2003-2006 Chevrolet Ssr Service & Repair Manual

2003 ENGINE Engine Mechanical - 5.3L - SSR SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Fastener Tightening Specifications Application Specification Metric English Air Cleaner Outlet Duct Clamp 7 N.m 62 lb in Air Conditioning Belt Tensioner Bolt 50 N.m 37 lb ft Air Conditioning Bracket Bolt 50 N.m 37 lb ft Air Conditioning Compressor Line-to-Condenser Bolt 16 N.m 12 lb ft Air Conditioning Compressor Line-to-Thermal Expansion Valve (TXV) Nut 20 N.m 15 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 Bolts - Outer Bolts - First Pass in Sequence 20 N.m 15 lb ft Crankshaft Bearing Cap Bolts - Outer Bolts - Final Pass in Sequence 51 degrees 2003 Chevrolet SSR 2003 ENGINE Engine Mechanical - 5.3L - SSR 2003 Chevrolet SSR 2003 ENGINE Engine Mechanical - 5.3L - SSR

Crankshaft Bearing Cap Side Bolts 25 N.m 18 lb ft Crankshaft Oil Deflector Nuts 25 N.m 18 lb ft Crankshaft Position Sensor Bolt 25 N.m 18 lb ft Cylinder Head Bolts - First Pass all M11 Bolts in Sequence 30 N.m 22 lb ft Cylinder Head Bolts - Second Pass all M11 Bolts in Sequence 90 degrees Cylinder Head Bolts - Final Pass all M11 Bolts in Sequence - Excluding the Medium Length Bolts at the Front and Rear of Each Cylinder 90 degrees Cylinder Head Bolts - Final Pass M11 Medium Length Bolts at the Front and Rear of Each Cylinder Head in Sequence 50 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 Drive Belt Idler Pulley Bolt 50 N.m 37 lb ft Drive Belt Tensioner Bolt 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 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 Cover Bolts 10 N.m 89 lb in Engine Front Cover Bolts 25 N.m 18 lb ft Engine Ground Strap-to-Frame Nut 25 N.m 18 lb ft Engine Ground-to-Engine Block Bolts 16 N.m 12 lb ft Engine Harness Bracket Nut 10 N.m 89 lb in Engine Mount Bracket Spacer 50 N.m 37 lb ft Engine Mount Frame Bracket 100 N.m 74 lb ft Engine Mount Nuts 50 N.m 37 lb ft Engine Rear Cover Bolts 25 N.m 18 lb ft Engine Service Lift Bracket M10 Bolts 50 N.m 37 lb ft Engine Service Lift Bracket M8 Bolt 25 N.m 18 lb ft Engine Sight Shield Bolt 10 N.m 89 lb in 2003 Chevrolet SSR 2003 ENGINE Engine Mechanical - 5.3L - SSR

Engine Sight Shield Bracket Bolt 5 N.m 44 lb in Engine Valley Cover Bolts 25 N.m 18 lb ft Evaporative (EVAP) Emission - Purge Solenoid Bolt 10 N.m 89 lb in Exhaust Manifold Bolts - First Pass 15 N.m 11 lb ft Exhaust Manifold Bolts - Final Pass 25 N.m 18 lb ft Exhaust Manifold Heat Shield Bolts 9 N.m 80 lb in Fuel Rail Bolts 10 N.m 89 lb in Fuel Rail Crossover Tube Bolts 3.8 N.m 34 lb in Fuel Rail Stop Bracket Bolt 50 N.m 37 lb ft Generator Power Lead Nut 9 N.m 80 lb in Ignition Coil-to-Bracket Bolts 8 N.m 71 lb in Ignition Coil Bracket-to-Valve Rocker Arm Cover 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 Intake Manifold Wiring Harness Stud 10 N.m 89 lb in J 42386-A Bolt 50 N.m 37 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 25 N.m 18 lb ft Oil Pan Baffle Bolts 12 N.m 106 lb in Oil Pan Closeout Cover Bolt - Left Side 9 N.m 80 lb in Oil Pan Closeout Cover Bolt - Right Side 9 N.m 80 lb in Oil Pan Cover Bolts 12 N.m 106 lb in Oil Pan Drain Plug 25 N.m 18 lb ft 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-to-Engine Block Bolts 25 N.m 18 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 2003 Chevrolet SSR 2003 ENGINE Engine Mechanical - 5.3L - SSR

ENGINE MECHANICAL SPECIFICATIONS Engine Mechanical Specifications Oil Pump Screen-to-Oil Pump Bolt 12 N.m 106 lb in Spark Plugs - New Cylinder Heads 20 N.m 15 lb ft Spark Plugs - All Subsequent Installations 15 N.m 11 lb ft Throttle Body Nuts 10 N.m 89 lb in Throttle Body Studs 6 N.m 53 lb in Upper Engine Mount Bracket 50 N.m 37 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 Metric English General  Engine Type V8  Displacement 5.3L 325 CID  RPO LM4  VIN P  Bore 96.0-96.018 mm 3.779-3.78 in  Stroke 92.0 mm 3.622 in  Compression Ratio 9.45:1  Firing Order 1-8-7-2-6-5-4-3  Spark Plug Gap 1.524 mm 0.06 in Block  Camshaft Bearing Bore 1 and 5 Diameter 59.08-59.13 mm 2.325-2.327 in  Camshaft Bearing Bore 2 and 4 Diameter 58.83-58.88 mm 2.316-2.318 in  Camshaft Bearing Bore 3 Diameter 58.58-58.63 mm 2.306-2.308 in  Crankshaft Main Bearing Bore Diameter 69.871-69.889 mm 2.75-2.751 in 2003 Chevrolet SSR 2003 ENGINE Engine Mechanical - 5.3L - SSR

 Crankshaft Main Bearing Bore Out-of-Round 0.006 mm 0.0002 in  Cylinder Bore Diameter 96.0-96.018 mm 3.779-3.78 in  Cylinder Bore Taper - Thrust Side 0.018 mm 0.0007 in  Cylinder Head Deck Height - Measuring from the Centerline of Crankshaft to the Deck Face 234.57-234.82 mm 9.235-9.245 in  Cylinder Head Deck Surface Flatness - Measured Within a 152.4 mm (6.0 in) Area 0.11 mm 0.004 in  Cylinder Head Deck Surface Flatness - Measuring the Overall Length of the Block Deck 0.22 mm 0.008 in  Valve Lifter Bore Diameter 21.417-21.443 mm 0.843-0.844 in Camshaft  Camshaft End Play 0.025-0.305 mm 0.001-0.012 in  Camshaft Journal Diameter 54.99-55.04 mm 2.164-2.166 in  Camshaft Journal Out-of-Round 0.025 mm 0.001 in  Camshaft Lobe Lift - Exhaust 6.96 mm 0.274 in  Camshaft Lobe Lift - Intake 6.82 mm 0.268 in  Camshaft Runout - Measured at the Intermediate Journals 0.05 mm 0.002 in Connecting Rod  Connecting Rod Bearing Clearance - Production 0.023-0.065 mm 0.0009-0.0025 in  Connecting Rod Bearing Clearance - Service 0.023-0.076 mm 0.0009-0.003 in  Connecting Rod Bore Diameter - Bearing End 56.505-56.525 mm 2.224-2.225 in  Connecting Rod Bore Out-of-Round - Bearing End - Production 0.004-0.008 mm 0.00015-0.0003 in  Connecting Rod Bore Out-of-Round - Bearing End - Service 0.004-0.008 mm 0.00015-0.0003 in  Connecting Rod Side Clearance 0.11-0.51 mm 0.00433-0.02 in Crankshaft  Connecting Rod Journal Diameter - Production 53.318-53.338 mm 2.0991-2.0999 in 2003 Chevrolet SSR 2003 ENGINE Engine Mechanical - 5.3L - SSR

 Connecting Rod Journal Diameter - Service 53.308 mm 2.0987 in  Connecting Rod Journal Out-of-Round - Production 0.005 mm 0.0002 in  Connecting Rod Journal Out-of-Round - Service 0.01 mm 0.0004 in  Connecting Rod Journal Taper - Maximum for 1/2 of Journal Length - Production 0.005 mm 0.0002 in  Connecting Rod Journal Taper - Maximum for 1/2 of Journal Length - Service 0.02 mm 0.00078 in  Crankshaft End Play 0.04-0.2 mm 0.0015-0.0078 in  Crankshaft Main Bearing Clearance - Production 0.02-0.052 mm 0.0008-0.0021 in  Crankshaft Main Bearing Clearance - Service 0.02-0.065 mm 0.0008-0.0025 in  Crankshaft Main Journal Diameter - Production 64.993-65.007 mm 2.558-2.559 in  Crankshaft Main Journal Diameter - Service 64.993 mm 2.558 in  Crankshaft Main Journal Out-of-Round - Production 0.003 mm 0.000118 in  Crankshaft Main Journal Out-of-Round - Service 0.008 mm 0.0003 in  Crankshaft Main Journal Taper - Production 0.01 mm 0.0004 in  Crankshaft Main Journal Taper - Service 0.02 mm 0.00078 in  Crankshaft Rear Flange Runout 0.05 mm 0.002 in  Crankshaft Reluctor Ring Runout - Measured 1.0 mm (0.04 in) Below Tooth Diameter 0.7 mm 0.028 in  Crankshaft Thrust Surface - Production 26.14-26.22 mm 1.029-1.0315 in  Crankshaft Thrust Surface - Service 26.22 mm 1.0315 in  Crankshaft Thrust Surface Runout 0.025 mm 0.001 in Cylinder Head  Cylinder Head Height/Thickness - Measured from the Cylinder Head Deck to the Valve Rocker Arm Cover Seal Surface 120.2 mm 4.732 in 2003 Chevrolet SSR 2003 ENGINE Engine Mechanical - 5.3L - SSR

 Surface Flatness - Block Deck - Measured Within a 152.4 mm (6.0 in) Area 0.08 mm 0.003 in  Surface Flatness - Block Deck - Measuring the Overall Length of the Cylinder Head 0.1 mm 0.004 in  Surface Flatness - Exhaust Manifold Deck 0.13 mm 0.005 in  Surface Flatness - Intake Manifold Deck 0.08 mm 0.0031 in  Valve Guide Installed Height - Measured from the Spring Seat Surface to the Top of the Guide 17.32 mm 0.682 in Intake Manifold  Surface Flatness - 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 Lubrication System  Oil Capacity - with Filter 5.68 Liters 6.0 Quarts  Oil Capacity - without Filter 5.20 Liters 5.5 Quarts  Oil 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  Front Cover Alignment - at Oil Pan Surface 0.0-0.5 mm 0.0-0.02 in  Rear Cover Alignment - at Oil Pan Surface 0.0-0.5 mm 0.0-0.02 in  Oil Pan Alignment - to Rear of Engine Block at Transmission Bell Housing Mounting Surface 0.0-0.25 mm 0.0-0.01 in Piston Rings  Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore - Production 0.23-0.44 mm 0.009-0.017 in  Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore - Service 0.23-0.5 mm 0.009-0.0196 in 2003 Chevrolet SSR 2003 ENGINE Engine Mechanical - 5.3L - SSR

 Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - Production 0.44-0.7 mm 0.017-0.027 in  Piston Ring End Gap - Second Compression Ring - Measured in Cylinder Bore - Service 0.44-0.76 mm 0.0173-0.03 in  Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore - Production 0.18-0.75 mm 0.007-0.029 in  Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore - Service 0.18-0.81 mm 0.007-0.032 in  Piston Ring to Groove Clearance - First Compression Ring - Production 0.04-0.085 mm 0.00157-0.00335 in  Piston Ring to Groove Clearance - First Compression Ring - Service 0.04-0.085 mm 0.00157-0.00335 in  Piston Ring to Groove Clearance - Second Compression Ring - Production 0.04-0.078 mm 0.00157-0.0031 in  Piston Ring to Groove Clearance - Second Compression Ring - Service 0.04-0.078 mm 0.00157-0.0031 in  Piston Ring to Groove Clearance - Oil Control Ring - Production 0.012-0.2 mm 0.0005-0.0078 in  Piston Ring to Groove Clearance - Oil Control Ring - Service 0.012-0.2 mm 0.0005-0.0078 in Pistons and Pins  Piston - Piston Diameter - Measured Over Skirt Coating 96.002-96.036 mm 3.779-3.78 in  Piston - Piston to Bore Clearance - Production -0.036 to +0.016 mm -0.0014 to +0.0006 in  Piston - Piston to Bore Clearance - Service Limit with Skirt Coating Worn Off 0.07 mm 0.0028 in  Pin - Piston Pin Fit in Connecting Rod Bore 0.02-0.043 mm - Interference 0.00078-0.00169 in - Interference  Pin - Piston Pin Clearance to Piston Pin Bore - Production 0.007-0.02 mm 0.00027-0.00078 in  Pin - Piston Pin Clearance to Piston Pin Bore - Service 0.007-0.021 mm 0.00027-0.00082 in 2003 Chevrolet SSR 2003 ENGINE Engine Mechanical - 5.3L - SSR

SEALERS, ADHESIVES, AND LUBRICANTS Sealers, Adhesives, and Lubricants  Pin - Piston Pin Diameter 23.997-24.0 mm 0.9447-0.9448 in Valve System  Valves - Valve Face Angle 45 degrees  Valves - Valve Face Width 1.25 mm 0.05 in  Valves - Valve Lash Net Lash - No Adjustment  Valves - Valve Lift - Intake 11.6 mm 0.457 in  Valves - Valve Lift - Exhaust 11.85 mm 0.466 in  Valves - Valve Seat Angle 46 degrees  Valves - Valve Seat Runout 0.05 mm 0.002 in  Valves - Valve Seat Width - Exhaust 1.78 mm 0.07 in  Valves - Seat Width - Intake 1.02 mm 0.04 in  Valves - Valve Stem Diameter - Production 7.955-7.976 mm 0.313-0.314 in  Valves - Valve Stem Diameter - Service 7.95 mm 0.313 in  Valves - Valve Stem-to-Guide Clearance - Production - Intake 0.025-0.066 mm 0.001-0.0026 in  Valves - Valve Stem-to-Guide Clearance - Service - Intake 0.093 mm 0.0037 in  Valves - Valve Stem-to-Guide Clearance - Production - Exhaust 0.025-0.066 mm 0.001-0.0026 in  Valves - Valve Stem-to-Guide Clearance - Service - Exhaust 0.093 mm 0.0037 in  Rocker Arms - Valve Rocker Arm Ratio 1.70:1  Valve Springs - Valve Spring Free Length 52.9 mm 2.08 in  Valve Springs - Valve Spring Installed Height 45.75 mm 1.8 in  Valve Springs - Valve Spring Load - Closed 340 N at 45.75 mm 76 lb at 1.8 in  Valve Springs - Valve Spring Load - Open 980 N at 33.55 mm 220 lb at 1.32 in 2003 Chevrolet SSR 2003 ENGINE Engine Mechanical - 5.3L - SSR

THREAD REPAIR SPECIFICATIONS Engine Block - Front View Application Type of Material GM Part Number United States Canada Coolant Temperature Sensor Threads Sealant 12346004 10953480 Cylinder Head Coolant Plugs Threadlock 12345382 10953489 Cylinder Head Core Hole Plugs - Aluminum Threadlock 12345382 10953489 Engine Block Front Oil Gallery Plug Threadlock 12345382 10953489 Engine Block Plug Sealing Washers Sealant 12346004 10953480 Engine Oil 5W-30 Oil 12345610 993193 Engine Oil Supplement Fluorescent Dye 12345795 10953470 Exhaust Manifold Bolt Threads Threadlock 12345493 10953488 Flywheel Bolt Threads Threadlock 12345382 10953489 Fuel Rail Bolt Threads Threadlock 12345382 10953489 Ignition Coil Bracket Bolts Threadlock 12345382 10953489 Ignition Coil to Bracket Bolts Threadlock 12345382 10953489 Intake Manifold Bolts 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 2003 Chevrolet SSR 2003 ENGINE Engine Mechanical - 5.3L - SSR

2003-2006 Chevrolet Ssr Service & Repair Manual

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