamshaft Bearing Bore 2 and 4 Diameter - First Design 58.83-58.88 mm 2.316-2.318 in
zCamshaft Bearing Bore 3 Diameter - First Design 58.58-58.63 mm 2.306-2.308 in
zCamshaft Bearing Bore 1 and 5 Diameter - Second
Design 59.58-59.63 mm 2.345-2.347 in
zCamshaft Bearing Bore 2 and 4 Diameter - Second
Design 59.08-59.13 mm 2.325-2.327 in
zCamshaft Bearing Bore 3 Diameter - Second Design 58.58-58.63 mm 2.306-2.308 in
zCrankshaft Main Bearing Bore Diameter 69.871-69.889
mm 2.75-2.751 in
zCrankshaft Main Bearing Bore Out-of-Round 0.005 mm 0.0002 in
zCylinder Bore Diameter 99.0-99.018 mm 3.897-3.898 in
zCylinder Bore Taper - Thrust Side 0.018 mm 0.0007 in
zCylinder Head Deck Height - Measuring from the
Centerline of Crankshaft to the Deck Face 234.57-234.82
mm 9.235-9.245 in
zCylinder Head Deck Surface Flatness - Measured Within
a 152.4 mm (6.0 in) Area 0.08 mm 0.003 in
zCylinder Head Deck Surface Flatness - Measuring the
Overall Length of the Block Deck 0.22 mm 0.008 in
zValve Lifter Bore Diameter 21.417-21.443
mm 0.843-0.844 in
Camshaft
zCamshaft End Play 0.025-0.305 mm 0.001-0.012 in
zCamshaft Journal Diameter 54.99-55.04 mm 2.164-2.166 in
zCamshaft Journal Out-of-Round 0.025 mm 0.001 in
zCamshaft Lobe Lift - Exhaust 7.13 mm 0.281 in
zCamshaft Lobe Lift - Intake 6.96 mm 0.274 in
zCamshaft Runout - Measured at the Intermediate Journals 0.05 mm 0.002 in
Connecting Rod
zConnecting Rod Bearing Clearance - Production 0.023-0.065 mm 0.0009-0.0025 in
zConnecting Rod Bearing Clearance - Service 0.023-0.076 mm 0.0009-0.003 in
zConnecting Rod Bore Diameter - Bearing End 56.505-56.525
mm 2.224-2.225 in
zConnecting Rod Bore Out-of-Round - Bearing End -
Production 0.006 mm 0.00023 in
zConnecting Rod Bore Out-of-Round - Bearing End -
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2004 ENGINE PERFORMANCE Engine Mechanical (Introduction) - 5.7L - Corvette
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Service 0.006 mm 0.00023 in
zConnecting Rod Side Clearance 0.11-0.51 mm 0.00433-0.02 in
Crankshaft
zConnecting Rod Journal Diameter - Production 53.318-53.338
mm 2.0991-2.0999 in
zConnecting Rod Journal Diameter - Service 53.308 mm 2.0987 in
zConnecting Rod Journal Out-of-Round - Production 0.005 mm 0.0002 in
zConnecting Rod Journal Out-of-Round - Service 0.01 mm 0.0004 in
zConnecting Rod Journal Taper - Maximum for 1/2 of
Journal Length - Production 0.005 mm 0.0002 in
zConnecting Rod Journal Taper - Maximum for 1/2 of
Journal Length - Service 0.02 mm 0.00078 in
zCrankshaft End Play 0.04-0.2 mm 0.0015-0.0078 in
zCrankshaft Main Bearing Clearance - Production 0.021-0.052 mm 0.0008-0.0021 in
zCrankshaft Main Bearing Clearance - Service 0.02-0.065 mm 0.0008-0.0025 in
zCrankshaft Main Journal Diameter - Production 64.993-65.007
mm 2.558-2.559 in
zCrankshaft Main Journal Diameter - Service 64.993 mm 2.558 in
zCrankshaft Main Journal Out-of-Round - Production 0.003 mm 0.000118 in
zCrankshaft Main Journal Out-of-Round - Service 0.008 mm 0.0003 in
zCrankshaft Main Journal Taper - Production 0.01 mm 0.0004 in
zCrankshaft Main Journal Taper - Service 0.02 mm 0.00078 in
zCrankshaft Rear Flange Runout 0.05 mm 0.002 in
zCrankshaft Reluctor Ring Runout - Measured 1.0 mm
(0.04 in) Below Tooth Diameter 0.7 mm 0.028 in
zCrankshaft Thrust Surface - Production 26.14-26.22 mm 1.029-1.0315 in
zCrankshaft Thrust Surface - Service 26.22 mm 1.0315 in
zCrankshaft Thrust Surface Runout 0.025 mm 0.001 in
Cylinder Head
zCylinder Head Height/Thickness - Measured from the
Cylinder Head Deck to the Valve Rocker Arm Cover
Seal Surface 120.2 mm 4.732 in
zSurface Flatness - Block Deck - Measured Within a 152.4
mm (6.0 in) Area 0.08 mm 0.003 in
zSurface Flatness - Block Deck - Measuring the Overall
Length of the Cylinder Head 0.1 mm 0.004 in
2004 Chevrolet Corvette
2004 ENGINE PERFORMANCE Engine Mechanical (Introduction) - 5.7L - Corvette
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zSurface Flatness - Exhaust Manifold Deck 0.22 mm 0.008 in
zSurface Flatness - Intake Manifold Deck 0.22 mm 0.008 in
Intake Manifold
zSurface Flatness - Measured at Gasket Sealing Surfaces 0.5 mm 0.02 in
Lubrication System
zOil Capacity - with Filter 6.151 Liters 6.5 Quarts
zOil Capacity - without Filter 5.678 Liters 6.0 Quarts
zOil Pressure - Minimum - Hot
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
Oil Pan
zFront Cover Alignment - at Oil Pan Surface 0.0-0.5 mm 0.0-0.02 in
zRear Cover Alignment - at Oil Pan Surface 0.0-0.5 mm 0.0-0.02 in
zOil Pan Alignment - to Rear of Engine Block at
Transmission Bellhousing Mounting Surface 0.0-0.25 mm 0.0-0.01 in
Piston Rings
zPiston Ring End Gap - First Compression Ring -
Measured in Cylinder Bore - Production 0.23-0.44 mm 0.009-0.017 in
zPiston Ring End Gap - First Compression Ring -
Measured in Cylinder Bore - Service 0.23-0.5 mm 0.009-0.0196 in
zPiston Ring End Gap - Second Compression Ring -
Measured in Cylinder Bore - Production 0.44-0.7 mm 0.017-0.027 in
zPiston Ring End Gap - Second Compression Ring -
Measured in Cylinder Bore - Service 0.44-0.76 mm 0.0173-0.03 in
zPiston Ring End Gap - Oil Control Ring - Measured in
Cylinder Bore - Production 0.18-0.75 mm 0.007-0.029 in
zPiston Ring End Gap - Oil Control Ring - Measured in
Cylinder Bore - Service 0.18-0.81 mm 0.007-0.032 in
zPiston Ring to Groove Clearance - First Compression
Ring - Production 0.04-0.086 mm 0.00157-0.0033 in
zPiston Ring to Groove Clearance - First Compression
Ring - Service 0.04-0.068 mm 0.00157-0.0033 in
zPiston Ring to Groove Clearance - Second Compression
Ring - Production 0.05-0.088 mm 0.002-0.0034 in
zPiston Ring to Groove Clearance - Second Compression
Ring - Service 0.05-0.088 mm 0.002-0.0034 in
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2004 ENGINE PERFORMANCE Engine Mechanical (Introduction) - 5.7L - Corvette
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zPiston Ring to Groove Clearance - Oil Control Ring -
Production -0.008 to +0.176
mm -0.0003 to +0.0069 in
zPiston Ring to Groove Clearance - Oil Control Ring -
Service -0.008 to +0.176
mm -0.0003 to +0.0069 in
Pistons and Pins
zPiston - Piston Diameter- Non Coated Skirt - at Size
Point 98.969-98.987
mm 3.8964-3.8997 in
zPiston - Piston Diameter- Measured Over Skirt Coating 98.984-99.027
mm 3.897-3.899 in
zPiston - Piston to Bore Clearance - Non Coated Skirt -
Production 0.013-0.049 mm 0.0005-0.0019 in
zPiston - Piston to Bore Clearance - Non Coated Skirt -
Service 0.013-0.074 mm 0.0005-0.0029 in
zPiston - Piston to Bore Clearance - Coated Skirt -
Production -0.027 to +0.029
mm -0.001 to +0.0011 in
zPiston - Piston to Bore Clearance - Coating Worn Off -
Service Limit 0.074 mm 0.0029 in
zPin - First Design Press Fit Pin Fit in Connecting Rod
Bore 0.02-0.043 mm -
Interference 0.00078-0.00169 in - Interference
zPin - First Design Press Fit Pin Clearance to Piston Pin
Bore - Production 0.01-0.02 mm 0.0004-0.00078 in
zPin - First Design Press Fit Pin Clearance to Piston Pin
Bore - Service 0.01-0.022 mm 0.0004-0.00086 in
zPin - First Design Press Fit Pin Diameter 23.997-24.0 mm 0.9447-0.9448 in
zPin - Second Design Full Floating Pin Fit in Connecting
Rod Bore - Production 0.007-0.02 mm 0.00027-0.00078 in
zPin - Second Design Full Floating Pin Fit in Connecting
Rod Bore - Service 0.007-0.022 mm 0.00027-0.00086 in
zPin - Second Design Full Floating Pin Clearance to
Piston Pin Bore - Production 0.002-0.01 mm 0.00008-0.0004 in
zPin - Second Design Full Floating Pin Clearance to
Piston Pin Bore - Service 0.002-0.015 mm 0.00008-0.0006 in
zPin - Second Design Full Floating Pin Diameter 23.952-23.955
mm 0.943-0.943 in
Valve System
zValves - Valve Face Angle 45 degrees
zValves - Valve Face Width 1.25 mm 0.05 in
zValves - Valve Lash Net Lash - No Adjustment
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2004 ENGINE PERFORMANCE Engine Mechanical (Introduction) - 5.7L - Corvette
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ENGINE MECHANICAL SPECIFICATIONS (LS6)
Engine Mechanical Specifications (LS6)
zValves - Valve Lift - Intake 11.79 mm 0.464 in
zValves - Valve Lift - Exhaust 12.16 mm 0.479 in
zValves - Valve Seat Angle 46 degrees
zValves - Valve Seat Runout 0.05 mm 0.002 in
zValves - Valve Seat Width - Exhaust 1.78 mm 0.07 in
zValves - Valve Seat Width - Intake 1.02 mm 0.04 in
zValves - Valve Stem Diameter- Production 7.955-7.976 mm 0.313-0.314 in
zValves - Valve Stem Diameter- Service 7.96 mm 0.314 in
zValves - Valve Stem-to-Guide Clearance - Production -
Intake 0.025-0.066 mm 0.001-0.0026 in
zValves - Valve Stem-to-Guide Clearance - Service -
Intake 0.093 mm 0.0037 in
zValves - Valve Stem-to-Guide Clearance - Production -
Exhaust 0.025-0.066 mm 0.001-0.0026 in
zValves - Valve Stem-to-Guide Clearance - Service -
Exhaust 0.093 mm 0.0037 in
zRocker Arms - Valve Rocker Arm Ratio 1.70:1
zValve Springs - Valve Spring Free Length 52.9 mm 2.08 in
zValve Springs - Valve Spring Installed Height 45.75 mm 1.8 in
zValve Springs - Valve Spring Load - Closed 340 N at 45.75
mm 76 lb at 1.8 in
zValve Springs - Valve Spring Load - Open 980 N at 33.55
mm 220 lb at 1.32 in
Application Specification Metric English
General
zEngine Type V 8
zDisplacement 5.7 L - 5665 cc 346 CID
zRPO LS6
zVIN S
zBore 99.0-99.018 mm 3.897-3.898 in
zStroke 92.0 mm 3.622 in
10.5:1
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2004 ENGINE PERFORMANCE Engine Mechanical (Introduction) - 5.7L - Corvette
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zCompression Ratio
zFiring Order 1-8-7-2-6-5-4-3
zSpark Plug Gap 1.016 mm 0.04 in
Block
zCamshaft Bearing Bore 1 and 5 Diameter - First Design 59.08-59.13 mm 2.325-2.327 in
zCamshaft Bearing Bore 2 and 4 Diameter - First Design 58.83-58.88 mm 2.316-2.318 in
zCamshaft Bearing Bore 3 Diameter - First Design 58.58-58.63 mm 2.306-2.308 in
zCamshaft Bearing Bore 1 and 5 Diameter - Second
Design 59.58-59.63 mm 2.345-2.347 in
zCamshaft Bearing Bore 2 and 4 Diameter - Second
Design 59.08-59.13 mm 2.325-2.327 in
zCamshaft Bearing Bore 3 Diameter - Second Design 58.58-58.63 mm 2.306-2.308 in
zCrankshaft Main Bearing Bore Diameter 69.871-69.889
mm 2.75-2.751 in
zCrankshaft Main Bearing Bore Out-of-Round 0.005 mm 0.0002 in
zCylinder Bore Diameter 99.0-99.018 mm 3.897-3.898 in
zCylinder Bore Taper - Thrust Side 0.018 mm 0.0007 in
zCylinder Head Deck Height - Measuring from the
Centerline of Crankshaft to the Deck Face 234.57-234.82
mm 9.235-9.245 in
zCylinder Head Deck Surface Flatness - Measured Within
a 152.4 mm (6.0 in) Area 0.08 mm 0.003 in
zCylinder Head Deck Surface Flatness - Measuring the
Overall Length of the Block Deck 0.22 mm 0.008 in
zValve Lifter Bore Diameter 21.417-21.443
mm 0.843-0.844 in
Camshaft
zCamshaft End Play 0.025-0.305 mm 0.001-0.012 in
zCamshaft Journal Diameter 54.99-55.04 mm 2.164-2.166 in
zCamshaft Journal Out-of-Round 0.025 mm 0.001 in
zCamshaft Lobe Lift - Exhaust 8.19 mm 0.322 in
zCamshaft Lobe Lift - Intake 8.24 mm 0.324 in
zCamshaft Runout - Measured at the Intermediate Journals 0.05 mm 0.002 in
Connecting Rod
zConnecting Rod Bearing Clearance - Production 0.023-0.065 mm 0.0009-0.0025 in
zConnecting Rod Bearing Clearance - Service 0.023-0.076 mm 0.0009-0.003 in
56.505-56.525 2.224-2.225 in
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zConnecting Rod Bore Diameter - Bearing End mm
zConnecting Rod Bore Out-of-Round - Bearing End 0.006 mm 0.00023 in
zConnecting Rod Bore Out-of-Round - Bearing End -
Service 0.006 mm 0.00023 in
zConnecting Rod Side Clearance 0.11-0.51 mm 0.00433-0.02 in
Crankshaft
zConnecting Rod Journal Diameter - Production 53.318-53.338
mm 2.0991-2.0999 in
zConnecting Rod Journal Diameter - Service 53.308 mm 2.0987 in
zConnecting Rod Journal Out-of-Round - Production 0.005 mm 0.0002 in
zConnecting Rod Journal Out-of-Round - Service 0.01 mm 0.0004 in
zConnecting Rod Journal Taper - Maximum for 1/2 of
Journal Length - Production 0.005 mm 0.0002 in
zConnecting Rod Journal Taper - Maximum for 1/2 of
Journal Length - Service 0.02 mm 0.00078 in
zCrankshaft End Play 0.04-0.2 mm 0.0015-0.0078 in
zCrankshaft Main Bearing Clearance - Production 0.02-0.052 mm 0.0008-0.0021 in
zCrankshaft Main Bearing Clearance - Service 0.02-0.065 mm 0.0008-0.0025 in
zCrankshaft Main Journal Diameter - Production 64.992-65.008
mm 2.558-2.559 in
zCrankshaft Main Journal Diameter - Service 64.992 mm 2.558 in
zCrankshaft Main Journal Out-of-Round - Production 0.003 mm 0.000118 in
zCrankshaft Main Journal Out-of-Round - Service 0.008 mm 0.0003 in
zCrankshaft Main Journal Taper - Production 0.01 mm 0.0004 in
zCrankshaft Main Journal Taper - Service 0.02 mm 0.00078 in
zCrankshaft Rear Flange Runout 0.05 mm 0.002 in
zCrankshaft Reluctor Ring Runout - Measured 1.0 mm
(0.04 in) Below Tooth Diameter 0.7 mm 0.028 in
zCrankshaft Thrust Surface - Production 26.14-26.22 mm 1.029-1.0315 in
zCrankshaft Thrust Surface - Service 26.22 mm 1.0315 in
zCrankshaft Thrust Surface Runout 0.025 mm 0.001 in
Cylinder Head
zCylinder Head Height/Thickness - Measured from the
Cylinder Head Deck to the Valve Rocker Arm Cover
Seal Surface 120.2 mm 4.732 in
zSurface Flatness - Block Deck - Measured Within a 152.4 0.08 mm 0.003 in
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mm (6.0 in) Area
zSurface Flatness - Block Deck - Measuring the Overall
Length of the Cylinder Head 0.1 mm 0.004 in
zSurface Flatness - Exhaust Manifold Deck 0.22 mm 0.008 in
zSurface Flatness - Intake Manifold Deck 0.22 mm 0.008 in
Intake Manifold
zSurface Flatness - Measured at Gasket Sealing Surfaces 0.5 mm 0.02 in
Lubrication System
zOil Capacity - with Filter 6.151 Liters 6.5 Quarts
zOil Capacity - without Filter 5.678 Liters 6.0 Quarts
zOil Pressure - Minimum - Hot
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
Oil Pan
zFront Cover Alignment - at Oil Pan Surface 0.0-0.5 mm 0.0-0.02 in
zRear Cover Alignment - at Oil Pan Surface 0.0-0.5 mm 0.0-0.02 in
zOil Pan Alignment - to Rear of Engine Block at
Transmission Bellhousing Mounting Surface 0.0-0.25 mm 0.0-0.01 in
Piston Rings
zPiston Ring End Gap - First Compression Ring -
Measured in Cylinder Bore - Production 0.23-0.44 mm 0.009-0.017 in
zPiston Ring End Gap - First Compression Ring -
Measured in Cylinder Bore 0.23-0.5 mm 0.009-0.0196 in
zPiston Ring End Gap - Second Compression Ring -
Measured in Cylinder Bore - Production 0.44-0.7 mm 0.017-0.027 in
zPiston Ring End Gap - Second Compression Ring -
Measured in Cylinder Bore 0.44-0.76 mm 0.0173-0.03 in
zPiston Ring End Gap - Oil Control Ring - Measured in
Cylinder Bore - Production 0.18-0.75 mm 0.007-0.029 in
zPiston Ring End Gap - Oil Control Ring - Measured in
Cylinder Bore - Service 0.18-0.81 mm 0.007-0.032 in
zPiston Ring to Groove Clearance - First Compression
Ring - Production 0.04-0.086 mm 0.00157-0.0033 in
zPiston Ring to Groove Clearance - First Compression
Ring - Service 0.04-0.068 mm 0.00157-0.0033 in
2004 Chevrolet Corvette
2004 ENGINE PERFORMANCE Engine Mechanical (Introduction) - 5.7L - Corvette
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zPiston Ring to Groove Clearance - Second Compression
Ring - Production 0.05-0.088 mm 0.002-0.0034 in
zPiston Ring to Groove Clearance - Second Compression
Ring - Service 0.05-0.088 mm 0.002-0.0034 in
zPiston Ring to Groove Clearance - Oil Control Ring -
Production -0.008 to +0.0176
mm -0.0003 to +0.0069 in
zPiston Ring to Groove Clearance - Oil Control Ring -
Service -0.008 to +0.0176
mm -0.0003 to +0.0069 in
Pistons and Pins
zPiston - Piston Diameter - Non Coated Skirt - at Size
Point 98.969-98.987
mm 3.8964-3.8997 in
zPiston - Piston Diameter - Measured Over Skirt Coating 98.984-99.027
mm 3.897-3.899 in
zPiston - Piston to Bore Clearance - Non Coated Skirt -
Production 0.013-0.049 mm 0.0005-0.0019 in
zPiston - Piston to Bore Clearance - Non Coated Skirt -
Service 0.013-0.074 mm 0.0005-0.0029 in
zPiston - Piston to Bore Clearance - Coated Skirt -
Production -0.027 to +0.029
mm -0.001 to +0.0011 in
zPiston - Piston to Bore Clearance - Coating Worn Off -
Service Limit 0.074 mm 0.0029 in
zPin - First Design Press Fit Pin Fit in Connecting Rod
Bore 0.02-0.043 mm -
Interference 0.00078-0.00169 in - Interference
zPin - First Design Press Fit Pin Clearance to Piston Pin
Bore - Production 0.01-0.02 mm 0.0004-0.00078 in
zPin - First Design Press Fit Pin Clearance to Piston Pin
Bore - Service 0.01-0.022 mm 0.0004-0.00086 in
zPin - First Design Press Fit Pin Diameter 23.997-24.0 mm 0.9447-0.9448 in
zPin - Second Design Full Floating Pin Fit in Connecting
Rod Bore - Production 0.007-0.02 mm 0.00027-0.00078 in
zPin - Second Design Full Floating Pin Fit in Connecting
Rod Bore - Service 0.007-0.022 mm 0.00027-0.00086 in
zPin - Second Design Full Floating Pin Clearance to
Piston Pin Bore - Production 0.002-0.01 mm 0.00008-0.0004 in
zPin - Second Design Full Floating Pin Clearance to
Piston Pin Bore - Service 0.002-0.015 mm 0.00008-0.0006 in
zPin - Second Design Full Floating Pin Diameter 23.952-23.955
mm 0.943-0.943 in
Valve System
2004 Chevrolet Corvette
2004 ENGINE PERFORMANCE Engine Mechanical (Introduction) - 5.7L - Corvette
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SEALERS, ADHESIVES, AND LUBRICANTS
Sealers, Adhesives, and Lubricants
zValves - Valve Face Angle 45 degrees
zValves - Valve Face Width 1.25 mm 0.05 in
zValves - Valve Lash Net Lash - No Adjustment
zValves - Valve Lift - Intake 14.02 mm 0.552 in
zValves - Valve Lift - Exhaust 13.92 mm 0.548 in
zValves - Valve Seat Angle 46 degrees
zValves - Valve Seat Runout 0.05 mm 0.002 in
zValves - Valve Seat Width - Exhaust 1.78 mm 0.07 in
zValves - Valve Seat Width - Intake 1.02 mm 0.04 in
zValves - Valve Stem Diameter - Production 7.955-7.976 mm 0.313-0.314 in
zValves - Valve Stem Diameter - Service 7.96 mm 0.314 in
zValves - Valve Stem-to-Guide Clearance - Production -
Intake 0.025-0.066 mm 0.001-0.0026 in
zValves - Valve Stem-to-Guide Clearance - Service -
Intake 0.093 mm 0.0037 in
zValves - Valve Stem-to-Guide Clearance - Production -
Exhaust 0.025-0.066 mm 0.001-0.0026 in
zValves - Valve Stem-to-Guide Clearance - Service -
Exhaust 0.093 mm 0.0037 in
zValve Rocker Arm - Valve Rocker Arm Ratio 1.70:1
zValve Springs - Valve Spring Free Length 53.4 mm 2.1 in
zValve Springs - Valve Spring Installed Height 45.75 mm 1.8 in
zValve Springs - Valve Spring Load - Closed 400 N at 45.75
mm 90 lb at 1.8 in
zValve Springs - Valve Spring Load- Open 1310 N at 31.75
mm 294 lb at 1.25 in
Application Type of Material GM Part Number United States Canada
Coolant Sensor Threads Sealant 12346004 10953480
Cylinder Head Core Hole Plugs Threadlock 12345382 10953489
Cylinder Head Expansion Plugs Threadlock 12345382 10953489
Engine Block Front Oil Gallery Plug Threadlock 12345382 10953489
Engine Block Plug Sealing Washers Sealant 12346004 10953480
2004 Chevrolet Corvette
2004 ENGINE PERFORMANCE Engine Mechanical (Introduction) - 5.7L - Corvette
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December-24-07 10:50:07 AM Page 14 © 2005 Mitchell Repair Information Company, LLC.

THREAD REPAIR SPECIFICATIONS
Engine Block - Front View
Fig. 1: Engine Block Bolt Holes Component View -Front View
Courtesy of GENERAL MOTORS CORP.
Engine Flywheel Bolt Threads Threadlock 12345382 10953489
Engine Oil 5W-30 Synthetic Oil 12345885 10953468
Engine Oil Supplement Fluorescent Dye 12345795 10953470
Exhaust Manifold Bolt Threads Threadlock 12345493 10953488
Fuel Rail Bolt Threads Threadlock 12345382 10953489
Ignition Coil and Bracket Assembly Bolts Threadlock 12345382 10953489
Intake Manifold Bolt Threads Threadlock 12345382 10953489
Oil Pan Surface at Front and Rear Covers Sealant 12378190 -
Oil Pressure Sensor Threads Sealant 12346004 10953480
Thread Repair Component Cleaner Cleaner 12346139 10953463
Thread Repair Component Cleaner Cleaner 12377981 10953463
Thread Repair Cutting Oil Lubricant 1052864 992881
2004 Chevrolet Corvette
2004 ENGINE PERFORMANCE Engine Mechanical (Introduction) - 5.7L - Corvette
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December-24-07 10:50:07 AM Page 15 © 2005 Mitchell Repair Information Company, LLC.

En
g
ine Block - Front View
Engine Block - Rear View
Hole Thread Size Insert Drill Counterbore Tool Tap Driver
Drill Depth -
Maximum mm
(in)
Tap Depth -
Maximum mm
(in)
1-6 M8 x
1.25
J
42385-
210
J
42385-
206 J 42385-207 J
42385-
208
J
42385-
209 22.5 (0.885) 17.5 (0.688)
7M10 x
1.5
J
42385-
215
J
42385-
211 J 42385-212 J
42385-
213
J
42385-
214 25.0 (0.984) 19.5 (0.767)
8M10 x
1.5
J
42385-
215
J
42385-
211 J 42385-212 J
42385-
213
J
42385-
214 32.5 (1.28) 25.0 (0.984)
9M8 x
1.25
J
42385-
210
J
42385-
206 J 42385-207 J
42385-
208
J
42385-
209 22.5 (0.885) 17.5 (0.688)
10 M10 x
1.5
J
42385-
215
J
42385-
211 J 42385-212 J
42385-
213
J
42385-
214 Thru Thru
11-
13 M8 x 1.25
J
42385-
210
J
42385-
206 J 42385-207 J
42385-
208
J
42385-
209 22.5 (0.885) 17.5 (0.688)
14 M8 x
1.25
J
42385-
210
J
42385-
206 J 42385-207 J
42385-
208
J
42385-
209 Thru 18.0 (0.708)
15 M8 x
1.25
J
42385-
210
J
42385-
206 J 42385-207 J
42385-
208
J
42385-
209 22.5 (0.885) 17.5 (0.688)
16 M8 x
1.25
J
42385-
210
J
42385-
206 J 42385-207 J
42385-
208
J
42385-
209 Thru 18.0 (0.708)
17-
27 M8 x 1.25
J
42385-
210
J
42385-
206 J 42385-207 J
42385-
208
J
42385-
209 22.5 (0.885) 17.5 (0.688)
2004 Chevrolet Corvette
2004 ENGINE PERFORMANCE Engine Mechanical (Introduction) - 5.7L - Corvette
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December-24-07 10:50:07 AM Page 16 © 2005 Mitchell Repair Information Company, LLC.

Fig. 2: Engine Block Bolt Holes Component View -Rear View
Courtesy of GENERAL MOTORS CORP.
Engine Block - Rear View
Hole Thread Size Insert Drill Counterbore Tool Tap Driver
Drill Depth -
Maximum mm
(in)
Tap Depth -
Maximum mm
(in)
1M10 x
1.5
J
42385-
215
J
42385-
211 J 42385-212 J
42385-
213
J
42385-
214 27.0 (1.06) 21.5 (0.846)
2-4 M8 x
1.25
J
42385-
210
J
42385-
206 J 42385-207 J
42385-
208
J
42385-
209 22.5 (0.885) 17.5 (0.688)
5-6 M10 x
1.5
J
42385-
215
J
42385-
211 J 42385-212 J
42385-
213
J
42385-
214 27.0 (1.06) 21.5 (0.846)
7-13 M8 x
1.25
J
42385-
210
J
42385-
206 J 42385-207 J
42385-
208
J
42385-
209 22.5 (0.885) 17.5 (0.688)
14-
16 M10 x 1.5
J
42385-
215
J
42385-
211 J 42385-212 J
42385-
213
J
42385-
214 27.0 (1.06) 21.5 (0.846)
2004 Chevrolet Corvette
2004 ENGINE PERFORMANCE Engine Mechanical (Introduction) - 5.7L - Corvette
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December-24-07 10:50:07 AM Page 17 © 2005 Mitchell Repair Information Company, LLC.

Engine Block - Left Side View
Fig. 3: Engine Block Bolt Holes Component View -Left Side View
Courtesy of GENERAL MOTORS CORP.
Engine Block - Left Side View
17-
18 M8 x 1.25
J
42385-
210
J
42385-
206 J 42385-207 J
42385-
208
J
42385-
209 22.5 (0.885) 17.5 (0.688)
Hole Thread
Size Insert Drill Counterbore Tool Tap Driver Drill Depth - Maximum mm (in)
Tap Depth -
Maximum mm
(in)
J 42385
1M28 x 1.25 N/A N/A N/A N/A N/A N/A N/A
2M8 x 1.25 210 206 207 208 209 28.5 (1.122) 23.0 (0.905)
3M8 x 1.25 210 206 207 208 209 21.5 (0.846) 16.0 (0.629)
4M10 x 1.25 215 211 212 213 214 29.0 (1.141) 23.0 (0.905)
5M10 x 1.5 215 211 212 213 214 27.0 (1.062) 21.5 (0.846)
6M16 x 1.5 N/A N/A N/A N/A N/A N/A N/A
2004 Chevrolet Corvette
2004 ENGINE PERFORMANCE Engine Mechanical (Introduction) - 5.7L - Corvette
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December-24-07 10:50:07 AM Page 18 © 2005 Mitchell Repair Information Company, LLC.

Engine Block - Right Side View
Fig. 4: Engine Block Bolt Holes Component View -Right Side View
Courtesy of GENERAL MOTORS CORP.
Engine Block - Right Side View
7M11 x 2.0 First
Design 108 105 N/A 106 107 124.0 (4.88) 115.0 (4.52)
7M11 x 2.0 Second
Design 108 105 N/A 106 107 69.0 (2.72) 60.0 (2.36)
8M11 x 2.0 108 105 N/A 106 107 69.0 (2.72) 60.0 (2.36)
zBolt holes 7, second design, and 8 have a 30 mm (1.18 in) counterbore included in the 69.0 mm
(2.72 in) drill depth. Use sleeve J 42385-315 with the drill and tap.
zBolt holes 7, first design, have a 85 mm (3.34 in) counterbore included in the 124.0 mm (4.88 in)
drill depth.
Hole Thread Size Insert Drill Counterbore Tool Tap Driver Drill Depth - Maximum mm (in)
Tap Depth -
Maximum mm
(in)
2004 Chevrolet Corvette
2004 ENGINE PERFORMANCE Engine Mechanical (Introduction) - 5.7L - Corvette
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December-24-07 10:50:07 AM Page 19 © 2005 Mitchell Repair Information Company, LLC.

Engine Block - Bottom View
J 42385
1M28 x 1.25 210 206 207 208 209 22.5 (0.885) 17.5 (0.688)
2M8 x 1.25 210 206 207 208 209 26.5 (1.04) 19.0 (0.784)
3M11 x 2.0 108 105 N/A 106 107 69.0 (2.72) 60.0 (2.36)
4M10 x 1.25 215 211 212 213 214 29.0 (1.141) 23.0 (0.905)
5M10 x 1.5 215 211 212 213 214 27.0 (1.062) 21.5 (0.846)
6M16 x 1.5 N/A N/A N/A N/A N/A N/A N/A
7M11 x 2.0 First
Design 108 105 N/A 106 107 124.0 (4.88) 115.0 (4.52)
7M11 x 2.0 Second
Design 108 105 N/A 106 107 69.0 (2.72) 60.0 (2.36)
zBolt holes 7, second design, and 3 have a 30 mm (1.18 in) counterbore included in the 69.0 mm
(2.72 in) drill depth. Use sleeve J 42385-315 with the drill and tap.
zBolt holes 7, first design, have a 85 mm (3.34 in) counterbore included in the 124.0 mm (4.88 in)
drill depth.
2004 Chevrolet Corvette
2004 ENGINE PERFORMANCE Engine Mechanical (Introduction) - 5.7L - Corvette
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December-24-07 10:50:07 AM Page 20 © 2005 Mitchell Repair Information Company, LLC.