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Author Topic: FAQ and general information on V8 RX7s  (Read 320280 times)

Offline mayhamfx

FAQ and general information on V8 RX7s
« on: May 29, 2010, 03:42:29 PM »
Welcome to the Frequently Asked Questions for V8 RX7s. It is organized into sub sections with links to various subjects. If you know of information that should be added to a section post it in the revision thread or PM me or another moderator and we will add it in. The same goes for broken links. This is just a start and will always be a work in progress that hopefully will grow into an encyclopedia of V8-RX7 knowledge.

Section 1) General RX7 and swap information
Section 2) Drivetrain
Section 3) Electical
Section 4) Chassis \ Brakes \ Wheels \ Suspension
Section 5) Body
Section 6) Forced induction
Section 7) Links
« Last Edit: February 03, 2011, 10:43:10 AM by digitalsolo »
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Offline mayhamfx

« Last Edit: February 03, 2011, 10:44:30 AM by digitalsolo »
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Offline mayhamfx

« Last Edit: February 03, 2011, 10:45:38 AM by digitalsolo »
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Offline mayhamfx

Section 4) Chassis \ Brakes \ Wheels \ Suspension
« Reply #4 on: May 29, 2010, 03:44:49 PM »
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Offline mayhamfx

Section 5) Body
« Reply #5 on: May 29, 2010, 03:45:19 PM »
« Last Edit: February 03, 2011, 10:48:52 AM by digitalsolo »
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Offline mayhamfx

Section 6) Forced induction
« Reply #6 on: May 29, 2010, 03:45:56 PM »
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Offline mayhamfx

Introduction, the cars
« Reply #7 on: May 29, 2010, 04:11:08 PM »


The Cars, an introduction:  (from Wikipedia}

The  Mazda RX-7 is a sports car produced by the Japanese automaker Mazda   from 1978 to 2002. The original RX-7 featured a twin-rotor Wankel   rotary engine and a sporty front-midship, rear-wheel drive layout. The   original RX-7 was a sports coupe. The compact and light-weight Wankel   engine or rotary engine is situated slightly behind the front axle, a   configuration marketed by Mazda as "front mid-engine". It was offered   in America as a two-seat coupe, with optional "occasional" rear-seats   in Japan, Australia, and other parts of the world.

First Generation: SA/FB



Series 1 (1979?1980)
   Is commonly referred to as the "SA22C" from the first alphanumerics of   the vehicle identification number. This series of RX-7 had exposed   steel bumpers and a high-mounted indentation-located license plate.
   In 1980 Mazda released 3000 special models known as the LS (Leather  Sport). This package added an LS badge, full leather upholstery,  sunroof, and gold-colored alloys. This model was only available in  three different colors Aura White (1250 made), Brilliant Black (1250  made) and Solar Gold (500 made).

Series 2 (1981?1983)
  Had  integrated plastic-covered bumpers, wide black rubber body side   moldings, wraparound taillights and updated engine control components.   The GSL package provided optional 4-wheel disc brakes, front  ventilated  (Australian model) and clutch-type rear limited slip  differential  (LSD). Known as the "FB" in North America after the US  Department of  Transportation mandated 17 digit Vehicle Identification  Number  changeover. Elsewhere in the world, the 1981-1985 RX-7 retained  the  'SA22C' VIN prefix. As a result, enthusiasts outside North America   never picked up the "FB" nickname.

Series 3 (1984?1985)
   Featured an updated lower front fascia. GSL package was continued into   this series, but Mazda introduced the GSL-SE sub-model. GSL-SEs had   much the same options as the GSL (clutch-type rear LSD and rear disc   brakes), but the brake rotors were larger, allowing Mazda to use the  more common lug nuts (versus  bolts), and a new bolt pattern of 4x114.3  (4x4.5"). Also, they had  upgraded suspension with stiffer springs and  shocks.
  The handling and acceleration of the car were noted to  be of a high  caliber for its day. This generation RX-7 had "live axle"  4-link rear  suspension with Watt's linkage, a 50/50 weight ratio, and  weighed under  2600 lb (1180 kg). It was the lightest generation of  RX-7 ever  produced.

Second Generation, FC



Series 4 (1986?1988)
   Was available with a naturally aspirated, fuel-injected 13B, or   optional turbocharged model, known as the Turbo II in the North   American market, was also available.

Series 5 (1989?1992)
  Featured updated styling. The Turbo II moniker was dropped, and the turbocharged model was simply dubbed Turbo. 
   The second generation RX-7 ("FC", VIN begins JM1FC3 or JMZFC1), still   known as the "Savanna RX-7" in Japan, featured a complete restyling   reminiscent of the Porsche 928. Mazda's stylists actually focused more   on the Porsche 944 for their inspiration in designing the FC because   the new car was being styled primarily for the American market, where   the majority of first generation RX-7's had been sold. While the   SA22/FB was a purer sports car, the FC tended toward the softer   sport-tourer trends of its day. Handling was much improved, with less   of the oversteer tendencies of the FB. Steering was more precise, with   rack and pinion steering replacing the old recirculating ball steering   of the FB. Disc brakes also became standard, with some models (S4:  GXL,  GTU, Turbo II, Convertible; S5: GXL, GTUs, Turbo, Convertible)  offering  four-piston front brakes. The rear seats were optional in  some models  of the FC RX-7, but are not commonly found in the American  Market.  Mazda also introduced Dynamic Tracking Suspension System  (DTSS)in the  2nd generation RX-7. The revised independent rear  suspension  incorporated special toe control hubs which were capable of  introducing  a limited degree of passive rear steering under cornering  loads. Mazda  also introduced Auto Adjusting Suspension (AAS) in the  2nd generation  RX-7. The system changed damping characteristics  according to the road  and driving conditions. The system compensated  for camber changes and provided anti-dive and  anti-squat effects. 80  lb (36 kg) heavier and more isolated than its  predecessor, the FC  continued to win accolades from the press.  Australian Motors Mazda  released a limited run of 250 'Sports' model  Series 4 RX-7's; each  with no power steering, power windows or rear wiper as an attempt to  reduce the weight of the car.

Convertible

Mazda  introduced a power operated, convertible version of the RX7 in   1988.The convertible featured a removable rigid section over the   passengers and a folding textile rear section with heatable rear glass   window. Mazda introduced with the convertible the first integral   windblocker, a rigid panel that folded up from behind the passenger   seats to block unwanted drafts from reaching the passengers ? thereby   extending the driving season for the car in open mode. The convertible   also featured optional headrest mounted audio speakers and a folding   vinyl snap-fastened tonneau cover.
 
Third Generation, FD
 
 

Series 6 (1992?1995)
    Was exported throughout the world and had the highest sales.  Only the  1993?1995 model years were sold in the U.S. and Canada. The third and  final generation of the RX-7, FD (with FD3S for the JDM  and JM1FD for  the USA VIN). In North America, three models were  offered; the "base",  the touring, and the R models. The touring FD had  a sunroof, leather  seats, and a complex Bose Acoustic Wave system. The  R (R1 in 1993 and  R2 in 1994?95) models featured stiffer suspensions,  an aerodynamics  package, suede seats, and Z-rated tires.
    It featured an  aerodynamic, futuristic-looking body design (a testament  to its near  11-year lifespan). Road&Track magazine proclaimed "The  ace in  Mazda's sleeve is the RX-7, a car once touted as the purest,  most  exhilarating sports car in the world.? Handling in the FD was  regarded  as world-class, and it is still regarded as being one of the  finest  handling and best balanced cars of all time.
 

Series 7 (1996?1998)
   Included minor changes to the car. In Japan, the Series 7 RX-7 was   marketed under the Mazda brand name. The Series 7 was also sold in   Australia, New Zealand and the UK. Series 7 RX-7s were produced only  in  right-hand-drive configuration.
 
Series 8 (January 1999? August 2002)
   Was the final series, and was only available in the Japanese market.   Improved radiator cooling was made possible by a revised frontal area.   The seats, steering wheel, and front and rear lights were all changed.   The rear spoiler was modified and gained adjustably.
 

 
 
 
« Last Edit: May 29, 2010, 04:13:03 PM by mayhamfx »
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Offline mayhamfx

General swap questions
« Reply #8 on: May 29, 2010, 04:30:10 PM »
How much will it cost?

If your handy with tools, can fabricate your own parts, plus have a  yard full of old cars to get donor parts from I'd say you could do it  for under $1000. Other people, skilled or not, have no problem putting  $15,000 into their cars creating beautiful examples. In general a  decent LSx based conversion will run you $5000 - $10,000 and it will  more likely be closer to the $10,000 end. There are ways to save money,  get a donor car (wrecked Camaro for instance), take the complete  drivetrain out and sell whatever other parts you can to help offset the  costs. These swaps have a habit of $25 and $50 dollaring you to death.

How long does it take to do a swap?

I've heard of guys doing a basic swap in a weekend with all the parts  in place, other people have been working on their cars for years. I  think most people collect the parts they need over a few months before  they start then take the plunge. It's your project, you decide how much  time and effort to put into it.
 
Whats involved in doing a swap?

Basically you're replacing the entire drivetrain of the car. The rotary  leaves for obvious reasons. You cannot reuse the transmission (no way,  no how, it's a square peg in a round hole thing), and unless you have  the stronger TII differential, that will have to be replaced too. Most  of if not all of the engine support systems, wiring, cooling, fuel,  mounting and exhaust will be replaced as well. Read the threads in the  build section, they will show you all sorts of different approaches. Read some of the build threads here: NoRotors Build Threads

What parts do I need for a swap?

Lots. It varies with each project and by how much you want to spend or how radical you want to go. Here's a very basic list:
  Engine and all the wiring and ECM/PCM (computer if it uses one)
  Transmission, Automatic or Manual plus clutch and clutch cylinder and slave etc.
  Driveshaft
  Differential, Solid or IRS plus halfshafts.
  Mounting hardware for all the above items
  Exhaust system
  Radiator and Electric fan or fans
  I could go on all the way down the page but that will give you a rough  idea, here's a link to a more detailed list for one swap: http://www.norotors.com/index.php?topic=193.msg1584.html#msg1584


Will the handling of the car be ruined by putting a V8 in?

In a word, No. If you use an LS1 (all aluminum block and heads) and  relocate your battery to the back the 50/50 weight distribution is  perfectly maintained. The V8 sits back which keeps the weight more balanced. Other engines that are heavier  will add a small amount to the front, but not enough to matter. Most  people are surprised to find that their V8 swapped RX7 handles just as  well as stock (except now you can steer with the throttle).
 
What Is the best motor to use?

  Here are the most common choices,:
  SBC small block Chevrolet 262-400 cid (first generation)
  SBF small block Ford 289 - 302 - 351 cid
  LT1 small block Chevrolet 350 cid (second generation)
  LS1 small block Chevrolet 350 cid (third generation)
  LSx any small block Chevrolet based on the third generation design including LS2, LS3, LS6, LS7 and all the truck motors too.
  It's up to you what you use, if you can make it fit go for it. The  above choices are proven and well documented so it will be easier to get help and advice than if you chose something more oddball.
« Last Edit: February 03, 2011, 10:46:51 AM by digitalsolo »
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Offline mayhamfx

« Last Edit: February 03, 2011, 10:48:29 AM by digitalsolo »
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Offline mayhamfx

Gen III / IV oil pans
« Reply #10 on: May 29, 2010, 08:49:08 PM »
2007 Truck 4.8, 5.3, 6.0, 6.2 with Filter,

Capacity: 6 qts
Oil pan: 12609074


2002-2006 4.8, 5.3, 6.0, Truck/Escalade
Truck "C/K"
Capacity: 6.5 qts
Oil pan: 12579273
Oil pump pickup: 12563961
Windage tray: 12558268 (same as CTS-V) updated to PN: 12611129
Dipstick tube: 12563918
Dipstick: 12558684
O-ring for Oil pump pickup: 12563963



F-Body
Camaro / Firebird
Capacity: 5.5 qts
Oil pan , List Price $266.39: 12558762
Oil pump pickup: 12558251
Windage tray: 12558253
Dipstick tube: 12551577
Dipstick: 12551581
O-ring for Oil pump pickup: 12557752 (Same as Corvette LS1/LS6)



Corvette LS2 with filter:
Corvette "Y" (not LS7)
Capacity: 5.5 qts
Oil pan: 12581810
Oil pump pickup: ?
Windage tray: ?
Dipstick tube: ?
Dipstick: 12570788
O-ring for Oil pump pickup:?



Corvette LS7 dry sump


ATS LS7 Sheet metal, dry sump oil pan
ATS  LS7 oil pan will fit into the 1st gen F body chassis with no   modifications, and fully retains all oil control, dry sump fittings,   and windage tray


Hummer H3 5.3 Alpha :

Capacity: 5.5 qts
Oil pan: 12614821
Oil pump pickup: 12608593
Windage tray: 12611129 (same as c/k truck)
Dipstick tube: 12612015 (need confirmation on this p/n) confirmed as pn: 12584738
Dipstick: 12603506 (need confirmation on this p/n) confirmed as pn: 12603506
O-ring for Oil pump pickup:? 12584922 green pn`s updated/added by G-Body



GTO

Capacity: 6.5 qts
Oil pan: 12599397  (5.7 pan is 12581209)
Oil pump pickup:
Windage tray:
Dipstick tube:
Dipstick:
O-ring for Oil pump pickup:?




SSR & Trailblazer SS and 5.3, 6 qt:
SSR & Trailblazer
Capacity: 6 qts
Oil pan: 12579203
Oil pump pickup: ?
Windage tray: ?
Dipstick tube: ?
Dipstick: ?
O-ring for Oil pump pickup:?



Cadillac CTSv  :
Capacity: 5.5 qts
Oil pan: 12577901
Oil pump pickup: 12577906
Windage tray: 12558268 (same as Truck C/K)
Dipstick tube: ?
Dipstick: ?
O-ring for Oil pump pickup:?
Oil pan baffle: 12577904



2010 Camaro LS3 Pan



2007 Holden,
( Vauxhall Monaro)
Capacity: 6.5 qts
Oil pan: 12561541
Oil pump pickup: 12572654
Windage tray: 12558189 (same as Corvette)
Dipstick tube: 12561544
Dipstick: 12562468 (same as Corvette)
O-ring for Oil pump pickup:


Canton LS1 Swap Pan P/N 13-274A :
Pan sump is 5 1/2 deep, 12-1/2 wide, and 8 3/4" long for a 6 1/2 quart system capacity.


Moroso Conversion LS Pan: 6-quart, P/N 20141
Pickup: P/N 24050:


Turbotime:


Autokraft:





Milodon 30915


Windage Trays, Y-Body (bottom) vs. F-Body (top)
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Offline mayhamfx

Gen III / IV Accessrory drive part numbers
« Reply #11 on: May 29, 2010, 08:52:31 PM »
 C5

Alternator (1)10246634 (production) 10316182 (service)
Alternator to bracket bolts (2) 24503609
Alt bracket to head bolts (3) 11516357
Alt bracket to head bolt (1) 11516356

P/S fluid reservoir bracket (1) 12555222
P/S fluid reservoir (1) 26046502
P/S reservoir hose (1) 26046910
P/S reservoir cap (1) 26022453
P/S pump (1) 26046503
P/S pump pulley (1) 12559890
P/S pump brace (1) 12555693 Same as f-body
P/S pump bolts (2) 14078896 Same as f-body
P/S pump bolts (2) 11515758 Same as f-body
Belt idler pulley (1) 12564401 Same as f-body

Harmonic balancer (1) 12560115
Belt tensioner assembly (1) 12559325

A/C belt tensioner assembly (1) 12560345 Same as f-body
A/C belt idler pulley (1) 12557334
A/C compressor bracket (1) 12556444
A/C compressor (1) 1137031
A/C bracket stud (1) 12556447
A/C bracket bolt (1) 11515768
A/C compressor bolt (1) 11516714
A/C compressor bolt (1) 12552922
A/C compressor bolt (1) 11509202
A/C compressor nut (1) 10255857

F-Body

Alternator:
Rear bracket P/N 12556915
Front bracket P/N 12563327

Power steering:
Main bracket P/N 12561584
Front brace P/N 12555693

CTS-V

bracket 12578551
bolt,pump to bracket 11518075
pulley,ps pump 12578552
bolt,bracket to head 11518633
hose,ps-fluid rsrvr to pump 25768914
hose,ps-fluid rsrvr to cooler 15145898
hose,ps pump to rack and pinion 89060184
hose,ps cooler to rack and pinion 15145899
cooler for ps fluid 25767911

Alternator system
bolt qty(2) 11518637
bracket 12578550
bolt 11518630
alternator 25750935

Belt/tensioner system

tensioner 12569301
bolt 11515768
belt/ac compressor 12585551
pulley,belt idler 12568996
belt,fan/wp/alt/ps 12578553

Air conditioning
bracket 12578548
compressor 25752698
bolt,ac compressor to bracket,long 11509202
bolt,ac compressor to bracket,short 11518627                                                                                                                                                                                     
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Offline mayhamfx

Gen III (LS1 LS6) Torque Specifications
« Reply #12 on: May 29, 2010, 08:56:40 PM »
« Last Edit: May 29, 2010, 08:58:56 PM by mayhamfx »
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Offline mayhamfx

Gen III (LS1 LS6) OEM Dimensions and Clearances
« Reply #13 on: May 29, 2010, 09:01:43 PM »
Production = (P), Service Limit = (SL), Out-of-Round = O-o-R
Run Out = RO, Inside Dia. = ID, Outside Dia. = OD

CAMSHAFT:
Base Circle Dia.:
'97-'04 LS1 = 19.7mm / 0.776"
'01 LS6 = 19.3mm / 0.760"
'02 -'04 LS6 = 19.0mm / 0.748
End Play: 0.025-0.305mm / 0.001-0.012"
Journal Dia.: 54.99-55.04mm / 2.164-2.166"
Journal Dia. O-o-R: 0.025mm / 0.001"
Intake Lobe Lift: 7.04mm / 0.277"
Exhaust Lobe Lift: 7.13mm / 0.281"
Poller Lifter Dia.: 17.78mm / 0.700"
RO @ Intermediate Journals: 0.05mm / 0.002"
Lobe Base Circle Radius:
'97-'04 LS1: 19.7mm / 0.776"
'01 LS6: 19.3mm / 0.760" (reduced for ^ valve lift)
'02-'04 LS6: 19.0mm / 0.748 " " " " " "

CONNECTING ROD:
Bearing Bore Dia.: 56.505-56.525mm / 2.224-2.225"
Bearing Bore O-o-R (P): 0.004mm / 0.00015"
Bearing Bore O-o-R (SL): 0.008mm / 0.0003"
Bearing Clearance (P): 0.015-0.063mm / 0.0006-0.00248"
Bearing Clearance (SL): 0.015-0.076mm/0.0006-0.003"
Bearing Width: 24mm / 0.9449"
Side Clearance: 0.11-0.51mm / 0.00433-0.02"
Center to Center: 154.89mm / 6.098"
Piston Pin Bore Dia.: 23.97mm / 0.9436"
Piston Pin Boss Width: 24mm / 0.9449"
Piston Pin Press Interference:0.020-0.043mm / 0.0008-0.0017"
Rod Bolts: M9 x 1" (replace with ARP/Katech if > 450HP)

CRANKSHAFT:
Rotation = Clockwise (looking at front of block)
Bearing Clearance (P): 0.018-0.054mm / 0.0007-0.00212"
Con Rod Journal Dia. (P): 53.318-53.338mm / 2.0991-2.0999"
Con Rod Journal Dia. (SL): 53.308mm Min. / 2.0987" Min.
Con Rod Journal Taper (P): 0.005mm / 0.0002"
(Maximum for 1/2 Journal length)
Con Rod Journal Taper (SL): 0.01mm Max. / 0.0004" Max.
Con Rod Journal O-o-R (P): 0.005mm / 0.0002"
Con Rod Journal O-o-R (SL): 0.01mm / 0.0004"
Con Rod Journal Width: 48.37mm / 1.902"
End Play: 0.04-0.2mm /0.0015-0.0078"
Main Journal Dia. (P): 64.993-65.007mm / 2.558-2.559"
Main Journal Dia. (SL): 64.993mm Min. / 2.558" Min.
Main Journal O-o-R (P): 0.003mm / 0.000118"
Main Journal O-o-R (SL): 0.008mm / 0.0003
Main Journal Taper (P): 0.01mm / 0.0004"
Main Journal Taper (SL): 0.02mm / 0.00078"
Main Journal Width: 22.99mm / 0.905"
Reluctor Ring RO: 0.25mm / 0.01"
(Measured @ 1.0mm/0.04" below tooth Dia.)
Crank RO : 0.05mm / 0.002" (Measured at rear flange)
Flywheel Bolt Base Circle: 78.99mm / 3.110"
Stroke: 92mm / 3.622"
Rear Seal ID: 114.99mm / 4.527"
Thrust Wall RO: 0.025mm / 0.001"
Thrust Wall Width (P): 26.14-26.22mm / 1.029-1.032"
Thrust Wall Width (SL): 26.32 Max. / 1.036" Max.

CYLINDER BORE:
Bore Dia.: 99.0-99.018mm / 3.897-3.898"
Bore Taper Thrust Side: 0.018mm Max. / 0.0007" Max.
Bank Angle = 45 degrees
Cylinder Bank Offset: 24.10mm / 0.949"

CYLINDER HEAD: A356 T6
Block Deck Flatness: 0.11mm / 0.004" (within a 6" area)
Block Deck Flatness: 0.22mm / 0.008" (length of head)
Exhaust Manifold Deck Flatness: 0.22mm / 0.008"
Intake Manifold Deck Flatness: 0.22mm / 0.008"
Height: 120.2mm / 4.732" (Deck to Rocker Cover Surfaces)
Valve Angle: 15 degrees
Valve Guide Material = Sintered Iron (Press IN)
Valve Guide Seperation: 48.6mm / 1.913"
Valve Seat Angles: 30/45/60 degree blend into chamber
Valve Stem Dia.: 8.001mm / 0.315"

ENGINE BLOCK: A319 T5 / 107#'s
Length: 519mm / 20.43"
Width: 460mm / 18.11"
Deck Height: 234.57-234.82mm / 9.235-9.245"
Cylinder Bank Angle = 45 degrees
Cylinder Bank Offset: 24.10mm / 0.949"
Center Main = Crank Thrust Wall #3
Indexing = Crank CenterLine
Camshaft Bearing Bore Dia.: 55.063-55.088mm / 2.168-2.169"
Block Deck Flatness: 0.11mm / 0.004" (measured within 6")
Block Deck Flatness: 0.22mm / 0.008" (length of Deck)
Main Bearing Bore Dia. (P): 69.871-69.889mm / 2.750-2.751"
Valve Lifter Bore Dia. (P):21.417-21.443 / 0.843-0.844"

FUEL INJECTION:
LS1 Static Flow Rate = 3.6 gal/sec.
Cranking Fuel pressure = 53 to 63 psi



IGNITION:
Coil Output = 60mJ
Sparkplug Wire length = 219mm
Sparkplug Type = AC 41-931 / Beru Silverstone S1K
Sparkplug gap = 1.5mm / 0.060"

INTAKE MANIFOLD;
Head Deck Flatness: 0.5mm / 0.02" @ gasket mating surface
LS1 MAF ID = 75mm
LS1 Throttle Body ID = 75mm
LS6 MAF ID = 80mm
LS6 Throttle Body ID = 80mm

OIL PAN & FRONT/REAR COVER Alignment:
Oil Pan to Rear of Block: 0.0-0.25mm / 0.0-0.01"
(@ Bellhousing Surface)
Front Cover: 0.0-0.5mm / 0.0-0.2" (@ Oil Pan Surface)
Rear Cover: 0.0-0.5mm / 0.0-0.2" (@ Oil Pan Surface)

OIL PUMP:
Dia: 89.99mm / 3.543"
Gear Thickness: 10.69mm / 0.421"
Pressure Relief Setting (Factory): 60 psig @ 5,000 RPM

PISTONS: Cast Eutectic Aluminum, +'03 have coated skirts
Weight = 434 grams
Piston OD: 98.964-98.982mm / 3.8962-3.8969"
Piston to Bore Clearance(P): 0.018-0.054mm/0.0007-0.00212"
Piston to Bore Clear. (SL): 0.018-0.054mm / 0.0007-0.00212"
(Maximum)
Piston Deck Height in Operation: 0.203mm / 0.008"
(Above Deck Surface)
Top Land Thickness: 34mm / 0.177"

PISTON PINS:
Pin to Piston Bore (P): 0.01-0.02mm / 0.0004-0.00078"
Pin to Piston Bore (SL): 0.01-0.02mm / 0.0004-0.00078" Max.
Pin Dia.: 23.997-24.0mm / 0.9447-0.9448"
Pin Fit in Con Rod: 0.02-0.043mm / 0.00078-0.00169"
(Interference)

PISTON RINGS:
Top Comp. Thickness: 1.500mm / 0.59"
Top Comp. Gap Clocking: None Required
Top Comp. End Gap (P): 0.23-0.38mm / 0.009-0.0149"
Top Comp. End Gap (SL): 0.23-0.38mm / 0.009-0.0149" Max.
Top Comp. Groove (P):0.04-0.085mm / 0.00157-0.003346"
Top Comp. Groove (SL):0.04-0.085mm/0.00157-0.003346"Max.
2nd Comp. Thickness: 1.500mm / 0.59"
Top Comp Gap Clocking: None Required
2nd Comp. End Gap (P): 0.44-0.64mm / 0.0173-0.0251"
2nd Comp. End gap (SL): 0.44-0.64mm / 0.0173-0.0251" Max.
2nd Comp. Groove (P): 0.04-0.08mm / 0.00157-0.003149"
2nd Comp. Groove (SL):0.04-0.08mm/0.00157-0.003149"Max.
Oil Cont. Rail Thickness (2): 3.00mm / .188" (EACH)
Oil Cont. Top Rail Gap Clocking: 25 degrees from Top Ring
Oil Cont. 2nd Rail gap Clocking: 25 degrees from Expander
Oil Cont. End Gap (P): 0.18-0.69mm / 0.007-0.0271"
Oil Cont. End Gap (SL): 0.18-0.69mm / 0.007-0.0271" Max.
Oil Cont. Groove (P): 0.01-0.22mm / 0.0004-0.00866"
Oil Cont. Groove (SL):0.01-0.22mm / 0.0004-0.00866" Max.

VALVETRAIN:Hydraulic Roller
Rocker Arm Ratio = 1.70:1
Valve Lash Net Lash: No Adjustment
Valve Face Angle = 45 degrees
Valve Seat Angle = 46 degrees
Valve Seat RO: 0.05mm / 0.002" Max.
Valve Seat Width (Intake) = 1.02mm / 0.04"
Valve Seat Width (Exhaust) = 1.78mm / 0.07"
Valve Stem:
Clearances:
Intake (P): 0.025-0.066mm / 0.001-0.0026"
Intake (SL): 0.093mm / 0.0037" Max.
Exhaust (P): 0.025-0.066mm / 0.001-0.0026"
Exhaust (SL): 0.093mm / 0.0037" Max
Oil Seal Installed Height = 18.1-19.1mm / 0.712-0.752"
(Measured from VS Shim toTop Edge od Seal Body)
Valve Stem Dia. (P): 7.955-7.976mm / 0.313-0.314"
Valve Stem Dia. (SL) 7.9mm / 0.311 Min.
Valve Spring:
Free Length = 52.9mm / 2.08"
Pressure (Closed) = 340 N @ 45.75mm / 76# @ 1.80"
Pressure (Open) = 980 N @ 33.55mm / 220# @ 1.32"
Installed Height (Intake) = 45.75mm / 1.800"
Installed Height (Exhaust) = 45.75mm / 1.8"
Valve Guide Installed Height = 17.32mm / 0.682"
(Measured from Spring Seat Surface to Top of valve Guide)
Roller Lifter Dia.:17.78mm / 0.700"
Valve Material: Stainless Steel, Hollow Stems, Na filled Exhaust


Cams
1997-2000
0.472/0.479, 202/210 on 117

2001 LS1
.500/0.500, 198/208 on 115.5LSA

2001 LS6
0.525/0.525, 204/211 on 116

2002 LS6
0.551/0.547, 204/218 on 117.5
90 Vert 5.3 / T-5   Back on the road.
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Offline mayhamfx

F-Body year by year differences
« Reply #14 on: May 29, 2010, 09:04:02 PM »
While all Gen III componentry is basically interchangable, there are  several differences during the standard LS1/LS6 production run.

- Year by year F-Body LS1 changes (jrp - www.ls1tech.com)

1998
1. Had different casting heads which had perimeter bolts and valve covers.
2. Ignition coils were mounted to the valve covers one at a time.
3.  1998-1999 automatic transmission LS1s could be started in 1st gear even  with the shifter in 2nd. Starting 2000, if you put the shifter in 2, it  would start off in 2, even from a stop.
4. 1998-1999 LS1 cars had a smaller throttle body cam, which caused the throttle to open to WOT faster than 2000+ cars
5. 1998 cars had 28 lb fuel injectors from the factory
6. 1998-2000 cars had a larger cam than the 01-02 cars
7. 1998-1999 cars had more restrictive exhaust manifolds
8. 1998-2000 cars had an LS1 intake with EGR
9. 1998 only LS1 blocks had a much smaller cylinder sleeve that only tolerated a .005" hone
10. 1998 only cars had a different PCV system with the PCV valve located above the passenger side valve cover
11.  1998 most cars did not have an idle adjustment screw on the throttle  body. Some 98 cars do have the idle throttle stop set screws.
12. 1998 cars have a completely different PCM from 99+ cars
13. A production shortage of F-body cams caused the use of a C5 cam to be installed in F-body LS1s for a very short time
14. 97-98 LS1's used a paper water pump gasket. The only gasket that isn't reuseable

1999
1. 1999-2000 cars switched to 26 lb fuel injectors
2.  Cylinder heads and valve covers redesigned to have center bolts instead  of perimeter bolts. Other than that, the heads were the same.
3. Redesigned cylinder sleeves that allowed for a small bore, up from .005" in 1998 models.
4. 1999 cars continued the LS1 intake with EGR provisions
5. 1999 cars continued more restrictive exhaust manifolds and larger cam r
6. Water temp gauge was redesigned to work basically as a dummy gauge and only show an overheat condition. h
7. 1999-02 cars had a different PCV system with the valve located to the side of the intake manifold

2000
1. Redesigned exhaust manifolds for new emissions standard actually flowed better and created a little more HP.
2. 2000 continued use of LS1 Intake, EGR, smaller cam, and 26 lb fuel injectors
3. Throttle body cam was increased in size to slow the speed at which the car reaches WOT
4.  Automatic transmission cars were reprogrammed to allow a car to start  off in 2nd gear from a stop when the shift lever is put into 2.

2001
1. A small percentage of 2001 and 2002 LS1s actually had LS6 blocks which had a different part number and a darker metal cast
2. Starting 2001, some LS1s came with an LS6 intake manifold without an EGR system
3. Advertised HP output was changed from 305 to 310 on base LS1s and from 320 to 325 on WS6s and SSs
4. 2001-02 cars have a smaller cam from the Vortec truck engines to increase low end torque
5. 2001-02 cars had 28 lb fuel injectors like the 98 cars (albeit different part numbers)
6. Manual transmission cars all came with the Z06 clutch

2002
1.  2002 LS1 head gaskets redesigned. The new ones are a pressed metal, as  opposed to the graphite ones and are no longer specific to the side of  the car theyre installed on
2. 2002 cars continued with the LS6 intake, 28 lb fuel inectors and smaller truck cam
3. 2002 continued the use of an LS6 block in some LS1 F-bodies
4. Manual transmission cars continued use of the Z06 clutch
90 Vert 5.3 / T-5   Back on the road.
"To save time let's just assume I know everything!"
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