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A3
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ENGINES
MECHANICAL INFORMATION
3A-0 - MECHANICAL INFORMATION 90-806535970 1296
Table of ContentsPage
Engine Identification 3A-1. . . . . . . . . . . . . . . . . . . . . . 4 Cylinder 3A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . V-6 3A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-8 3A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
181 CID / 3.0L 3A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools 3A-2. . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants/Sealers/Adhesives 3A-3. . . . . . . . . . . 181 CID / 3.0L Torque Specifications 3A-3. . . . . 181 CID / 3.0L Engine Specifications 3A-4. . . . .
262 CID / 4.3L Gen+ 3A-7. . . . . . . . . . . . . . . . . . . . . . Special Tools 3A-7. . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants/Sealers/Adhesives 3A-8. . . . . . . . . . . 262 CID / 4.3L Torque Specifications 3A-8. . . . . 262 CID / 4.3L Torque Specifications 3A-9. . . . . 262 CID / 4.3L Gen + Engine Specifications 3A-11. . . . . . . . . . . . . . . . . . . . . . . 262 CID / 4.3L Gen + Engine Specifications 3A-13. . . . . . . . . . . . . . . . . . . . . . .
350 CID / 5.7L 3A-15. . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools 3A-15. . . . . . . . . . . . . . . . . . . . . . . . . Lubricants/Sealers/Adhesives 3A-16. . . . . . . . . . 350 CID / 5.7L Torque Specifications 3A-16. . . . 350 CID / 5.7L Engine Specifications (Does Not Include Gen +) 3A-18. . . . . . . . . . . . . 350 CID / 5.7L Engine Specifications (Does Not Include Gen +) 3A-24. . . . . . . . . . . . . 350 Gen + Engine Specifications 3A-29. . . . . . .
454 CID / 7.4L / 502 CID / 8.2L 3A-30. . . . . . . . . . . Special Tools 3A-30. . . . . . . . . . . . . . . . . . . . . . . . . Lubricants/Sealers/Adhesives 3A-30. . . . . . . . . . 454 CID / 7.4L / 502 CID / 8.2L Torque Specifications 3A-31. . . . . . . . . . . . . . . . . 454 CID / 7.4L / 502 CID / 8.2L Torque Specifications 3A-32. . . . . . . . . . . . . . . . .
Cylinder Head Torque Sequences 3A-39. . . . . . . . . Intake Manifold Torque Sequence 3A-41. . . . . . . . .
MECHANICAL INFORMATION - 3A-190-806535970 1296
Engine Identification
4 Cylinder
73584
a
a - Location of G.M. Engine Code
MCM (Stern Drive) Code Rotation
3.0LX RK LH
V-6
72312
a - Location of GM Engine Code
a
MCM(Stern Drive) Code Rotation
4.3LX Gen + Alpha and Bravo LJ
LH4.3LXH Gen + Alpha and Bravo LK
LH
262 Magnum EFI Gen +
V-8
MCM (Stern Drive) Code Rotation
5.7L Bravo
MJ
LH
5.7L AlphaMJ
LH
5.7L Alpha EFIMJ
LH
5.7L Bravo EFI
LH5.7LX, Alpha5.7LX Bravo
350 Magnum AlphaMD LH
350 Magnum EFIAlpha Gen +
MH5.7L Bravo EFI Gen+ MH
350 Magnum MPI Gen + Bravo and Blackhawk
MIE (Inboard) Code Rotation
5.7L MM
LH5.7L Competition Ski MJ
LH350 Magnum Tournament SkiMH
LH
350 Magnum MPI TournamentSki (Black Scorpion)
MH
MCM (Stern Drive) Code Rotation
7.4L XW
LH
7.4L Bravo Three (Note) XX
LH
7.4LX EFI Bravo UJ
LH7.4LX MPI Bravo UD LH
454 Magnum XA
454 Magnum MPI UA
502 Magnum MPI HJ
MIE (Inboard) Code Rotation
7.4L XY
LH
7.4L EFI UK
LH7.4L MPI UD LH
8.2L HH
454 EFI Ski UA
3A-2 - MECHANICAL INFORMATION 90-806535970 1296
181 CID / 3.0L
Special Tools
MERCURY MARINE SPECIAL TOOLS
DESCRIPTION PART NUMBER
Piston Ring Expander 91-24697
Torch Lamp 91-63209
KENT MOORE SPECIAL TOOLS
DESCRIPTION PART NUMBER
Valve Spring Compressor (Head on) J5892
Valve Spring Compressor (Head off) J8062
Valve Stem Seal Tester J23738-A
Valve Guide Cleaner J8101
Valve Guide Reamer (Standard) J8814
Valve Guide Reamer (.015 in. oversize) J5830-02
Rocker Arm Stud Remover J5802-01
Rocker Arm Stud Installer J6880
Stud Bore Reamer (.003 in. oversize) J5715
Stud Bore Reamer (.013 in. oversize) J6036
Carbon Remover Brush J8089
Piston Support Tool J5910-04
Piston Pin Tool J24086-B
Piston Ring Groove Cleaner J3936-03
Piston Ring Compressor J8037
Connecting Rod Guide Tool (3/8 -24) J5239
Cylinder Bore Checker J8087
Oil Pump Suction Pipe Installer J8369
Timing Cover Seal Aligner J23042-B
Cam Lobe Lift Indicator J8520
Camshaft Bearing Installer/Remover Tool J6098-01
Distributor Shaft Lower Bearing Installer/Remover J9534-01
Pulley Hub Puller J6978-E
Pulley Hub Installer J5590
Universal Torsional Damper Remover J24420
MECHANICAL INFORMATION - 3A-390-806535970 1296
Lubricants/Sealers/Adhesives
PART NUMBER DESCRIPTION
Quicksilver Perfect Seal 92-34227-1
Quicksilver 2-C-4 Marine Lubricant with Teflon 92-825407A3
Quicksilver RTV Sealer 92–91601-1
181 CID / 3.0L Torque Specifications
DESCRIPTION Lb. In. Lb. Ft. N⋅mCamshaft Sprocket Bolts 80 9
Connecting Rod Cap Nuts 45 61
Cylinder Head Bolts 90 (Note 1) 122 (Note 1)
Distributor Clamp 20 27
Engine Coupler to Flywheel 35 47
Flywheel Housing to Block 21 28
Flywheel to Crankshaft Bolts 65 88
Front Cover Bolts 30 3.4
Front Mount to Block 21 28
Main Bearing Cap Bolts 65 88
Manifold to Head 23 (Note 2) 31 (Note 2)
Oil Pan Bolts-Crankcase 80 9
Oil Pan Bolts - to Front Cover 45 5
Oil Pan Studs to Oil Seal Retainer orCrankcase
15 1.7
Oil Pump Cover 72 8
Oil Pump to Block 120 14
Oil Pump Pickup 60 7
Rocker Arm Cover and Bolts 40 4.5
Rear Crankshaft Oil Seal Retainer Nuts 135 15
Spark Plugs 22 30
Starter Motor to Block 37 50
Timing Gear Cover 72 8
Torsional Damper Bolt 50 68
Water Pump to Block 15 20
Note 1: Retorque after first 20 hours of operation.
Note 2: Retorque after first start up.
3A-4 - MECHANICAL INFORMATION 90-806535970 1296
181 CID / 3.0L Engine Specifications
UNIT OF MEASUREMENTin. (mm)
CYLINDER BORE
Diameter 3.9995-4.0025(101.588-101.790)
Out of RoundProduction .0005(0.012) Max
Out of RoundService .002(0.05) Max
TProduction
Thrust Side .0005(0.012) Max
TaperProduction
Relief Side .0005(0.012) Max
Service .001(0.02) Max
PISTON CLEARANCE
Production .0025-.0035(0.064-0.088) Max
Service .0035(0.08) Max
PISTON RING: COMPRESSION
Groove ProductionTop
0012- 0029(0 030-0 073)GrooveClearance
Production2nd
.0012-.0029(0.030-0.073)Clearance
Service .003(0.09) Max
GProduction
Top010- 020(0 254-0 762)
GapProduction
2nd.010-.020(0.254-0.762)
Service .035(0.88) Max
PISTON RING: OIL
Groove ClearanceProduction .001-.006(0.026-0.152)
Groove ClearanceService Limit .007(0.17) Max
GapProduction .010-.030(0.254-0.762) Max
GapService Limit .040(1.01) Max
PISTON PIN
Diameter .9270-.9271(23.546-23.550)
ClearanceProduction .0003-.0006(0.008-0.016)
ClearanceService Limit .001(0.02) Max
Fit in Rod .0008-.0019(0.020-0.050) Interference
MECHANICAL INFORMATION - 3A-590-806535970 1296
181 CID / 3.0L Engine Specifications
CRANKSHAFT
M i J l
Diameter 2.2979-2.294(58.367-58.404)
M i J lTaper
Production .0002(0.005) Max
Main JournalTaper
Service .001(0.02) Max
Out of RoundProduction .0002(0.005) Max
Out of RoundService .001(0.02) Max
M i B i
Production No.1-No.4 .001-.0024(0.025-0.060)
Main BearingC
Service No.5 .0016-.0035(0.041-0.088)gClearance Production No.1-No.4 .001-.0025(0.03-0.06)
Service No.5 .002-.0035(0.05-0.08)
Crankshaft End Play .002-.006(0.05-0.15)
C k i
Diameter 2.09980-20995(53.289-53.327)
C k iTaper
Production .0003(0.007) Max
CrankpinTaper
Service .001(0.02) Max
Out of RoundProduction .0002(0.51) Max
Out of RoundService .001(0.02) Max
Rod BearingClearance
Production .0017-.0027(0.044-0.0686)Clearance Service N/A
Rod Size Clearance .006-.017(0.153-0.4318) Max
CAMSHAFT
Lobe Lift (Max )Intake .2529(6.425)
Lobe Lift (Max.)Exhaust .2529(6.425)
Journal Diameter 1.8677-18697(47.440-47.490)
Camshaft End Play .003-.008(0.08-0.2032) Max
CYLINDER HEAD
Gasket Surface Flatness .003-.008 in any 6 in.(152)or .007(0.15) Overall Maximum
3A-6 - MECHANICAL INFORMATION 90-806535970 1296
181 CID / 3.0L Engine Specifications
VALVE SYSTEM
Lifter Hydraulic
Rocker Arm Ratio 1.75 to 1
Collapsed Tappet Gap 3/4 Turn Down from Zero Lash
Face AngleIntake 45°
Face AngleExhaust 45°
Seat Angle (Intake & Exhaust) 46°Seat Runout (Intake & Exhaust) .002(0.05) Max
Seat WidthIntake 1/16 [.0625] in. (1.16 mm)
Seat WidthExhaust 1/16-5/64 [.0625-.07812] in. (1.6-2.0 mm)
SProduction
Intake .0010-.0027(0.025-0.069)
StemC
ProductionExhaust .0007-.0027(0.018-0.069)
ClearanceService
Intake .003(0.09) MaxService
Exhaust .004(0.11) Max
S i
Free Length 2-1/16(52)
S iPressure
Valve Closed 100-110 lb. (136-149 N) at 1-19/32 in. (41 mm)
SpringPressure
Valve Open 208-220 lb. (282-300 N) at 1-7/32 in. (31 mm)p gInstalledHeight±
Intake1/32[1 6562] (42)Height±
.031(8) Exhaust1/32[1.6562] (42)
Internal Damper None
MECHANICAL INFORMATION - 3A-790-806535970 1296
262 CID / 4.3L Gen+
Special Tools
MERCURY MARINE SPECIAL TOOLS
DESCRIPTION PART NUMBER
Piston Ring Expander 91-24697
Engine Coupler Wrench 91-35547
SNAP-ON SPECIAL TOOLS
DESCRIPTION PART NUMBER
Torque Angle Gauge (Degree Wheel Torquing) TA360
KENT-MOORE SPECIAL TOOLS
DESCRIPTION PART NUMBER
Valve Spring Compressor (Head On) J5982
Valve Spring Compressor (Head Off) J8062
Valve Spring Tester J8056
Valve Guide Cleaner J8101
Valve Guide Reamer J5830-2
Valve Guide Reamer J7049
Carbon Remover Brush J8089
Piston Pin Remover Kit J24086-B
Piston Ring Groove Cleaner J3936-03
Piston Ring Compressor J8037
Connecting Rod Bolt Guide Set (3/8-24) J5239
Oil Pump Suction Pipe Installer J21882
Camshaft Bearing Remover and Installer Set J6098-01
Ball Socket Adapter Tool Kit (Lift Indicator) J8520-1
Torsional Damper Remover and Installer J23523-E
Crankcase Front Cover Seal Installer J35468
Crankcase Gear and Sprocket Puller J5825-A
Crankcase Gear and Sprocket Installer J5590
Air Adapter J23590
Main Bearing Remover and Installer J8080
Rear Main Seal Installer J26817-A
Balance Shaft Rear Bearing Remover J26941
Balance Shaft Bearing Remover and Installer J38834
3A-8 - MECHANICAL INFORMATION 90-806535970 1296
Lubricants/Sealers/Adhesives
DESCRIPTION PART NUMBER
Quicksilver Loctite 8831 92-823089-1
Quicksilver Perfect Seal 92-34227-1
Quicksilver RTV Sealer 92-91601-1
General Motors Cam and Lifter Prelude Obtain Locally
262 CID / 4.3L Torque Specifications
DESCRIPTION Lb. In. Lb. Ft. N·m
Alternator Brace to Alternator 192 28
Alternator Brace to Engine 30 41
Alternator to Mounting Bracket 35 48
Alternator Mounting Bracket 30 41
Balance Shaft Drive Gear Retaining Stud 120 14
Balance Shaft Driven Gear Bolt (Torque Plus 35°) 15 20
Balance Shaft Thrust Plate 120 14
Camshaft Sprocket 20 27
Camshaft Thrust Plate 106 12
Carburetor 132 15
Connecting Rod Cap Nuts (Torque Plus 70 °) 20 27
Coupler/Flywheel(MCM) 35 48
Crankcase Front Cover 124 14
Crankshaft Pulley Bolt (Cast Aluminum) 40 54
Cylinder Head Bolts 65 88
Cylinder Head Bolts First Sequence
Angle Torque Second Sequence Short Bolt
22 30
Angle Torque Second Sequence Short Bolt
Medium Bolt55 Degrees
Medium Bolt
Long Bolt65 Degrees
Long Bolt 75 Degrees
Distributor Hold Down 25 34
Exhaust Manifold 20 27
Flywheel 75 100
Flywheel Housing to Block 30 41
Flywheel Housing Cover 80 9
Front Mount Bracket 30 41
Fuel Filter Bracket Bolt 25 25
MECHANICAL INFORMATION - 3A-990-806535970 1296
262 CID / 4.3L Torque Specifications
DESCRIPTION Lb. In. Lb. Ft. N⋅mFuel Pump Bracket Bolt 25 25
Fuel Pump Inlet Fitting (Large Diameter See Note) 96 10.8
Fuel Pump Inlet Fitting (Small Diameter See Note) 84 9.6
Intake Manifold Bolts (Torque Three Steps) First Step 27 3
Second Step 106 12
Third Step 133 15
Knock Sensor 15 20
Main Bearing Cap 75 100
Oil Filter Adapter Bolts15 20
Oil Pan Drain Plug15 20
Oil Pan Screw (1/4-20) 80 9
Oil Pan Nuts (5/16-20) 165 19
Oil Pump 65 68
Oil Pump Cover 80 9
Power Steering Pump Brace to Block30 41
Power Steering Pump Bracket30 41
Rear Crankshaft Oil Seal Retainer Screws and Nuts 133 15
Rear Mount (MCM) 40 54
Rocker Arm Cover 106 12
Rocker Arm Nuts 20 27
Roller Lifter Restrictor Plate 144 16
Seawater Pump Brace (if equipped)30 41
Seawater Pump Bracket (if equipped)30 41
Spark Plugs 15 20
Starter Motor 50 68
Thermostat Housing 30 41
Torsional Damper 40 54
Water Circulating Pump 30 41
Water Temperature Sender 20 27
Note : Hold fuel pump using wrench on flat surface at outlet before tightening brass fitting
3A-10 - MECHANICAL INFORMATION 90-806535970 1296
262 CID / 4.3L Gen+ Engine Specifications)
Unit of Measurement in. (mm)
Displacement 262 CID (4.3 Litre)
Bore 4.00(101.6)
Stoke 3.48(88.39)
Compression Ratio 9.3:1
Heads Cast Iron
Intake Manifold Cast Iron
Block Cast Iron (2 Bolt Main Bearing Caps)
Rods Forged Steel
Pistons Cast Aluminum
Crankshaft Cast Iron
Camshaft Steel
72976
LH ROTATIONFRONT
Firing Order1-6-5-4-3-2
MECHANICAL INFORMATION - 3A-1190-806535970 1296
262 CID / 4.3L Gen + Engine Specifications
Unit of Measurement in. (mm)
CYLINDER BORE
Diameter 4.0007-4.0017(101.618-101.643)
Out of RoundProduction .001 (0.025) Maximum
Out of RoundService .002 (0.051) Maximum
TProduction
Thrust Side .0005 (0.012) Maximum
TaperProduction
Relief Side .001 (0.025) Maximum
Service .001 (0.025) Maximum
PISTON CLEARANCE
Production .0007-.002 (0.017-0.05)
Service .0024 (.001)
PISTON RING: COMPRESSION (MEASURED IN CYLINDER BORE)
G ClProduction
Top .02-.06 (0.51-1.52)
Groove ClearanceProduction
2nd .04-.08 (1.02-2.03)
Service .0042 (0.107) Maximum
GProduction
Top .010-.016 (0.25-0.40)
GapProduction
2nd .018-.026 (.046-.066) Maximum
Service 0.06-0.035 (1.524-0.88) Maximum
PISTON RING: OIL
Groove ClearanceProduction .002-.007 (0.51-0.20)
Groove ClearanceService 0.02-0.08 (0.51-2.032)
GapProduction .015-.050 (0.38-1.27)
GapService Limit 0.009-0.065 (0.23-1.65)
PISTON PIN
Diameter .9267-.9271 (23.545-23.548)
ClearanceProduction .0002-.0007 (0.005-0.0178)
ClearanceService Limit .001 (0.025) Maximum
Fit in Rod .0008-.0016 (0.021-0.040) Interference
3A-12 - MECHANICAL INFORMATION 90-806535970 1296
262 CID / 4.3L Engine Gen + Specifications
Unit of Measurement in. (mm)
CRANKSHAFT
M i
Di
No.1 2.4488-2.4495 (62.199-62.217)
M i
Diameter No. 2, 3 2.4485-2.4494 (62.191-62.215)
MainNo.4 2.4479-2.4489 (62.179-62.203)
Main Journal Taper
Production .0003 (0.007) MaximumJournal Taper
Service .001 (0.025) Maximum
Out of RoundProduction .0002 (0.005) Maximum
Out of RoundService .001 (0.025) Maximum
Main Bearing ProductionNo.1 .0008-.0020 (0.020-0.051)
Main BearingC
ProductionNo.2, 3, 4 .0010-.025 (0.025-0.635)g
ClearanceNo.2, 3, 4 .0010-.025 (0.025-0.635)
ClearanceService No 1 2 3 4 0010 0020 (0 03 0 051)Service No.1, 2, 3, 4 .0010-.0020 (0.03-0.051)Service No.1, 2, 3, 4 .0010 .0020 (0.03 0.051)
Crankshaft End Play .002-.008 (0.05-0.20)
C i R d
Diameter 2.2487-2.2497 (57.117-57.142)
Connecting Rod TaperProduction .0003 (0.007) Maximum
Connecting RodJournal
TaperService .001 (0.025) Maximum
Journal
Out of RoundProduction .0002 (0.0051) Maximum
Out of RoundService .001 (0.025) Maximum
Rod Bearing ClearanceProduction .0013-.0035 (0.033-0.088)
Rod Bearing ClearanceService .0010-.0030 (0.025-0.076)
Rod Side Clearance .006-.017 (0.15-0.43)
Crankshaft Runout .001 (0.025) Maximum
MECHANICAL INFORMATION - 3A-1390-806535970 1296
262 CID / 4.3L Gen + Engine Specifications
Unit of Measurement in. (mm)
VALVE SYSTEM
Lifter Hydraulic Roller
Rocker Arm Ratio 1.50 to 1
Valve LiftIntake .414 (10.52)
Valve LiftExhaust .428 (10.87)
Valve Lash (Intake and Exhaust) Net Lash No Adjustment
Face Angle (Intake & Exhaust) 45°Seat Angle (Intake & Exhaust) 46°
Seat Runout (Intake & Exhaust) .002 (0.05) Maximum
Seat WidthIntake .035-.060 (0.89-1.52)
Seat WidthExhaust .062-.093 (1.58-2.38)
SProduction
Intake0010- 0027 (0 025-0 069)
Stem C
ProductionExhaust
.0010-.0027 (0.025-0.069)
ClearanceService
Intake .001 (0.025) MaximumService
Exhaust .002 (0.51) Maximum
Stem DiameterIntake
3400- 3407 (8 636-8 653)Stem DiameterExhaust
.3400-.3407 (8.636-8.653)
Valve Margin Intake and Exhaust .031 (0.79)
VALVE SPRING
Free Length 2.03 (51.6)
V l S i PressureValve Closed 76-84 Lb. (338-374 N) at 1.7 in (43.16 mm)
Valve Spring PressureValve Open 187-203 Lb. (832-903 N) at 1.27 in (32.25 mm)
Installed Height 1.690-1.710 in (42.93-43.43 mm)
3A-14 - MECHANICAL INFORMATION 90-806535970 1296
262 CID / 4.3L Gen + Engine Specifications
Unit of Measurement in. (mm)
CAMSHAFT AND DRIVE
Lobe Lift ±( )
Intake .286-.290 (7.26-7.36).002(0.051) Exhaust .292-.296 (7.42-7.52)
Journal Diameter 1.8682-1.8692 (47.452-47.478)
Journal Out of Round .001 (0.025) Maximum
Camshaft Runout .002 (0.051) Maximum
Camshaft End Play .001-.009 (0.0254-0.2286)
Timing Chain Deflection .375(9.5) from taut position [total .75 (19)]
FLYWHEEL
Runout .008 (0.203) Max
CYLINDER HEAD
Gasket Surface Flatness .010 (0.254) Overall Maximum
BALANCE SHAFT
Front Bearing Journal 2.1648-2.1654 (54.985-55.001)
Rear Bearing Journal 1.4994-1.500 (38.084-38.100)
Rear Bearing Journal Clearance .001-.0036 (.025-.091)
MECHANICAL INFORMATION - 3A-1590-806535970 1296
350 CID / 5.7L
Special Tools
MERCURY MARINE SPECIAL TOOLS
DESCRIPTION PART NUMBER
Piston Ring Expander 91-24697
Engine Coupler Wrench 91-35547
Rocker Stopper 91-66273
KENT-MOORE SPECIAL TOOLS
DESCRIPTION PART NUMBER
Valve Spring Compressor (Head on) J5892
Valve Spring Compressor (Head off) J8062
Valve Spring Tester J8056
Valve Guide Cleaner J8101
Valve Guide Reamer (Standard) J7049
Valve Guide Reamer (.015 in. oversize) J5830-02
Rocker Arm Stud Remover J5802-01
Rocker Arm Stud Installer J6880
Stud Bore Reamer (.003 in. oversize) J5715
Stud Bore Reamer (.013 in. oversize) J6036
Carbon Remover Brush J8089
Piston Pin Tool J24086-B
Piston Ring Groove Cleaner J3936-03
Piston Ring Compressor J8037
Connecting Rod Guide Tool (3/8 -24) J5239
Oil Pump Suction Pipe Installer J21882
Camshaft Bearing Installer/Remover Tool J6098-01
Ball Socket Adapter J8520-1
Torsional Damper Remover and Installer J23523-E
Crankcase Front Cover Seal Installer J35468
Crankshaft Gear and Sprocket Puller J5825-A
Crankshaft Gear and Sprocket Installer J5590
Air Adapter J23590
Main Bearing Remover and Installer J8080
Rear Main Seal Installer J26817-A
3A-16 - MECHANICAL INFORMATION 90-806535970 1296
Lubricants/Sealers/Adhesives
DESCRIPTION PART NUMBER
Quicksilver Loctite 8831 92-823089-1
Quicksilver Perfect Seal 92-34227-1
Quicksilver Needle Bearing Assembly Lubricant 92-825265A1
Quicksilver RTV Sealer 92-91601-1
General Motors Cam and Lifter Prelube or Equiva-lent
Obtain Locally
350 CID / 5.7L Torque SpecificationsNOTE: Any Differences in Gen + Engines Will Be Noted With ”Gen +”.
DESCRIPTION Lb. In. Lb. Ft. N⋅mAlternator Brace to Alternator 192 28
Alternator Brace to Engine 30 41
Alternator to Mounting Bracket 35 48
Alternator Mounting Bracket 30 41
Camshaft Sprocket Gear 216 24
Carburetor 132 15
Connecting Rod Cap Nuts 45 61
Connecting Rod Cap NutsGen +(Plus An Additional 55 Degrees) 20 27
Coupler/Flywheel(MCM)35 48
Crankshaft Pulley35 48
Cylinder Head Bolt 65 88
Cylinder Head Bolt Gen + First Sequence
A l T S d S Sh t B lt
22 30
Angle Torque Second Sequence Short BoltMedium Bolt
55 DegreesMedium BoltLong Bolt
g65 Degrees
DLong Boltg
75 Degrees
Distributor Hold Down 25 34
Exhaust Manifold20 27
Filter Adapter (5/16-18)20 27
Flywheel 75 100
Flywheel Drive Plate (MIE) 35 48
Flywheel Housing to Block 30 41
Flywheel Housing Cover 80 9
Front Mount Bracket 30 41
Fuel Pump 25 34
Intake Manifold 35 48
MECHANICAL INFORMATION - 3A-1790-806535970 1296
350 CID / 5.7L Torque Specifications (Continued)NOTE: Any Differences in Gen + Engines Will Be Noted With Gen +.
DESCRIPTION Lb. In. Lb. Ft. N⋅mIntake Manifold Bolts Gen+(Torque Three Steps) First Step
27 3
Second Step 106 12
Third Step 133 15
Main Bearing Cap 80 109
Main Bearing Cap Bolt Gen + 74 100
Oil Baffle Nuts 25 34
Oil Filter Adapter Bolt 15 20
Oil Pan Drain Plug 15 20
Oil Pan Corner Nut 15 20
Oil Pan Nuts (5/16-18) 106 12
Oil Pump 65 88
Oil Pump Cover 80 9
Power Steering Pump Brace to Block30 41
Power Steering Pump Bracket30 41
Rear Crankshaft Oil Seal Retainer Screws andNuts
133 15
Rear Mount (MCM) 40 54
Rear Mount (MIE) 50 68
Remote Oil Connector (1/2 in. x 13) 25 34
Remote Oil Filter Adapter Nut/Fitting 20 27
Spark Plugs 15 20
Starter Motor 50 50
Thermostat Housing 30 41
Timing Chain or Gear Cover 106 12
Torsional Damper 40 54
Transmission To Housing 50 68
Water Circulating Pump 30 41
Water Temperature Sender 20 27
Rocker Arm Cover 90 10
Roller Lifter Restrictor Retainer Plate 144 16
Seawater Pump Brace30 41
Seawater Pump Bracket30 41
3A-18 - MECHANICAL INFORMATION 90-806535970 1296
350 CID / 5.7L Engine Specifications (Does Not Include Gen +)
Unit Of Measurement In. (mm)
EngineModel
MCM5.7L
Alpha
MCM5.7L
Bravo
MCM 350Magnum
AlphaDisplacement 350 CID (5.7 Litre)
Bore 4.00(101.6)
Stroke 3.48(88.4)
Compression Ratio 9.3:1
Heads Cast Iron
IntakeManifold
Cast Iron (Magnums-High Rise-See Note 2)
Block Cast Iron (2 Bolt Main Bearing Caps)
Rods Forged Steel
Crankshaft Cast Iron
Pistons Cast Aluminum
Camshaft Cast Iron Steel (See Note 1)
Fuel PumpPush Rod
Steel Cast Iron(See Note 1)
Note1: Engine with roller lifters and steel camshaft
Note 2: Includes - 350 Magnum Alpha, 5.7LX Bravo and 350 Magnum Tournament Ski
MECHANICAL INFORMATION - 3A-1990-806535970 1296
350 CID / 5.7L Engine Specifications (Does Not Include Gen +)
Unit Of Measurement In. (mm)
EngineModel
MCM5.7L EFI Alpha
MCM5.7L EFI Bravo
Displacement 350 CID (5.7 Litre)
Bore 4.00(101.6)
Stroke 3.48(88.4)
Compression Ratio 9.3:1
Heads Cast Iron
Intake Manifold Cast Iron
Block Cast Iron (2 Bolt Main Bearing Caps)
Rods Forged Steel
Crankshaft Cast Iron
Pistons Cast Aluminum
Camshaft Steel (See Note 1)
Fuel PumpPush Rod
Cast Iron (See Note 1)
Note 1: Engine with roller lifters and steel camshaft
3A-20 - MECHANICAL INFORMATION 90-806535970 1296
350 CID / 5.7L Engine Specifications (Does Not Include Gen +)
Unit Of Measurement In. (mm)
EngineModel
MIE5.7L
MIE5.7L
CompetitionSki
MIE350 MagnumTournament
Ski
Displacement 350 CID (5.7 Litre)
Bore 4.00(101.6)
Stroke 3.48(88.4)
Compression Ratio 9.3:1
Heads Cast Iron
Intake Manifold Cast Iron (Magnum-High Rise-See Note 2)
Block Cast Iron (2 Bolt Main Bearing Caps)
Rods Forged Steel
Crankshaft Cast Iron
Pistons Cast Aluminum
Camshaft Cast Iron Steel (Note 1)
Fuel Pump Push Rod
Steel Cast Iron (Note 1)
Note1: Engine with roller lifters and steel camshaft
Note 2: Includes- 350 Magnum Tournament Ski and 350 EFI Magnum Tournament Ski. Gen + engines withan aluminum manifold.
72008
ALH ROTATION
FRONT
Firing Order1-8-4-3-6-5-7-2
MECHANICAL INFORMATION - 3A-2190-806535970 1296
350 CID / 5.7L Engine Specifications (Does Not Include Gen +)
Unit Of Measurement In. (mm)
CYLINDER BORE
Diameter 3.9995-4.0025(101.5873-101.6635)
Out of RoundProduction .001(0.025) Max
Out of RoundService .002(0.05) Max
TProduction
Thrust Side .0005(0.012) Max
TaperProduction
Relief Side .001(0.02) Max
Service .001(0.02) Over Production
PISTON CLEARANCE
Production .0007-.0017(0.017-0.043) Max
Service .0027(0.07) Max
PISTON RING: COMPRESSION
G ClProduction
Top0012- 0032(0 030-0 081)
Groove ClearanceProduction
2nd.0012-.0032(0.030-0.081)
Service High Limit Production + .001(0.025)
GProduction
Top .010-.020(0.254-0.508)( )Gap
Production2nd
( ).010-.025(.0254-.0635)
Service High Limit Production + .010(0.25)
PISTON RING: OIL
Groove ClearanceProduction .002-.007(0.051-0.177)
Groove ClearanceService High Limit Production + .001(0.025)
GapProduction .015-.055(0.381-1.397)
GapService Limit High Limit Production + .010(0.254)
PISTON PIN
Diameter .9269-.9271(23.545-23.553)
ClearanceProduction .0002–.0007(0.005-0.017)
ClearanceService Limit .001(0.02) Max
Fit in Rod .0008-.0016(0.020-0.406) Interference
3A-22 - MECHANICAL INFORMATION 90-806535970 1296
350 CID / 5.7L Engine Specifications (Does Not Include Gen +)
Unit Of Measurement In. (mm)
CRANKSHAFT
M i
Di
No.1 2.4484-2.4493 (62.198-62.212)
M i
Diameter No. 2, 3 2.4481-2.4490 (62.181-62.204)
MainNo.4 2.4479-2.4488 (62.176-62.199)
Main Journal Taper
Production .0002 (0.005) MaxJournal Taper
Service .001 (0.02) Max
Out of RoundProduction .0002 (0.005) Max
Out of RoundService .001 (0.005) Max
M i B i
P d i
No.1 .0008-.0020 (0.020-0.050)
M i B i
Production No. 2, 3 .0011-.0023 (0.027-0.058)
Main BearingCl
No.4 .0017-.0032 (0.043-0.081)gClearance
S i
No.1 .0010-.0015 (0.025-0.038)
Service No. 2, 3 .0010-.0025 (0.03-0.06)
No.4 .0025-.0035 (0.07-0.08)
Crankshaft End Play .002-.006 (0.05-0.15)
C i R d
Diameter 2.0988-2.0998 (57.117–57.142)
Connecting Rod TaperProduction .0005 (0.021) Max
Connecting RodJournal
TaperService .001 (0.02) Max
Journal
Out of RoundProduction .0005 (0.021) Max
Out of RoundService .001 (0.02) Max
Rod Bearing ClearanceProduction .0013-.0035 (0.033-0.088)
Rod Bearing ClearanceService .003 (0.07) Max
Rod Side Clearance .006-.014 (0.15-0.35)
Crankshaft Runout .0015 (0.0381) Max
MECHANICAL INFORMATION - 3A-2390-806535970 1296
350 CID / 5.7L Engine Specifications (Does Not Include Gen +)
Unit Of Measurement In. (mm)
VALVE SYSTEM
Lifter Type (NOTE 1)Flat Hydraulic
Lifter Type (NOTE 1)Roller Hydraulic
Rocker Arm Ratio 1.50 to 1
Valve LiftIntake .394(10.00)
Valve LiftExhaust .404(10.26)
Valve Lash (Intake and Exhaust) 1 Turn Down from Zero Lash
Face AngleIntake 45°
Face AngleExhaust 45°
Seat Angle (Intake & Exhaust) 46°Seat Runout (Intake & Exhaust) .002(0.05) Max
Seat WidthIntake .03215-.0625 (0.79-1.58)
Seat WidthExhaust .0625-.09375 (1.58-2.38)
SProduction
Intake .0010-.0027(0.025-0.069)
StemCl
ProductionExhaust .0010-.0027(0.025-0.069)
ClearanceService
Intake .0037(0.09) MaxService
Exhaust .0047(0.11) Max
Stem DiameterIntake .341(8.66)
Stem DiameterExhaust .372(9.45)
Valve Margin Intake and Exhaust .0312(0.79)
VALVE SPRING
Free Length 2.03(51.6) (See Note 1)
Valve Spring24-48347
Pressure(NOTE 2)
ValveClosed
76-84 Lb. Ft.(103-113 N⋅m) at1.785(43.16)24 48347Lavender
Stripe
(NOTE 2)Valve Open 194-204 Lb. Ft. (263-279 N⋅m) at 1.250(31.75)
Stripe Installed Height Intake 1.7[1-45/64](43)
DamperFree Length 1.86[1-55/64](47)
DamperApproximate Number of Coils 4
NOTE 1: Engines are equipped either roller hydraulic or flat hydraulic depending on model designation.NOTE 2: Test spring pressure with damper removed
3A-24 - MECHANICAL INFORMATION 90-806535970 1296
350 CID / 5.7L Engine Specifications (Does Not Include Gen +)
Unit Of Measurement In. (mm)
CAMSHAFT AND DRIVE
Lobe Lift ± 002(0 051)Exhaust .263(6.680)
Lobe Lift ± .002(0.051)Intake .287(7.29) (See Note)
Duration at .050 In.(1.27mm)C f
Exhaust .269(6.833)( )Cam Lift Intake .300(7.62) (See Note)
Journal Diameter 1.8682-1.8692(47.452-47.478)
Journal Out Of Round .001(0.025) Max
Camshaft Runout .002(0.051) Max
Timing Chain Deflection[LH Rotation]
.375(9.5) from taut position [total .75(19)]
FLYWHEEL
Runout .008(0.203) Max
CYLINDER HEAD
Gasket Surface Flatness .004(0.1016) Overall Maximum
MECHANICAL INFORMATION - 3A-2590-806535970 1296
350 CID / 5.7L Gen+ Engine Specifications
Unit Of Measurement In. (mm)
EngineModel 350 CID / 5.7L
Displacement 350 CID (5.7 Litre)
Bore 4.00(101.6)
Stroke 3.48(88.4)
Compression Ratio 9.4:1
Heads Cast Iron
Intake Manifold Cast Aluminum
Block Cast Iron (2 Bolt Main Bearing Caps)
Rods Powdered Metal
Crankshaft Cast Iron
Pistons Cast Aluminum
Camshaft Steel
3A-26 - MECHANICAL INFORMATION 90-806535970 1296
350 CID Gen + Engine Specifications
Unit Of Measurement In. (mm)
NOTE: These specifications cover only Gen + engines.
CYLINDER BORE
Diameter 4.0007-4.0017(101.618-101.643)
Out of RoundProduction .0005(0.12) Max
Out of RoundService .002(0.05) Max
TProduction
Thrust Side .0005(0.012) Max
TaperProduction
Relief Side .001(0.025) Max
Service .001(0.025) Over Production
PISTON CLEARANCE
Production .0007-.0021(0.018-0.053) Max
Service .0027(0.068) Max
PISTON RING: COMPRESSION
G ClProduction
Top0012- 0032(0 030-0 081)
Groove ClearanceProduction
2nd.0012-.0032(0.030-0.081)
Service High Limit Production + .001(0.025)
GProduction
Top .010-.020(0.25-0.51)
GapProduction
2nd .018-.026(0.46-0.66)
Service High Limit Production ± .010(0.25)
PISTON RING: OIL
Groove ClearanceProduction .002-.007(0.051-0.17)
Groove ClearanceService High Limit Production ± .001(0.025)
GapProduction .010-.030(0.25-0.76)
GapService Limit High Limit Production ± .001(0.25)
PISTON PIN
Diameter .9270-.9271(23.545-23.548)
ClearanceProduction .0004-.0008(0.0120-0.0210)
ClearanceService Limit .0010(0.025) Max
Fit in Rod .0008-.0016(0.021-0.40) Interference
MECHANICAL INFORMATION - 3A-2790-806535970 1296
350 CID Gen + Engine Specifications
Unit Of Measurement In. (mm)
CRANKSHAFT
Main Journal
Diameter No.1 2.4484-2.4493(62.189-62.212)
M i
DiameterNo. 2, 3, 4 2.4481-2.4490(62.182-62.205)
M i
DiameterNo.5 2.4479-2.4488(62.177-62.199)
Main TaperProduction .0002(0.005) Max
JournalTaper
Service .001(0.025) Max
Out of RoundProduction .0002(0.005) Max
Out of RoundService .001(0.005) Max
M i B i
P d i
No.1 .0007-.0021(0.018-0.053)
M i B i
Production No.2, 3, 4 .0022-.00610(0.0009-0.0024)
Main BearingC
No.5 .00250-.00690(0.0010-0.0027)gClearance
S i
No.1 .0010-.0.0020(0.250-0.510)
Service No.2, 3, 4 .0010-.0025(0.0250-0.0640)
No.5 .0025-.0035(0.0760-0.0380)
Crankshaft End Play .002-.008(0.0500-0.2000)
C i R d
Diameter 2.0978-2.0998(53.2840-53.3340)
Connecting Rod TaperProduction .0003(0.007) Max
Connecting RodJournal
TaperService .001(0.025) Max
Journal
Out of RoundProduction .0003(0.007) Max
Out of RoundService .001(0.025) Max
Rod Bearing ClearanceProduction .0006-.0014(0.16-0.35)
Rod Bearing ClearanceService 0.0010-0.0030(0.025-0.076)
Rod Side Clearance .006-.014(0.15-0.35)
3A-28 - MECHANICAL INFORMATION 90-806535970 1296
350 CID Gen + Engine Specifications
Unit Of Measurement In. (mm)
VALVE SYSTEM
Lifter Type Roller Hydraulic
Rocker Arm Ratio 1.50 to 1
Valve LiftIntake .431(10.947)
Valve LiftExhaust .450(11.43)
Valve Lash (Intake & Exhaust) 1 Turn Down from Zero Lash
Face Angle (Intake & Exhaust) 45°Seat Angle (Intake & Exhaust) 46°
Seat Runout (Intake & Exhaust) .002(0.05) Max
Seat WidthIntake .040-.0625(1.02-1.65)
Seat WidthExhaust .065-.098(1.65-2.49)
SProduction
Intake .0010-.0027(0.025-0.069)
StemCl
ProductionExhaust .0010-.0027(0.025-0.069)
ClearanceService
Intake High Limit Production + .001(0.025)Service
Exhaust High Limit Production + .0002(0.050)
VALVE SPRING
Free Length 2.02(51.3)
Valve SpringPressure
ValveClosed
76-84 Lb. Ft.(338-374 N) at 1.70(43.18)
Valve Spring Valve Open 187-203 Lb. Ft. (832-903 N) at 1.27(32.26)
Installed Height Intake 1.69-1.71(42.92-43.43)
MECHANICAL INFORMATION - 3A-2990-806535970 1296
350 Gen + Engine Specifications
Unit Of Measurement In. (mm)
CAMSHAFT
Lobe Lift ± 002(0 051)Exhaust .300(7.62)
Lobe Lift ± .002(0.051)Intake .287(7.289)
Duration at .050 In.(1.27mm)C f
Exhaust .294(7.467)( )Cam Lift Intake .307(7.797)
Journal Diameter 1.8682-1.8692(47.440-47.490)
End Play .011-0.030(0.004-0.0012)
Timing Chain Deflection[LH Rotation]
.375(9.5) from taut position [total .75(19)]
FLYWHEEL
Runout .008(0.203) Max
CYLINDER HEAD
Gasket Surface Flatness .004(0.10) Overall Maximum
3A-30 - MECHANICAL INFORMATION 90-806535970 1296
454 CID / 7.4L / 502 CID / 8.2L
Special Tools
MERCURY MARINE SPECIAL TOOLS
DESCRIPTION PART NUMBER
Piston Ring Expander 91-24697
Engine Coupler Wrench 91-35547
KENT-MOORE SPECIAL TOOLS
DESCRIPTION PART NUMBER
Valve Spring Compressor (Head on) J5892
Valve Spring Compressor (Head off) J8062
Valve Spring Tester J8056
Valve Guide Cleaner J8101
Carbon Remover Brush J8089
Piston Pin Tool J24086-B
Piston Ring Groove Cleaner J3936-03
Piston Ring Compressor J8037
Connecting Rod Guide Tool (3/8 -24) J5239
Connecting Rod Guide Tool (7/16-20) J35228
Oil Pump Suction Pipe Installer J21882
Lift Indicator Tool J8520
Torsional Damper Remover and Installer J23523-E
Crankcase Front Cover Seal Installer J22102
Crankshaft Gear and Sprocket Puller J24420-B
Crankshaft Gear and Sprocket Installer J20158-20
Air Adapter (Cylinder Inflator) J23590
Main Bearing Remover and Installer J8080
Rear Main Seal Installer J38841
Lubricants/Sealers/Adhesives
DESCRIPTION PART NUMBER
Quicksilver Loctite 8831 92-32609-1
Quicksilver Perfect Seal 92-34227-1
Quicksilver RTV Sealer 92-91601-1
General Motors Cam and Lifter Prelubeor Equivalent
Obtain Locally
MECHANICAL INFORMATION - 3A-3190-806535970 1296
454 CID / 7.4L / 502 CID / 8.2L Torque Specifications
DESCRIPTION Lb. In. Lb. Ft. N⋅mAlternator Brace to Alternator 192 9
Alternator Brace to Engine 30 41
Alternator to Mounting Bracket 35 48
Alternator Mounting Bracket 30 41
Camshaft Sprocket Gear 18 24
Carburetor 132 15
Connecting Rod Caps (3/8-24 Nuts) 50 68
(7/16-20 Nuts) 73 99
Coupler/Flywheel(MCM) 35 48
Crankcase Front Cover 120 14
Crankshaft Pulley 35 48
Cylinder Head 85 115
Distributor Hold Down 20 27
Exhaust Manifold 30 41
Exhaust Manifold Elbow 30 41
Filter Adapter (5/16-18) 20 27
Flywheel 75 100
Flywheel Drive Plate (MIE) 35 48
Flywheel Housing to Block 30 41
Flywheel Housing Cover 80 9
Front Mount Bracket 30 41
Fuel Pump 25 34
Intake Manifold 35 48 (See Note)
Main Bearing Cap 110 149
Oil Baffle Nuts 25 34
Oil Filter Adapter Nuts 40 54
Oil Pan Bolts (5/16-18) 80 9
Oil Pan Drain Plug 15 20
Oil Pump 70 95
Oil Pump Cover 80 9
Power Steering Pump Brace to Block 30 41
Power Steering Pump Bracket 30 41
Rear Mount (MCM) 40 54
Rear Mount (MIE) 50 68
Remote Oil Connector (1/2 in. x 13) 25 34
Rocker Arm Cover 90 10
Rocker Arm Bolts 7.4L/454/
40 54454 Magnum/502 45 61
Note: 7.4L / 454 and 502 MPI engines, Torque intake manifold fasteners to 25-30 Lb. Ft. (34-41 N·m).
3A-32 - MECHANICAL INFORMATION 90-806535970 1296
454 CID / 7.4L / 502 CID / 8.2L Torque Specifications
DESCRIPTION Lb. Ft. N⋅mRemote Oil Filter Adapter Nut/Fitting 20 27
Seawater Pump Brace 30 41
Seawater Pump Bracket 30 41
Spark Plugs 15 20
Starter Motor 50 68
Thermostat Housing 30 41
Torsional Damper 40 54
Transmission To Housing 50 68
Water Circulating Pump 35 48
Water Temperature Sender 20 27
MECHANICAL INFORMATION - 3A-3390-806535970 1296
454 CID / 7.4L / 502 CID / 8.2L Engine Specifications
Unit of Measurement In. (mm)
DISPLACEMENT 7.4L 454 MAGNUM 502 MAGNUM / 8.2L
Bore 4.25 (108) 4.46 (113.28)
Stroke 4.00 (101.6)
Compression Ratio 8.0:1 8.6:1 8.75:1
Heads Cast Iron(Oval Port)
Cast Iron(Rectangular Port)
Intake Manifold Cast Iron Aluminum With Brass Inserts-High Rise (See Note)
Block Cast Iron (4 Bolt Main Bearing Caps)
Rods Forged Steel
Pistons Cast Aluminum Forged Aluminum
Crankshaft Cast Steel Forged Steel
Camshaft Cast Iron
Note: 7.4L / 454 and 502 Magnum MPI are equipped with a cast aluminum intake manifold with brass inserts.
CYLINDER BORE
ENGINE 7.4L 454 MAGNUM 502 MAGNUM/8.2L
Diameter 4.2500-4.2507(107.950-107.967)
4.2451-4.2525(107.826-108.013)
4.4655-4.4662(113.423-113.441)
Out of RoundProduction .001(0.025) Max
Out of RoundService .002(0.05) Max
TProduction
Thrust Side .0005(0.0127) Max
TaperProduction
Relief Side .001(0.0254) Max
Service .001(0.02) Over Production
PISTON
ClearanceProduction .0018-.0030
(0.0457-0.0762).0025-.0037
(0.0635-0.0939).0040-.0057
(0.1016-0.1447)Clearance
Service .0018(0.0457)Max
.0075(0.15) Max .0065(0.16) Max
3A-34 - MECHANICAL INFORMATION 90-806535970 1296
454 CID / 7.4L / 502 CID / 8.2L Engine Specifications
Unit of Measurement In. (mm)
PISTON RING
ENGINE 7.4L 454 MAGNUM 502 MAGNUM8.2L
C Groove Production
Top .0012-.0029(0.0305-0.0737)
.0017-.0032(0.044-0.081)
.0017-.0032(0.044-0.081)
Comp
GrooveSide
Clearance
Production
2nd .0012-.0029(0.0305-0.0737)
.0017-.0032(0.044-0.081)
.0017-.0032(0.044-0.081)
pr Service High Production Limit +.010(0.02) Max
ess
GProduction
Top .010-.018(0.25-0.46)
.011-.021(0.28-0.53)
sion
GapProduction
2nd .016-.024(0.41-0.61)
.016-.026(0.41-0.66)
nService High Limit Production + .010(0.25) Max
Oil
GrooveProduction .0050-.0065(0.127-0.165)
Oil
GrooveSide
Clearance Service High Limit Production + .001(0.25)High Limit
Production.005(0.12) Max
Oil
G
Production .010-.030(0.254-0.762)
.020-.035(0.508-0.889)
.010-.030(0.254-0.76)
GapService High Limit Production + .001(0.25)
High Limit Production
.005(0.12) Max
PISTON PIN
ENGINE 7.4L 454 MAGNUM 502 MAGNUM8.2L
Diameter .9895-.9897(25.132-25.1371)
.9895-.9898(25.134-24.140)
Clearance In PinProduc-
tion.0002-.0007
(0.0050-0.0177).00025-.00035
(0.0064-0.0088)
Service .001(0.025) Max
Fit In Rod.0021-.0031
(0.0533-0.0787)Interference
.0008-.0016(0.021-0.040)Interference
MECHANICAL INFORMATION - 3A-3590-806535970 1296
454 CID / 7.4L / 502 CID / 8.2L Engine Specifications
Unit of Measurement In. (mm)
CRANKSHAFT
ENGINE 7.4L 502 MAGNUM / 8.2L 454 MAGNUM
M i
Diameter No.1,2,3,4,5 2.7482-2.7489(69.8042-69.8220)
Main TaperProduction .0004(0.010) Max .0002(0.005) Max
Main Journal
TaperService .001(0.02) Max
Journal
Out of RoundProduction .0002(0.005) Max
Out of RoundService .001(0.005) Max
M i B i
ProductionNo.1,2,3,4 .0017-.0030
(0.043-0.076).0017-.0030
(0.043-0.076)
M i B i
No.5 .0025-.0038(0.063-0.096)
Main BearingClearance
S i
No.1 .001-.003(0.03-0.07)
.0010-.0015(0.0254-0.0381)
Service No.2,3,4 .001-.003(0.03-0.07)
.0010-.0025(0.0254-0.0635)
No.5 .0025-.0040(.0635-.1016)
Crankshaft End Play .005-.0011(0.127-0.279)
.006-.0010(0.15-0.2)
C i
Diameter 2.1990-2.1996(55.8546–55.8698)
Connecting TaperProduction .0005(0.0127) Max
ConnectingRod Journal
TaperService .001(0.0254) Max
Rod Journal
Out of RoundProduction .0005(0.0127) Max
Out of RoundService .001(0.0254) Max
Rod Bearing ClearanceProduction .0011-.0029(0.028-0.074)
Rod Bearing ClearanceService .001(0.0254) Max .003(0.076) Max
Rod Side Clearance .013-.023(0.35-0.58)
Crankshaft Runout @ No.3 main Bearing .0015(0.038) Max .0035(0.088) Max
3A-36 - MECHANICAL INFORMATION 90-806535970 1296
454 CID / 7.4L / 502 CID / 8.2L Engine Specifications
Unit of Measurement In. (mm)
VALVE SYSTEM
ENGINE MODEL 7.4L 454 MAGNUM 502 MAGNUM 8.2L
Lifter Hydraulic
Rocker Arm Ratio 1.70 to 1
Face Angle (Intake & Exhaust) 45°Seat Angle (Intake & Exhaust) 46°
Seat Runout (Intake & Exhaust) .002(0.05) Max
Seat Width
Intake.0300 .0600 in.(0.7620-1.5240
mm)
.03125 .0625 in.(0.79-1.58 mm)
Seat Width
Exhaust.0600-.0950 in.(1.5240-2.4130
mm)
.0625-.09375 in.(1.58-2.38 mm)
SProduction
Intake .0010-.0029(0.0254-0.737)
.0010-.0027(0.025-0.069)
StemClearance
ProductionExhaust .0012-.0031
(0.0300-0.0787).0012-.0029(0.0304-0.0736)
ServiceIntake .001(0.02) .003(0.07) .0037(0.09)
ServiceExhaust .002(0.05) .004(0.10) .0049(0.12)
Stem DiameterIntake .372(9.45)
Stem DiameterExhaust .372(9.45)
Valve Margin Intake and Exhaust .0312(0.79)
Valve Lash (Intake and Exhaust) Fixed Lash
MECHANICAL INFORMATION - 3A-3790-806535970 1296
454 CID / 7.4L / 502 CID / 8.2L Engine Specifications
Unit of Measurement In. (mm)
VALVE SPRING
ENGINE MODEL 7.4L454 MAGNUM502 MAGNUM
8.2L
V l S i
Free Length 2.12(53.9) 2.15(54.6)
V l S iP
Closed at1.88 in. (47.8 mm)
Does Not Apply
110Lbs.(489 N)
Valve Spring(Note 1) Pressure
Closed at1.838 in. (46.7 mm)
71-79 Lbs.(316-351 N)
Does Not Apply
(Note 1)(Note 2)
PressureOpen at
1.34 in. (35.1 mm)Does Not
Apply316 Lbs.(1406 N)
Open at1.347 in. (34.120 mm)
238-262 Lbs.(1059-1165 N)
Does Not Apply
Installed Height 1.838(46.7) 1.88(47.7)
Damper or DamperS
Free Length Does Not 1.86(47.2)p pShield Approximate Number Of Coils Apply 4
Damper or DamperShield
Valve Spring Fit in Damper Shield .42-.094(1.07-2.38)Interference
Does Not Apply
Note 1: 454/502/8.2L Models Only-Test spring pressure with inner and outer spring assembled.
Note 2: 7.4L Models Only Test spring pressure with damper shield installed.
3A-38 - MECHANICAL INFORMATION 90-806535970 1296
454 CID / 7.4L / 502 CID / 8.2L Engine Specifications
Unit of Measurement In. (mm)
ROLLER TAPPET CAMSHAFT
ENGINE MODEL 7.4L454 MAGNUM502 MAGNUM
8.2L
Lobe Lift ± 020 (0 051)Exhaust .284 (7.214) .342 (8.687)
Lobe Lift ± .020 (0.051)Intake .282 (7.163) .342 (8.687)
Duration at .050 In.(1.27mm)C f
Exhaust 209° 227°( )Cam Lift Intake 209° 211°
Journal Diameter 1.9482-1.9492(49.485-49.509)
Journal Out Of Round .001(0.025) Max
Camshaft Runout .002(0.051) Max
Timing Chain Deflection .375(9.5) from taut position [total .75(19)]
FLYWHEEL
Runout .008(0.203) Max
CYLINDER HEAD
Gasket Surface Flatness
.004(0.1016)Overall Maximum
.003(0.076)within a6 in.(152 mm) Span
.007(0.178)Overall Maximum
.003(0.076)within a6 in.(152 mm) Span
MECHANICAL INFORMATION - 3A-3990-806535970 1296
Cylinder Head Torque Sequences
IMPORTANT: Torque to specifications listed in sequence until maximum torque is reached.
3.0LX
20 lb. ft. (27 N⋅m)26 31
07
50 lb. ft. (68 N⋅m)
15 4
0
90 lb. ft. (120 N⋅m)15 4
9 8
4.3LX / 4.3LXH / 262 Magnum Gen+
22 lb. ft. (30 N⋅m) First Sequence
Angle Torque Second Sequence
Short Bolts 55 Degrees
Medium Bolts 65 Degrees
Long Bolts 75 Degrees 72883
5.7L / 350 CID
20 lb. ft. (27 N⋅m)
40 lb. ft. (54 N⋅m)
65 lb. ft. (88 N⋅m)72332
3A-40 - MECHANICAL INFORMATION 90-806535970 1296
Cylinder Head Torque Sequences (Continued)
350 Gen +
22 lb. ft. (30 N⋅m) First Sequence
Angle Torque Second Sequence
Short Bolts 55 Degrees
Medium Bolts 65 Degrees
Long Bolts 75 Degrees 72332
7.4L / 454 CID / 8.2L / 502 CID
20 lb. ft. (27 N⋅m)
50 lb. ft. (68 N⋅m)
85 lb. ft. (115 N⋅m)72944
MECHANICAL INFORMATION - 3A-4190-806535970 1296
Intake Manifold Torque Sequence
IMPORTANT: Install and hand tighten all manifold bolts, then torque to specification in sequence asshown.
5.7L / 350
35 lb. ft. (48 N⋅m) FRONT
72878
4.3LX / 4.3 LXH / 5.7L / 350 CID Gen +
14 58
Torque Three StepsFirst Step - 27 lb. in. (3 N·m)Second Step - 106 lb. in. (12 N·m)Third Step - 133 lb. in. (15 N⋅m)
FRONT
1
2 3
4 5
6 7
8
72878
454 CID / 7.4L / 502 CID / 8.2L
Carburetor and Throttle Body Injection35 lb. ft. (48 N⋅m) 9 8 10 2 3 11 12 13
Multi-Port Injection 25-30 lb. ft. (34-41 N⋅m)
FRONT
7 6 5 1 4 16 14 167 6 5 1 4 16 14 16
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3A-42 - MECHANICAL INFORMATION 90-806535970 1296
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MECHANICAL INFORMATION - 3A-4390-806535970 1296