454 CID (7.4L) / 502 CID (8.2L)

Transcription

1 ENGINE 3 A CID (7.4L) / 502 CID (8.2L) CID (7.4L) / 502 CID (8.2L) - 3A- 3

2 Tle of Contents Pge Torque Specifictions A-1 Specil Tools A-3 Luricnts/Selers/Adhesives A-3 Gen V And Gen VI (Except 7.4L Gen VI) Engine Specifictions A-4 7.4L Gen VI Engine Specifictions A-10 Generl A-15 Engine Identifiction A-15 Cylinder Hed Identifiction A-15 Engine Rottion A-16 Crnkshft A-16 Piston nd Connecting Rods A-16 Cmshft nd Drive A-16 Cylinder Hed A-16 Vlve Trin A-16 Intke Mnifold A-17 Luriction System A-17 Bering Filures A-18 Piston Filures A-19 Pre-Ignition A-19 Detontion A-19 Engine Mounts A-20 Rocker Arm Cover A-22 Removl A-22 Instlltion A-22 Intke Mnifold A-22 Removl A-22 Clening nd Inspection A-22 Instlltion A-23 Rocker Arm / Push Rod A-24 Removl A-24 Clening nd Inspection A-24 Instlltion A-24 Vlve Adjustment A-24 Hydrulic Vlve Lifters (Flt nd Roller Lifter) A-24 Locting Noisy Lifters A-25 Removl A-25 Instlltion A-26 Vlve Stem Oil Sel/Vlve Spring A-26 Removl - Hed Instlled A-26 Vlve Assemly (Exploded View) A-27 Instlltion - Hed Instlled A-28 Cylinder Hed A-29 Removl A-29 Clening nd Inspection A-29 Instlltion A-29 Cylinder Hed nd Vlve Conditioning A-30 Disssemly A-30 Clening A-30 Pge Inspection A-31 Vlve Guide Bore Repir A-31 Vlve Springs - Checking Tension A-32 Vlve Set Repir A-32 Vlve Grinding A-33 Ressemly A-33 Dipstick Specifictions A-36 All Engines A-36 Oil Pn A-37 Removl A-37 Instlltion A-37 Oil Pump A-38 Removl A-38 Disssemly A-38 Clening nd Inspection A-39 Ressemly A-39 Instlltion A-39 Torsionl Dmper A-39 Removl A-39 Instlltion A-40 Crnkcse Front Cover / Oil Sel A-41 Oil Sel Replcement (Without Removing Front Cover) A-41 Crnkcse Front Cover A-41 Removl A-41 Clening nd Inspection A-41 Instlltion A-42 Flywheel A-42 Removl A-42 Inspection A-43 Instlltion A-43 Rer Min Oil Sel A-44 Removl A-44 Clening nd Inspection A-44 Instlltion A-45 Min Berings A-45 Inspection A-45 Checking Clernces A-45 Replcement A-46 Connecting Rod Berings A-47 Inspection nd Replcement A-47 Connecting Rod/Piston Assemly A-49 Removl A-49 Disssemly A-50 Clening nd Inspection A-50 Ressemly A-51 Instlltion A-53 Crnkshft A-54 Removl A-54 3A C.I.D. (7.4L) / 502 C.I.D. (8.2L)

3 Pge Clening nd Inspection A-54 Instlltion A-54 Timing Chin nd Sprocket A-55 Removl A-55 Clening nd Inspection A-56 Instlltion A-56 Crnkshft Sprocket A-56 Removl A-56 Instlltion A-56 Checking Timing Chin Deflection A-56 Cmshft A-57 Mesuring Loe Lift A-57 Removl A-58 Inspection A-58 Instlltion A-58 Cmshft Berings A-58 Removl A-58 Inspection A-59 Instlltion A-59 Cylinder Block A-60 Clening nd Inspection A-60 Oil Filter By-Pss Vlve nd Adptor A-63 Inspection nd/or Replcement A CID (7.4L) / 502 CID (8.2L) - 3A- 1

4 THIS PAGE IS INTENTIONALLY BLANK 3A C.I.D. (7.4L) / 502 C.I.D. (8.2L)

5 Torque Specifictions DESCRIPTION L. In. L. Ft. N m Alterntor Brce to Alterntor Alterntor Brce to Engine Alterntor to Mounting Brcket Alterntor Mounting Brcket Cmshft Sprocket Ger Cruretor Connecting Rod Cps (3/8-24 Nuts) (7/16-20 Nuts) Coupler/Flywheel(MCM) Crnkcse Front Cover Crnkshft Pulley Cylinder Hed Distriutor Hold Down Exhust Mnifold Exhust Mnifold Elow Filter Adpter (5/16-18) Flywheel Flywheel Drive Plte (MIE) Flywheel Housing to Block Flywheel Housing Cover 80 9 Front Mount Brcket Fuel Pump Intke Mnifold (See Note) Min Bering Cp Oil Bffle Nuts Oil Filter Adpter Nuts Oil Pn Bolts (5/16-18) 80 9 Oil Pn Drin Plug Oil Pump Oil Pump Cover 80 9 Power Steering Pump Brce to Block Power Steering Pump Brcket Rer Mount (MCM) Rer Mount (MIE) Remote Oil Connector (1/2 in. x 13) Rocker Arm Cover Rocker Arm Bolts 7.4L/ Mgnum/ Note: 7.4L / 454 nd 502 Multi-Port engines, Torque intke mnifold fsteners to L. Ft. (34-41 N m) CID (7.4L) / 502 CID (8.2L) - 3A-1

6 Torque Specifictions (Continued) DESCRIPTION L. Ft. N m Remote Oil Filter Adpter Nut/Fitting Sewter Pump Brce Sewter Pump Brcket Sprk Plugs Strter Motor Thermostt Housing Torsionl Dmper Trnsmission To Housing Wter Circulting Pump Wter Temperture Sender A C.I.D. (7.4L) / 502 C.I.D. (8.2L)

7 Specil Tools MERCURY MARINE SPECIAL TOOLS DESCRIPTION PART NUMBER Piston Ring Expnder Engine Coupler Wrench KENT-MOORE SPECIAL TOOLS DESCRIPTION PART NUMBER Vlve Spring Compressor (Hed on) J5892 Vlve Spring Compressor (Hed off) J8062 Vlve Spring Tester J8056 Vlve Guide Clener J8101 Cron Remover Brush J8089 Piston Pin Tool J24086-B Piston Ring Groove Clener J Piston Ring Compressor J8037 Connecting Rod Guide Tool (3/8-24) J5239 Connecting Rod Guide Tool (7/16-20) J35228 Oil Pump Suction Pipe Instller J21882 Lift Indictor Tool J8520 Torsionl Dmper Remover nd Instller J23523-E Crnkcse Front Cover Sel Instller J22102 Crnkshft Ger nd Sprocket Puller J24420-B Crnkshft Ger nd Sprocket Instller J Air Adpter (Cylinder Infltor) J23590 Min Bering Remover nd Instller J8080 Rer Min Sel Instller J38841 Luricnts/Selers/Adhesives DESCRIPTION PART NUMBER Quicksilver Loctite Quicksilver Perfect Sel Quicksilver RTV Seler Generl Motors Cm nd Lifter Prelue or Equivlent Otin Loclly CID (7.4L) / 502 CID (8.2L) - 3A-3

8 Gen V And Gen VI (Except 7.4L Gen VI) Engine Specifictions 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 Rtio 8.0:1 8.6:1 8.75:1 Heds Cst Iron (Ovl Port) Cst Iron (Rectngulr Port) Intke Mnifold Cst Iron (Note 3) Aluminum With Brss Inserts-High Rise (Note 1) Block Cst Iron (4 Bolt Min Bering Cps) Rods Forged Steel Pistons Cst Aluminum (Note 2) Forged Aluminum Crnkshft Cst Steel Forged Steel Cmshft Cst Iron (Gen V) Steel (Gen VI) Note 1: 7.4L / 454 nd 502 Mgnum Multi-Port engine is equipped with cst luminum intke mnifold with rss inserts. Note 2: 7.4L Brvo Three engines with engine code UB with seril numer OF nd lower will hve forged pistons. XX with seril numer OF nd higher will hve cst pistons Note 3: Seril numers OD thru OF re equipped with cst luminum intke mnifolds. CYLINDER BORE IMPORTANT: 7.4L Brvo Three engines with engine code UB with seril numer OF nd lower hve forged pistons. The piston specifictions for the 454 Mgnum must e used. Tper Out of Round Production ENGINE 7.4L 454 MAGNUM Dimeter Production Service Thrust Side Relief Side Service ( ) ( ).001 (0.025) Mx.002 (0.05) Mx.0005 (0.0127) Mx.001 (0.0254) Mx.001 (0.02) Over Production 502 MAGNUM/ 8.2L ( ) PISTON Clernce Production ( ) ( ) ( ) Service.005 (0.12) Mx.0075 (0.15) Mx.0065 (0.16) Mx 3A C.I.D. (7.4L) / 502 C.I.D. (8.2L)

9 Gen V And Gen VI (Except 7.4L Gen VI) Engine Specifictions PISTON RING Unit of Mesurement In. (mm) ENGINE 7.4L 454 MAGNUM C Groove Production o Side m Clernce p r Service e s s Production i Gp o n Service Oil Top 2nd Top 2nd ( ) ( ) ( ) ( ) High Production Limit (0.02) Mx ( ) ( ) High Limit Production (0.25) Mx Groove Production ( ) Side Clernce Service High Limit Production (0.25) Gp Production ( ) ( ) Service High Limit Production (0.25) 502 MAGNUM 8.2L ( ) ( ) ( ) ( ) High Limit Production.005 (0.12) Mx ( ) High Limit Production.005 (0.12) Mx PISTON PIN ENGINE 7.4L 454 MAGNUM Dimeter Clernce In Pin Fit In Rod Production Service ( ) ( ) ( ) Interference 502 MAGNUM 8.2L ( ) ( ).001 (0.025) Mx ( ) Interference CID (7.4L) / 502 CID (8.2L) - 3A-5

10 Gen V And Gen VI (Except 7.4L Gen VI) Engine Specifictions CRANKSHAFT Min Journl Min Bering Clernce Unit of Mesurement In. (mm) ENGINE 7.4L / 454 MAGNUM 502 MAGNUM / 8.2L Dimeter No.1,2,3,4, ( ) Tper Production.0002 (0.005) Mx Service.001 (0.02) Mx Out of Round Production.0002 (0.005) Mx Service.001 (0.005) Mx Production No.1,2,3, ( ) No ( ) Service No.1 No.2,3, ( ) ( ) ( ) ( ) No ( ) Crnkshft End Ply ( ) Dimeter ( ) Production.0005 (0.0127) Mx Connecting Tper Service.001 (0.0254) Mx Rod Journl Production.0005 (0.0127) Mx Out of Round Service.001 (0.0254) Mx Rod Bering Clernce Production ( ) Service.003 (0.076) Mx Rod Side Clernce ( ) Crnkshft No.3 Min Bering.0015 (0.038) Mx.0035 (0.088) Mx 3A C.I.D. (7.4L) / 502 C.I.D. (8.2L)

11 Gen V And Gen VI (Except 7.4L Gen VI) Engine Specifictions VALVE SYSTEM Unit of Mesurement In. (mm) ENGINE MODEL 7.4L 454 MAGNUM Lifter Hydrulic Rocker Arm Rtio 1.70 to 1 Fce Angle (Intke & Exhust) 45 Set Angle (Intke & Exhust) 46 Set Runout (Intke & Exhust) Stem Clernce Set Width Production Service Stem Dimeter Intke Exhust.002(0.05) Mx 502 MAGNUM 8.2L 1/32-1/16 [ ] in. ( mm) 1/16-3/32 [ ] in. ( mm) Intke ( ) Exhust ( ) Intke.001 (0.02).003 (0.07).0037 (0.09) Exhust.002 (0.05).004 (0.10).0049 (0.12) Intke.372 (9.45) Exhust.372 (9.45) Vlve Mrgin (Intke nd Exhust).0312 (0.79) Vlve Lsh (Intke nd Exhust) Fixed Lsh CID (7.4L) / 502 CID (8.2L) - 3A-7

12 Gen V And Gen VI (Except 7.4L Gen VI) Engine Specifictions VALVE SPRING Vl Vlve Spring (Note 1) (Note 2) Unit of Mesurement In. (mm) ENGINE MODEL 7.4L 454 MAGNUM 502 MAGNUM 8.2L Free Length 2.12 (53.9) 2.15 (54.6) Pressure Closed t 1.88 in. (47.8 mm) Closed t 1.80 in. (45.7 mm) Open t 1.34 in. (35.1 mm) Open t 1.40 in. (35.6 mm) Does Not Apply Ls. ( N) Does Not Apply Ls. ( N) 110 Ls. (489 N) Does Not Apply 316 Ls. (1406 N) Does Not Apply Instlled Height (47.6) 1.88 (47.7) Dmper or Dmper Free Length Does Not 1.86 (47.2) Shield Approximte Numer Of Coils Apply 4 Dmper or Dmper Shield Vlve Spring Fit in Dmper Shield ( ) Interference Note 1: 454/502/8.2L Models Only-Test spring pressure with inner nd outer spring ssemled. Note 2: 7.4L Models Only Test spring pressure with dmper shield instlled. Does Not Apply 3A C.I.D. (7.4L) / 502 C.I.D. (8.2L)

13 Gen V And Gen VI (Except 7.4L Gen VI) Engine Specifictions HYDRAULIC FLAT TAPPET CAMSHAFT Unit of Mesurement In. (mm) ENGINE MODEL 7.4L 454 MAGNUM 502 MAGNUM 8.2L Loe Lift ±.002 (0.051) 051) Exhust.271 (6.683).300 (7.62) Intke.282 (7.163).300 (7.62) Durtion t.050 In. (1.27mm) Exhust Cm Lift Intke ROLLER TAPPET CAMSHAFT ENGINE MODEL 7.4L 454 MAGNUM 502 MAGNUM 8.2L Loe Lift ±.020 (0.051) 051) Exhust.284 (7.214).342 (8.687) Intke.282 (7.163).342 (8.687) Durtion t.050 In.(1.27mm) Exhust Cm Lift Intke FLYWHEEL Journl Dimeter ( ) Journl Out Of Round Cmshft Runout.001 (0.025) Mx.002 (0.051) Mx Timing Chin Deflection.375 (9.5) from tut position [totl.75 (19)] Runout.008 (0.203) Mx CYLINDER HEAD Gsket Surfce Fltness.007 (0.178) Overll Mximum.003 (0.076) within 6 in. (152 mm) Spn CID (7.4L) / 502 CID (8.2L) - 3A-9

14 7.4L Gen VI Engine Specifictions Unit of Mesurement In. (mm) Displcement 454 CID (7.4L) Bore 4.25 (108) Stroke 4.00 (101.6) Compression Rtio 8.0:1 Heds Cst Iron (Ovl Port) Intke Mnifold Cst Iron Block Cst Iron (4 Bolt Min Bering Cps) Rods Forged Steel Pistons Cst Aluminum Crnkshft Cst Steel Cmshft Steel CYLINDER BORE Out of Round Production Tper Dimeter ( ) Production.001 (0.025) Mx Service.002 (0.051) Mx Thrust Side.0005 (0.0120) Mx Relief Side.001 (0.0254) Mx Service.001 (0.0254) Over Production PISTON Clernce Production ( ) Service.0018 (0.0457) Mx 3A C.I.D. (7.4L) / 502 C.I.D. (8.2L)

15 7.4L Gen VI Engine Specifictions Unit of Mesurement In. (mm) PISTON RING Production 2nd ( ) Groove C Side o Clernce Service High Production Limit (0.0254) Mx m p r Top ( ) e s Production s i Gp 2nd ( ) o n Service High Limit Production (0.254) Mx Oil Groove Side Clernce Production Service ( ) High Limit Production (0.254) Gp Production ( ) Service High Limit Production (0.254) PISTON PIN Dimeter ( ) Clernce In Piston Production ( ) Service.001 (0.0254) Mx Fit In Rod ( ) Interference CID (7.4L) / 502 CID (8.2L) - 3A-11

16 7.4L Gen VI Engine Specifictions Unit of Mesurement In. (mm) CRANKSHAFT Dimeter No. 1, 2, 3, 4, ( ) Production.0004 (0.0102) Mx Min Tper Service.001 (0.0254) Mx Journl Production.0004 (0.0102) Mx Out of Round Service.001 (0.0254) Mx Production No ( ) No. 1, 2, 3, ( ) Min Bering Clernce Production No ( ) Service No. 1, 2, 3, ( ) No ( ) Crnkshft End Ply ( ) Dimeter ( ) Production.0005 (0.0127) Mx Tper Connecting Rod Journl Service.001 (0.0254) Mx Out of Round Production.0005 (0.0127) Mx Service.001 (0.0254) Mx Rod Bering Clernce Production ( ) Service.001 (0.0254) Mx Rod Side Clernce ( ) 3A C.I.D. (7.4L) / 502 C.I.D. (8.2L)

17 7.4L Gen VI Engine Specifictions VALVE SYSTEM Unit of Mesurement In. (mm) Stem Clernce Lifter Hydrulic Roller Rocker Arm Rtio 1.70 to 1 Fce Angle (Intke & Exhust) 45 Set Angle (Intke & Exhust) 46 Set Runout (Intke & Exhust).002 (0.05) Mx Set Width Intke ( ) Exhust ( ) Production Intke ( ) Exhust ( ) Service Intke.0037 (0.0939) Exhust.0049 (0.1244) Vlve Lsh (Intke nd Exhust) Net Lsh VALVE SPRING Vl Vlve Spring Pressure Free Length 2.12 (53.9) Closed in. ( mm) t Ls. ( N) Open in. ( mm) t Ls. ( N) Instlled Height ( ) ± (47.6) CID (7.4L) / 502 CID (8.2L) - 3A-13

18 7.4L Gen Gen VI Engine Specifictions FLYWHEEL Unit of Mesurement In. (mm) Runout.008 (0.203) Mx CYLINDER HEAD Gsket Surfce Fltness.004 (0.1016) Overll Mximum.003 (0.076) within 6 in. (152mm) Spn Loe Lift ±.020 (0.051) 051) Exhust.284 (7.214) Intke.282 (7.163) Durtion t.050 In. (1.27mm) Exhust 209 Cm Lift Intke 209 Journl Dimeter ( ) Journl Out Of Round Cmshft Runout Timing Chin Deflection.001 (0.025) Mx.002 (0.051) Mx.375 (9.5) from tut position [totl.75 (19)] 3A C.I.D. (7.4L) / 502 C.I.D. (8.2L)

19 Generl Some of the repirs in this section must e completed with engine removed from ot. Engine removl depends upon type of repir nd ot design. Plce engine on repir stnd for mjor repirs. When engine removl is not required, mke certin tht ttery cles re disconnected t the ttery prior to performing ny on-ord repir procedures. Luricte ll moving prts (during ressemly) with engine oil. Apply Quicksilver Perfect Sel on threds of nd under heds of cylinder hed olts, nd on threds of ll cylinder lock externl olts, screws nd studs. Engine Identifiction The MerCruiser Model cn e determined y looking t the lst two letters of the engine code stmped into the cylinder lock. This code numer is stmped on ll MerCruiser power pckges nd replcement prtil engines, ut not replcement cylinder lock ssemlies. If the engine seril numer nd/or model decls re missing, the engine code letters my help in determining the engine models. Following is list of GM engines nd their respective code letters. MIE (Inord) Code Rottion 7.4L XY 7.4L EFI UK 7.4L MPI UD LH 8.2L FH,HH 454 EFI Ski UA NOTE:Engines with 6 or 7 preceding the lock code Gen VI engines. Exmple: 6XW would e 7.4L Brvo. Cylinder Hed Identifiction 7.4L Gen V nd VI Cylinder heds re identified y their smller nd rounded intke ports MAGNUM / 502 MAGNUM / 8.2L Mrk IV cylinder heds re identified y HI PERF cst in the hed under the rocker cover. Gen V nd VI cylinder heds re y their lrge rectngulr intke ports Loction Of GM Engine Code MCM (Stern Drive) Code Rottion 7.4L XW 7.4L Brvo Three UW,UB,XX 7.4LX EFI Brvo UJ 7.4LX MPI Brvo UC 454 Mgnum XA LH 454 Mgnum MPI UA 502 Mgnum FJ 502 Mgnum MPI FJ,HJ CID (7.4L) / 502 CID (8.2L) - 3A-15

20 Engine Rottion Engine rottion terminology t times hs cused confusion. To clrify, engine rottion is determined y oserving flywheel rottion from the rer (trnsmission or stern drive end) of the engine looking forwrd (wter pump end). PROPELLER ROTATION IS NOT NECESSARILY THE SAME s engine rottion. When ordering replcement engines, short locks or prts for engines, e certin to check engine rottion. Do not rely on propeller rottion in determining engine rottion. Cmshft nd Drive Flt tppet cmshfts mde of cst iron nd roller lifter cmshft re mde of steel. All cmshfts re driven t one-hlf crnkshft speed y timing chin nd sprockets, or y timing gers, nd re supported y five min erings, which re pressed into the lock. A helicl ger on the ft end of the cmshft drives the distriutor nd oil pump. On engines with cst iron cmshft nd flt fced lifters, tper on the loes, coupled with sphericl foot on the hydrulic vlve lifters, cuses the vlve lifters to rotte, thus reducing wer. Cylinder Hed The cylinder heds re mde of cst iron nd hve individul intke nd exhust ports for ech cylinder. Stinless steel or grphite composition hed gskets re used to retrd corrosion Left-hnd Rottion (CCW) - All Stern Drive (MCM) Engines And Inord (MIE) (Stndrd) Rottion Crnkshft The crnkshft is supported in the lock y five insert type erings. Crnkshft end thrust is controlled y flnges on the No. 5 ering. A torsionl dmper on the forwrd end of the crnkshft serves to help dmpen ny engine torsionl virtion. Vlve Trin The vlves nd vlve springs re of hevy-duty design to withstnd the high engine speeds encountered. Vlve tips hve een hrdened to extend vlve life. Exhust vlve rottors re used on some engines (7.4L only) to help extend vlve life. Hydrulic vlve lifters ride directly on the cmshft loes nd trnsmit the thrust of the loes to the push rods which in turn ctute the vlves through the rocker rm. In ddition to trnsmitting thrust of the cm loes, the hydrulic lifters lso serve to remove ny clernce (lsh) from the vlve trin to keep ll prts in constnt contct. The vlve lifters lso re used to luricte the vlve trin ering surfces. Piston nd Connecting Rods Piston pins re offset slightly towrd the thrust side of the pistons to provide grdul chnge in thrust pressure ginst the cylinder wll s the piston trvels its pth. Pins hve floting fit in the piston nd press fit in the connecting rod (to hold them in plce). Connecting rods re mde of forged steel nd re connected to the crnkshft through insert type erings. 3A C.I.D. (7.4L) / 502 C.I.D. (8.2L)

21 Intke Mnifold CARBURETED AND THROTTLE BODY INJECTION The mnifold is of the doule level design for efficient fuel distriution. The upper level of pssges feeds cylinders 2, 3, 5 nd 8 while the lower level pssges feed cylinders 1, 4, 6 nd 7. All pssges re of pproximtely equl length to ssure more even fuel-ir mixture to the cylinders. MULTI-PORT INJECTION The mnifold is cross flow design, with equl length runners. Injectors re positioned directly ove the intke ports of ech cylinder. Luriction System The engine luriction system is of the force-feed type in which oil is supplied under full pressure to the crnkshft, connecting rods, cmshft erings nd vlve lifters, nd is supplied under controlled volume to the push rods nd rocker rms. All other moving prts re luricted y grvity flow or splsh. A positive displcement ger-type oil pump is mounted on the rer min ering cp nd is driven y n extension shft from the distriutor (which is driven y the cmshft). Oil from the ottom of the pump in the rer of the oil pn is drwn into the oil pump through n oil pickup screen nd pipe ssemly. If the screen should ecome clogged, relief vlve in the screen will open nd continue to llow oil to e drwn into the system. Once the oil reches the pump, the pump forces the oil through the luriction system. A spring-loded relief vlve in the pump limits the mximum pump output pressure. After leving the pump, the pressurized oil flows through full-flow oil filter. On engines with n engine oil cooler, the oil lso flows through the cooler efore returning to the lock. A ypss vlve llows oil to ypss the filter nd oil cooler should they ecome restricted. Some of the oil, fter leving the oil cooler nd/or filter, is routed to the No. 5 crnkshft min ering. The reminder of the oil is routed to the min oil gllery, which is locted directly ove the cmshft nd runs the entire length of the lock. From the min oil gllery, the oil is routed through individul oil pssges to n nnulr groove in ech cmshft ering ore. Some of the oil is then used to luricte cmshft erings. The reminder of the oil is routed to the vlve lifter oil glleries nd No. 1, 2, 3, nd 4 crnkshft min erings y mens of individul oil pssges which intersect with the nnulr grooves. The cmshft erings hve holes which lign with the oil pssges or nnulr grooves in the lock nd llow oil to flow in-etween the erings nd the cmshft journls. The oil tht is forced out the front end of the No. 1 cmshft ering drins down onto the cmshft drive nd keeps it luricted. The oil which reches the crnkshft min erings is forced through hole in the upper hlf of ech ering nd flows in-etween the erings nd the crnkshft journls. Some of the oil is then routed to the connecting rod erings through grooves in the upper hlf of the crnkshft min erings nd oil pssges in the crnkshft. Oil which is forced out the ends of the connecting rod erings nd crnkshft min erings is splshed onto the cmshft, cylinder wlls, pistons nd piston pins, keeping them luricted. Oil which is forced out the front end of the No. 1 crnkshft min ering lso ssists in luricting the cmshft drive. A ffle plte, mounted on the ottom of the min erings or in the oil pn, prevents oil thrown from the crnkshft nd connecting rods from erting the oil in the oil pn. Oil which reches the vlve lifter oil glleries is forced into ech hydrulic vlve lifter through holes in the side of the lifter. From here, the oil is forced through the metering vlve in ech of the lifters (which controls the volume of oil flow) nd then up through the push rods to the rocker rms. A hole in ech rocker rm push rod set llows the oil to pss through the rocker rm nd luricte the vlve trin ering surfces. After luricting the vlve trin, oil drins ck to the oil pn through oil return holes in the cylinder hed nd lock. The distriutor shft nd ger lso is luricted y the oil flowing through the right vlve lifter oil gllery CID (7.4L) / 502 CID (8.2L) - 3A-17

22 Bering Filures Scrtched By Dirt Scrtches - Dirt Imedded In Bering Mteril Rdius Ride - Worn Are Tpered Journl - Overly Gone From Entire Surfce Improper Seting - Bright Or Polished Sections Lck Of Oil - Overly Worn Off Ftigue Filure - Crters or Pockets A C.I.D. (7.4L) / 502 C.I.D. (8.2L)

23 Piston Filures Pre-Ignition Pre-ignition is norml fuel ignition, cused y comustion chmer hot spots. Control of the strt of ignition is lost, s comustion pressure rises too erly, cusing power loss nd rough running. The upwrd motion on the piston is opposed y the pressure rise. This cn result in extensive dmge to the internl prts from the high increse in comustion chmer temperture. PRE-IGNITION CAUSES 1. Hot spots in the comustion chmer from glowing deposits (due in turn to the use of improper oils nd/or fuels). 2. Overheted sprk plug electrodes (improper het rnge or defective plug). 3. Any other protuernce in the comustion chmer, such s n overhnging piece of gsket, n improperly seted vlve or ny other indequtely cooled section of mteril which cn serve s source. Engine filures, which result from the foregoing conditions, re eyond the control of Mercury Mrine; therefore, no wrrnty will pply to filures which occur under these conditions. Pre-Ignition Dmge Detontion Detontion, commonly clled fuel knock, sprk knock or cron knock, is norml comustion of the fuel which cuses the fuel to explode violently. The explosion, in turn, cuses overheting or dmge to the sprk plugs, pistons, vlves nd, in severe cses, results in pre-ignition. Use of low octne gsoline is one of the most common cuses of detontion. Even with high octne gsoline, detontion could occur if engine mintennce is neglected. OTHER CAUSES OF DETONATION c - Ignited By Hot Deposits - Regulr Ignition Sprk c - ignites Remining Fuel d - Flme Front Collide d IMPORTANT: Use of improper fuels will cuse engine dmge nd poor performnce. 1. Over-dvnced ignition timing. 2. Len fuel mixture t or ner full throttle (could e cused y cruretor or leking intke mnifold). 3. Cross-firing sprk plugs. 4. Excess ccumultion of deposits on piston nd/ or comustion chmer (results in higher compression rtio). 5. Indequte cooling of engine y deteriortion of cooling system CID (7.4L) / 502 CID (8.2L) - 3A-19

24 NOTE:Engine filures, which result from the foregoing conditions, re eyond the control of MerCruiser; therefore, no wrrnty will pply to filures which occur under these conditions. Engine Mounts Detontion Dmge Front Mount - All MCM (Stern Drive) Models c d Rer Mount/Flywheel Housing - All MCM (Stern Drive) Models - Sprk Occurs - Comustion Begins c - Comustion Continues d - Detontion Occurs A C.I.D. (7.4L) / 502 C.I.D. (8.2L)

25 Engine Mounts (Continued) Flywheel Housing - All MIE (Inord) Models Rer Mount Assemly - MIE 7.4L/8.2L with Hurth Down Angle nd V-Drive Trnsmission Rer Mount Assemly - MIE 7.4L/8.2L with Borg-Wrner In-Line Trnsmission Rer Mount Assemly - MIE 7.4L with Borg-Wrner Remote V-Drive Trnsmission - Ruer Insert Cnnot Be Removed Front Mount Assemly - All MIE Models - Ruer Insert Cnnot Be Removed CID (7.4L) / 502 CID (8.2L) - 3A-21

26 Rocker Arm Cover Removl On Engines with Center Exhust Outlet Exhust Mnifolds: It my e necessry to remove exhust mnifold efore removing rocker rm cover. Refer to Section 7B for removl. Also remove ny component tht will interfere with the removl of the mnifold. 1. Disconnect crnkcse ventiltion hoses. 2. Remove ny items tht interfere with the removl of rocker rm covers. 3. Remove rocker rm cover. Instlltion 1. Clen seling surfces on cylinder hed nd rocker rm cover with degreser. 2. Plce new rocker rm cover gsket in position in rocker rm cover. Intke Mnifold NOTICE For repir procedures on Fuel Injection Engines, refer to Section 5C. Removl 1. Drin engine cooling system. 2. Disconnect hoses from thermostt housing. 3. Disconnect intke mnifold-to-circulting pump y-pss hose from circulting pump. 4. Disconnect electricl leds interfering with removl. 5. Disconnect crnkcse ventiltion hoses from rocker rm covers. 6. Disconnect throttle cle from cruretor. Remove fuel line nd sight tue running etween fuel pump nd cruretor. 7. Remove distriutor cp nd mrk position of rotor on distriutor housing. Also, mrk position of distriutor housing on intke mnifold. Remove distriutor. IMPORTANT: Do not crnk engine over fter distriutor hs een removed. 8. Remove other ignition components. 9. Disconnect ny other miscellneous items tht will prevent removl of mnifold IMPORTANT: It my e necessry to pry intke mnifold wy from cylinder heds nd lock, in next step. Use extreme cre to prevent dmge to seling surfces. - Rocker Arm Cover Gsket 3. Instll rocker rm cover. Torque olts to 70 l. in. (10 N m). 4. Reinstll exhust mnifolds, if removed. 5. Reinstll ny items which were removed to llow removl of rocker rm covers. 6. Connect crnkcse ventiltion hoses to rocker rm covers. 7. Strt engine nd check for oil leks. 10. Remove intke mnifold olts, then remove intke mnifold nd cruretor ssemly. NOTE:If intke mnifold requires replcement, trnsfer ll remining prts to new mnifold. Clening nd Inspection 1. Clen gsket mteril from ll mting surfces. IMPORTANT: When clening cylinder hed mting surfce, do not llow gsket mteril to enter engine crnkcse or intke ports. 3A C.I.D. (7.4L) / 502 C.I.D. (8.2L)

27 2. Inspect mnifold for crcks or scrtches. Mchined surfces must e clen nd free of ll mrks nd deep scrtches or leks my result. 3. Check intke pssges for vrnish uildup nd other foreign mteril. Clen s necessry. Instlltion 2. Using Quicksilver Bellows Adhesive, glue neoprene gskets to engine lock etween cylinder heds. 3. Apply smll mount of RTV Seler on neoprene gsket ends. 4. Set intke mnifold gskets in plce, ligning olt holes. IMPORTANT: When instlling intke mnifold gskets, in next step, e sure to do the following: Be sure to instll gsket with mrked side up. Both gskets re identicl. All MerCruiser V-8 GM engines tht hve utomtic cruretor chokes must use n intke gsket tht hs n opening for the exhust crossover port in the intke mnifold. Without this opening the utomtic cruretor choke will not operte properly. The choke will remin ON longer cusing rough engine opertion nd wsted fuel. 1. Apply Quicksilver Perfect Sel to intke mnifold gskets round coolnt pssges (oth sides). - Neoprene Gskets - RTV Seler c - Gskets c c c 5. Crefully instll mnifold ssemly. On ll engines except 7.4L / 454 / 502 Mgnum Multi-Port Injection, torque olts to 35 l. ft. (48 N m) in sequence s shown Exhust Crossover Port Opening in Gsket - Intke Vlve Port c - Coolnt Pssges! WARNING Be sure to red nd follow pckge lel directions when using ellows dhesive Intke Mnifold Torque Sequence CID (7.4L) / 502 CID (8.2L) - 3A-23

28 6. Connect ll electricl leds. 7. Connect hoses to thermostt housing. 8. Instll fuel line nd sight tue to cruretor nd fuel pump. 9. Connect crnkcse ventiltion hoses to rocker rm covers. Reconnect throttle cle to cruretor. 10. Instll distriutor. Position rotor nd housing to lign with mrks mde during removl, then instll distriutor cp. 11. Instll other ignition components nd reconnect wires. 12. Connect ny other items which were disconnected from mnifold during removl. 13. Strt engine. Adjust ignition timing nd cruretor. Check hose connections, gskets nd sels for leks. 14. Inspect fuel line connections for fuel leks. Rocker Arm / Push Rod Removl NOTE:When servicing only one cylinder s rocker rms, ring tht cylinder s piston up to TDC efore removing rocker rms. When servicing ll rocker rms, ring No. 1 piston up to TDC efore removing rocker rms. 1. Remove rocker rm covers s outlined. 2. Remove rocker rm ssemlies nd push rods. IMPORTANT: Plce rocker rm ssemlies nd push rods in rck for ressemly in their originl loctions. 1. Instll push rods in their originl loctions. Be sure push rods set in lifter socket. 2. Instll rocker rms, rocker rm lls nd rocker rm olts in their originl loctions. Torque to specifiction. Vlve Adjustment No djustment is required. Vlve lsh is utomticlly set when rocker rm olts re torqued to 45 l. ft. (61 N m). Hydrulic Vlve Lifters (Flt nd Roller Lifter) Clening nd Inspection 1. Clen prts with solvent nd dry with compressed ir. 2. Inspect ll contct surfces for wer. Replce ll dmged prts. Instlltion IMPORTANT: When instlling rocker rms nd rocker rm lls, cot ering surfces of rocker rms nd rocker rm lls with engine oil. 1 - Push Rod Set Retiner 2 - Push Rod Set 3 - Metering Vlve 4 - Plunger 5 - Check Bll 6 - Check Bll Spring 7 - Check Bll Retiner 8 - Plunger Spring 9 - Lifter Body A C.I.D. (7.4L) / 502 C.I.D. (8.2L)

29 Hydrulic vlve lifters require little ttention. Lifters re extremely simple in design. Normlly, redjustments re not necessry nd servicing requires only tht cre nd clenliness e exercised in the hndling of prts. Locting Noisy Lifters Locte noisy vlve lifter y using piece of grden hose pproximtely 4 ft. (1.2 m) in length. Plce one end of hose ner end of ech intke nd exhust vlve, with other end of hose to the er. In this mnner, sound is loclized, mking it esy to determine which lifter is t fult. Another method is to plce finger on fce of vlve spring retiner. If lifter is not functioning properly, distinct shock will e felt when vlve returns to its set. Generl types of vlve lifter noise re s follows: 1. Hrd rpping noise - usully cused y plunger ecoming tight in ore of lifter ody so tht return spring cnnot push plunger ck up to working position. Prole cuses re:. Excessive vrnish or cron deposit, cusing norml stickiness.. Glling or pickup etween plunger nd ore of lifter ody, usully cused y n rsive piece of dirt or metl wedged etween plunger nd lifter ody. 2. Moderte rpping noise - prole cuses re:. Excessively high lekdown rte.. Leky check vlve set. c. Improper djustment. 3. Generl noise throughout vlve trin - this will, in most cses, e definite indiction of insufficient oil supply or improper djustment. 4. Intermittent clicking - prole cuses re:. A microscopic piece of dirt momentrily cught etween ll set nd check vlve ll.. In rre cses, ll itself my e out of round or hve flt spot. c. Improper djustment. In most cses, where noise exists in one or more lifters, ll lifter units should e removed, disssemled, clened in solvent, ressemled nd reinstlled in engine. If dirt, corrosion, cron, etc., is shown to exist in one unit, it more likely exists in ll the units; thus it would only e mtter of time efore ll lifters cused troule. Removl IMPORTANT: Keep push rod nd hydrulic vlve lifter from ech vlve together s mtched set nd mrk them so they cn e reinstlled in the sme loction lter. Remove s outlined: 1. Remove rocker rm covers. 2. Remove intke mnifold. 3. Remove rocker rm ssemlies nd push rods. 4. Remove vlve lifters. NOTE:Gen VI engines with roller lifters hve dditionl vlve trin components shown elow. - Lifter Restrictor Retiner - Fsteners Roller Lifter Restrictor - Roller Lifter 5. Remove lifter restrictors on roller lifters models. 6. Remove vlve lifters CID (7.4L) / 502 CID (8.2L) - 3A-25

30 Instlltion 3. Using vlve spring compressor s shown, compress vlve spring nd remove vlve locks. IMPORTANT: It is recommended tht the engine oil e chnged nd new oil filter e instlled whenever servicing vlve lifters or cmshft. IMPORTANT: Before instlling lifters, cot the ottom of the lifter with engine oil. If new lifters or new cmshft hve een instlled, n dditive contining EP lue (such s Generl Motors Cm nd Lifter Pre-lue or equivlent) should e poured over cmshft loes efore instlling lifters. IMPORTANT: Before instlltion, cot entire vlve lifter with engine oil. IMPORTANT: DO NOT instll used vlve lifters if new cmshft hs een instlled. 1. Instll hydrulic vlve lifters nd components. 2. Instll intke mnifold. 3. Instll push rods nd rocker rms. Torque rocker rm olts to specifiction. 4. Instll rocker rm cover. 5. Strt engine nd check for leks. - Vlve Spring Compressor (J-5892) - Rocker Arm Nut Slowly relese vlve spring compressor. Remove cp, shield, nd vlve spring. IMPORTANT: Keep ir pressure in cylinder while springs, cps, nd vlve locks re removed or vlves will fll into cylinder. 5. Remove oil shields from vlve stems. Vlve Stem Oil Sel/Vlve Spring Removl - Hed Instlled 1. Remove:. Rocker rm cover.. Sprk plug of ffected cylinder. c. Rocker rm ssemly. 2. Instll ir line dptor tool (J-23590) in sprk plug hole nd pply compressed ir to hold vlves in plce. NOTE:If compressed ir is not ville, piston my e rought up to TDC nd used to keep vlves from flling out of vlve guides. - Vlve Stem Oil Shield IMPORTANT: Do not turn crnkshft while vlve springs, retiners, nd locks re removed or vlves will fll into cylinder. 3A C.I.D. (7.4L) / 502 C.I.D. (8.2L)

31 Vlve Assemly (Exploded View) L Only 1 - Vlve Lock 2 - Retiner 3 - Oil Shield Sel 4 - Oil Shield 5 - Outer Spring 6 - Dmper Shield 7 - Rottor 8 - Intke Vlve 9 - Exhust Vlve Mgnum / 502 Mgnum/ 8.2L 1 - Vlve Lock 2 - Retiner 3 - Oil Shield 4 - Inner Spring 5 - Outer Spring 6 - Shim 7 - Intke Vlve 8 - Exhust Vlve CID (7.4L) / 502 CID (8.2L) - 3A-27

32 Instlltion - Hed Instlled 7.4L 1. Plce rottor or shim on vlve spring set. 2. Cot vlve stem nd new sel with engine oil. Instll sel over vlve stem. 3. If tken prt, ressemle dmper nd vlve spring. Plce on top of rottor or shim. 4. Set vlve spring ssemly nd cp in position over vlve stem. 5. Compress spring, using vlve spring compressor, nd instll vlve locks (grese my e used to hold vlve locks in plce). Slowly relese tool, mking sure vlve locks set properly in vlve stem grooves. 454 MAGNUM / 502 MAGNUM / 8.2L 1. Plce shim on vlve spring set. 2. If tken prt, ressemle dmper nd vlve spring s shown. Mke sure tighter wound coils of spring nd dmper re on the sme end Plce vlve spring ssemly in position with tighter wound coils ginst spring set. IMPORTANT: Vlve sel nd cp must e ssemled s shown efore instlltion. - Vlve Spring Compressor (J-5892) - Rocker Arm Nut Instll push rods nd rocker rm ssemlies. Torque to specifictions. 7. Instll rocker rm cover [torque to 90 in. ft. (10 N m)] nd sprk plug [torque to 22 l. ft. (30 N m)] Cot vlve stem nd new sel with engine oil. 5. Set cp nd sel ssemly on vlve stem. Align vlve stem with center of vlve sel. 6. Compress vlve spring, using vlve spring compressor, nd instll vlve locks (grese my e used to hold vlve locks in plce). Slowly relese tool to prevent dmging sel. Mke sure vlve locks set properly in vlve stem grooves. 7. Instll push rods nd rocker rm ssemlies. Torque to specifictions. 8. Instll rocker rm cover [torque to 90 in. ft. (10 N m)] nd sprk plug [torque to 22 l. ft. (30 N m)]. 3A C.I.D. (7.4L) / 502 C.I.D. (8.2L)

33 Cylinder Hed Removl 1. Drin engine cooling system. 2. Remove s outlined:. Exhust mnifolds.. Intke mnifold. c. Rocker rm covers. d. Rocker rm ssemlies nd push rods (keep in order for ressemly in their originl loctions). e. Any components ttched to front or rer of cylinder hed. f. Sprk plugs. g. Hed olts. Instlltion! CAUTION DO NOT use seler on hed gskets. 1. Plce hed gsket in position over dowel pins. 2. Crefully set cylinder hed in plce over dowel pins. 3. Cot threds of hed olts with Quicksilver Perfect Sel nd instll finger-tight. 4. To insure gsket seling, torque hed olts in three steps, following torque sequence for ech step. Strt first step t 20 l. ft. (27 N m), second step t 50 l. ft. (68 N m), nd finish with finl torque of 7.4L 85 l. ft. (115 N m) 454/502 Mgnum 92 l. ft. (124 N m)! CAUTION The hed gsket my e holding cylinder hed to lock. Use cre when prying off cylinder heds. DO NOT dmge gsket surfces. DO NOT drop cylinder heds. 3. Plce cylinder hed on wooden locks to prevent dmge to gsket surfces. Cylinder Hed Torque Sequence Clening nd Inspection 1. Clen gsket mteril nd seler from engine lock nd cylinder heds. 2. Inspect seling surfces for deep nicks nd scrtches. 3. Inspect for corrosion round cooling pssges. 4. Clen hed olt threds nd engine lock olt hole threds, mking sure no dirt, old oil or coolnt remin. 5. Instll push rods nd rocker rm ssemlies in their originl positions. Cot threds on rocker rm olt with Perfect Sel. Torque 7.4L 40 l. ft. (54 N m) 454/502 Mgnum 45 l. ft. (61 N m) 6. Instll s outlined:. Intke mnifold.. Rocker rm covers. c. Exhust mnifolds. d. Sprk plugs. e. Any components removed from front or rer of cylinder heds CID (7.4L) / 502 CID (8.2L) - 3A-29

34 7. Follow procedures in Section 6A or 6B of this mnul: Sewter Cooled Models: Provide for dequte wter supply to sewter pickup (see Section 6A). Closed Cooled Models: Refill closed cooling section (see Section 6B), nd provide dequte wter supply to sewter pickup.! CAUTION Ensure tht cooling wter supply is ville efore strting the engine. 8. Strt engine, set timing, set idle speed, nd check for leks. Clening 1. Clen push rods nd rocker rm ssemlies. 2. Clen cron from vlves using wire wheel. 3. Clen gsket mteril from cylinder hed mting surfces. 4. Clen ll cron from comustion chmers nd vlve ports using cron remover rush. Cylinder Hed nd Vlve Conditioning Disssemly 1. Using vlve spring compressor, compress vlve spring nd remove vlve locks. Slowly relese tool. - Cron Remover Brush (J-8089) Thoroughly clen vlve guides with vlve guide clener Vlve Guide Clener (J-8101) Vlve Spring Compressor (J-8062) 2. Remove ll vlve components. 3. Remove vlves from cylinder hed nd plce in rck, in order, for ressemly in their originl loctions. 3A C.I.D. (7.4L) / 502 C.I.D. (8.2L)

35 Inspection 1. Inspect cylinder heds for crcks in exhust ports, wter jckets, nd comustion chmers (especilly round sprk plug holes nd vlve sets). Replce heds if ny crcks re found. 2. Inspect cylinder hed gsket surfce for urrs, nicks, or erosion or other dmge. Also, check fltness of cylinder hed gsket surfce, using mchinist s stright edge nd feeler guges s shown. Refer to Specifictions. c. Holding vlve hed off set out 1/16 in. (2 mm), move vlve stem ck nd forth in direction shown. Compre stem clernce with specifictions. c Stright Edge - Feeler Guge c - Tke Both Mesurements Digonlly Across Hed (Both Wys) And Stright Down Center Of The Hed IMPORTANT: Cylinder hed-to-lock gsket surfce should e resurfced if wrped more thn specified. When hed resurfcing is required, cylinder hed-to-intke mnifold gsket surfce on hed must e milled to provide proper lignment etween intke mnifold nd hed. 3. Inspect vlves for urned heds, crcked fces or dmged stems. 4. Inspect rocker rm olts nd push rod guides for wer nd dmge. IMPORTANT: Excessive vlve stem to ore clernce will cuse excessive oil consumption nd possile vlve rekge. Insufficient clernce will result in noisy nd sticky vlves. - Vlve Stem - Dil Indictor c - Vlve Guide c. If clernce exceeds specifictions, it will e necessry to rem vlve guides for oversized vlves, s outlined under Vlve Guide Bore Repir. Vlve Guide Bore Repir IMPORTANT: Be sure to mesure vlve stem dimeter of oth the intke nd exhust vlve, s vlve stem dimeter my or my not e the sme for oth vlves. If.015 in. oversize vlves re required, rem vlve guide ores for oversize vlves, s follows: 5. Mesure vlve stem clernce s follows:. Attch dil indictor to cylinder hed, positioning it ginst the vlve stem nd close to the vlve guide CID (7.4L) / 502 CID (8.2L) - 3A-31

36 1. Mesure vlve stem dimeter of old vlve eing replced nd select proper size vlve guide remer from chrt elow. Stndrd Vlve Stem Dimeter Remer Required For.015 In. Oversize Vlve.372 In. J Rem vlve guide ores, s shown. Vlve Set Repir Vlve set reconditioning is very importnt, since seting of vlves must e perfect for engine to deliver mximum power nd performnce. Another importnt fctor is vlve hed cooling. Good contct etween ech vlve nd its set in hed is importnt to ensure tht het in vlve hed will e properly dispersed. Severl different types of equipment re ville for reseting vlve sets. Equipment mnufcturer s recommendtions should e followed crefully to ttin proper results. c d Remove the shrp corner creted y remer t top of vlve guide. Vlve Springs - Checking Tension NOTE:On 7.4L models, spring tension must e tested with dmper removed. All other models require testing with dmpers instlled. Refer to Specifictions. IMPORTANT: Springs should e replced if not within 10 l. (44 N) of specified tension. Typicl 3 Angle Vlve Set - Top Angle (30 ) - Set Angle (46 ) c - Bottom Angle (60 ) d - Set Width IIntke in ( mm) Exhust in ( mm) Regrdless of type of equipment, however, it is essentil tht vlve guide ores e free from cron or dirt to chieve proper centering of pilot in vlve guide, ensuring concentricity. - Vlve Spring Tester (J-8056) - Torque Wrench Mesuring Vlve Set Concentricity A C.I.D. (7.4L) / 502 C.I.D. (8.2L)

37 Vlve Grinding Vlves tht re pitted must e refced to the proper ngle. Vlve stems which show excessive wer, or vlves tht re wrped excessively, must e replced. When vlve hed which is wrped excessively is refced, knife edge will e ground on prt or ll of the vlve hed, due to the mount of metl tht must e removed to completely refce. Knife edges led to rekge, urning, or pre-ignition due to het loclizing on this knife edge. If the edge of the vlve hed is less thn 1/32 in. (0.8 mm) fter grinding, replce the vlve. Severl different types of equipment re ville for refcing vlves. The recommendtion of the mnufcturer of the equipment eing used should e crefully followed to ttin proper results. Ressemly 1. Luricte vlve guides nd vlve stems with engine oil. 2. Instll ech vlve in the port from which it ws removed or to which it ws fitted. 3. Instll vlve rottors, shims, springs, sels, nd cps s shown under Vlve Assemly (Exploded View) for ech prticulr engine. 4. Using vlve spring compressor, compress vlve spring nd instll vlve locks (grese my e used to hold locks in plce). EXHAUST INTAKE Vlve Spring Compressor (J-8062) Exhust In. (9.45 mm) - 1/32 [.031] In. (0.79 mm) Min. Intke In. (9.45 mm) - 1/32 [.031] In. (0.79 mm) Min CID (7.4L) / 502 CID (8.2L) - 3A-33

38 5. Slowly relese tool, mking sure vlve locks set properly in grooves of vlve stem L 1 - Vlve Lock 2 - Retiner 3 - Oil Shield 4 - Oil Shield Sel 5 - Outer Spring 6 - Dmper Shield 7 - Rottor 8 - Intke Vlve 9 - Exhust Vlve Mgnum / 502 Mgnum / 8.2L - Vlve Lock - Retiner c - Oil Shield d - Inner Spring e - Outer Spring f - Shim g - Intke Vlve h - Exhust Vlve A C.I.D. (7.4L) / 502 C.I.D. (8.2L)

39 6. Check instlled height of vlve springs using nrrow, thin scle cutwy s shown. Mesure from spring set to top of vlve spring, s shown. If mesurement exceeds specified height, instll vlve spring shim nd recheck. DO NOT shim vlve springs to give n instlled height less thn the minimum specified Cutwy Scle - Cut Awy This Portion (1/2 Inch) - Vlve Spring Instlled Height CID (7.4L) / 502 CID (8.2L) - 3A-35