Problems
In the early production run of the LS-series engine, some engines encountered abnormal amounts of 'piston slap' - a problem caused by too much clearance between the cylinder bore and the piston. 'Piston slap' sometimes sounds more like a knock or the sound of a diesel engine running. It is typically worse when the engine is cold and lessens as the engine reaches operating temperature. The noise of 'piston slap' often is louder when listening for it below the oil pan.
Another common problem with the 04-06 5.3L engines was cracking cylinder heads. This is commonly called the 'Castech Head' failure on the internet. GM issued a TSB on this failure to help service techs identify the problem. The head casting (which can be viewed from the passenger side of the vehicle just in front of the valve cover) was 706. Some heads with this casting number would fail, but not all of them as GM had different suppliers for the same head. The failure was due to undetected porosity around the oil drains in the head.
Read more about this topic: GM LS Engine
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