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

ENGINE 3 A 72851 454 CID (7.4L) / 502 CID (8.2L) 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A- 3

Tle of Contents Pge Torque Specifictions..................... 3A-1 Specil Tools.......................... 3A-3 Luricnts/Selers/Adhesives........... 3A-3 Gen V And Gen VI (Except 7.4L Gen VI) Engine Specifictions.................... 3A-4 7.4L Gen VI Engine Specifictions......... 3A-10 Generl................................ 3A-15 Engine Identifiction.................. 3A-15 Cylinder Hed Identifiction............ 3A-15 Engine Rottion...................... 3A-16 Crnkshft........................... 3A-16 Piston nd Connecting Rods........... 3A-16 Cmshft nd Drive................... 3A-16 Cylinder Hed........................ 3A-16 Vlve Trin.......................... 3A-16 Intke Mnifold....................... 3A-17 Luriction System................... 3A-17 Bering Filures........................ 3A-18 Piston Filures.......................... 3A-19 Pre-Ignition.......................... 3A-19 Detontion........................... 3A-19 Engine Mounts.......................... 3A-20 Rocker Arm Cover....................... 3A-22 Removl............................ 3A-22 Instlltion........................... 3A-22 Intke Mnifold......................... 3A-22 Removl............................ 3A-22 Clening nd Inspection............... 3A-22 Instlltion........................... 3A-23 Rocker Arm / Push Rod.................. 3A-24 Removl............................ 3A-24 Clening nd Inspection............... 3A-24 Instlltion........................... 3A-24 Vlve Adjustment........................ 3A-24 Hydrulic Vlve Lifters (Flt nd Roller Lifter).................... 3A-24 Locting Noisy Lifters................. 3A-25 Removl............................ 3A-25 Instlltion........................... 3A-26 Vlve Stem Oil Sel/Vlve Spring.......... 3A-26 Removl - Hed Instlled.............. 3A-26 Vlve Assemly (Exploded View)....... 3A-27 Instlltion - Hed Instlled............ 3A-28 Cylinder Hed.......................... 3A-29 Removl............................ 3A-29 Clening nd Inspection............... 3A-29 Instlltion........................... 3A-29 Cylinder Hed nd Vlve Conditioning..... 3A-30 Disssemly......................... 3A-30 Clening............................ 3A-30 Pge Inspection........................... 3A-31 Vlve Guide Bore Repir.............. 3A-31 Vlve Springs - Checking Tension....... 3A-32 Vlve Set Repir.................... 3A-32 Vlve Grinding....................... 3A-33 Ressemly......................... 3A-33 Dipstick Specifictions................... 3A-36 All Engines.......................... 3A-36 Oil Pn................................ 3A-37 Removl............................ 3A-37 Instlltion........................... 3A-37 Oil Pump............................... 3A-38 Removl............................ 3A-38 Disssemly......................... 3A-38 Clening nd Inspection............... 3A-39 Ressemly......................... 3A-39 Instlltion........................... 3A-39 Torsionl Dmper....................... 3A-39 Removl............................ 3A-39 Instlltion........................... 3A-40 Crnkcse Front Cover / Oil Sel.......... 3A-41 Oil Sel Replcement (Without Removing Front Cover)........ 3A-41 Crnkcse Front Cover.................. 3A-41 Removl............................ 3A-41 Clening nd Inspection............... 3A-41 Instlltion........................... 3A-42 Flywheel............................... 3A-42 Removl............................ 3A-42 Inspection........................... 3A-43 Instlltion........................... 3A-43 Rer Min Oil Sel...................... 3A-44 Removl............................ 3A-44 Clening nd Inspection............... 3A-44 Instlltion........................... 3A-45 Min Berings.......................... 3A-45 Inspection........................... 3A-45 Checking Clernces................. 3A-45 Replcement......................... 3A-46 Connecting Rod Berings................ 3A-47 Inspection nd Replcement........... 3A-47 Connecting Rod/Piston Assemly......... 3A-49 Removl............................ 3A-49 Disssemly......................... 3A-50 Clening nd Inspection............... 3A-50 Ressemly......................... 3A-51 Instlltion........................... 3A-53 Crnkshft............................. 3A-54 Removl............................ 3A-54 3A- 2-454 C.I.D. (7.4L) / 502 C.I.D. (8.2L) 90-823224--2796 796

Pge Clening nd Inspection............... 3A-54 Instlltion........................... 3A-54 Timing Chin nd Sprocket............... 3A-55 Removl............................ 3A-55 Clening nd Inspection............... 3A-56 Instlltion........................... 3A-56 Crnkshft Sprocket..................... 3A-56 Removl............................ 3A-56 Instlltion........................... 3A-56 Checking Timing Chin Deflection...... 3A-56 Cmshft.............................. 3A-57 Mesuring Loe Lift................... 3A-57 Removl............................ 3A-58 Inspection........................... 3A-58 Instlltion........................... 3A-58 Cmshft Berings...................... 3A-58 Removl............................ 3A-58 Inspection........................... 3A-59 Instlltion........................... 3A-59 Cylinder Block.......................... 3A-60 Clening nd Inspection............... 3A-60 Oil Filter By-Pss Vlve nd Adptor....... 3A-63 Inspection nd/or Replcement......... 3A-63 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A- 1

THIS PAGE IS INTENTIONALLY BLANK 3A-0-454 C.I.D. (7.4L) / 502 C.I.D. (8.2L) 90-823224--2 796

Torque Specifictions DESCRIPTION L. In. L. Ft. N m Alterntor Brce to Alterntor 192 9 Alterntor Brce to Engine 30 41 Alterntor to Mounting Brcket 35 48 Alterntor Mounting Brcket 30 41 Cmshft Sprocket Ger 18 24 Cruretor 132 15 Connecting Rod Cps (3/8-24 Nuts) 50 68 (7/16-20 Nuts) 73 99 Coupler/Flywheel(MCM) 35 48 Crnkcse Front Cover 120 14 Crnkshft Pulley 35 48 Cylinder Hed 85 115 Distriutor Hold Down 20 27 Exhust Mnifold 30 41 Exhust Mnifold Elow 30 41 Filter Adpter (5/16-18) 20 27 Flywheel 75 100 Flywheel Drive Plte (MIE) 35 48 Flywheel Housing to Block 30 41 Flywheel Housing Cover 80 9 Front Mount Brcket 30 41 Fuel Pump 25 34 Intke Mnifold 35 48 (See Note) Min Bering Cp 110 149 Oil Bffle Nuts 25 34 Oil Filter Adpter Nuts 40 54 Oil Pn Bolts (5/16-18) 80 9 Oil Pn Drin Plug 15 20 Oil Pump 70 95 Oil Pump Cover 80 9 Power Steering Pump Brce to Block 30 41 Power Steering Pump Brcket 30 41 Rer Mount (MCM) 40 54 Rer 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 54 454 Mgnum/502 45 61 Note: 7.4L / 454 nd 502 Multi-Port engines, Torque intke mnifold fsteners to 25-30 L. Ft. (34-41 N m). 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A-1

Torque Specifictions (Continued) DESCRIPTION L. Ft. N m Remote Oil Filter Adpter Nut/Fitting 20 27 Sewter Pump Brce 30 41 Sewter Pump Brcket 30 41 Sprk Plugs 15 20 Strter Motor 50 68 Thermostt Housing 30 41 Torsionl Dmper 40 54 Trnsmission To Housing 50 68 Wter Circulting Pump 35 48 Wter Temperture Sender 20 27 3A-2-454 C.I.D. (7.4L) / 502 C.I.D. (8.2L) 90-823224--2 796

Specil Tools MERCURY MARINE SPECIAL TOOLS DESCRIPTION PART NUMBER Piston Ring Expnder 91-24697 Engine Coupler Wrench 91-35547 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 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 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 J20158-20 Air Adpter (Cylinder Infltor) J23590 Min Bering Remover nd Instller J8080 Rer Min Sel Instller J38841 Luricnts/Selers/Adhesives DESCRIPTION PART NUMBER Quicksilver Loctite 8831 92-32609-1 Quicksilver Perfect Sel 92-34227-1 Quicksilver RTV Seler 92-91601-1 Generl Motors Cm nd Lifter Prelue or Equivlent Otin Loclly 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A-3

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 OF1589289 nd lower will hve forged pistons. XX with seril numer OF159290 nd higher will hve cst pistons Note 3: Seril numers OD838819 thru OF800699 re equipped with cst luminum intke mnifolds. CYLINDER BORE IMPORTANT: 7.4L Brvo Three engines with engine code UB with seril numer OF1589289 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 4.2500-4.2507 (107.950-107.967) 4.2451-4.2525 (107.826-108.013).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 4.4655-4.4662 (113.423-113.441) PISTON Clernce Production.0030-.0042 (0.0762-0.1066).0025-.0037 (0.0635-0.0939).0040-.0057 (0.1016-0.1447) Service.005 (0.12) Mx.0075 (0.15) Mx.0065 (0.16) Mx 3A-4-454 C.I.D. (7.4L) / 502 C.I.D. (8.2L) 90-823224--2 796

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.0012-.0029 (0.0305-0.0737).0012-.0029 (0.0305-0.0737).0017-.0032 (0.044-0.081).0017-.0032 (0.044-0.081) High Production Limit +.010 (0.02) Mx.010-.018 (0.25-0.46).016-.024 (0.41-0.61) High Limit Production +.010 (0.25) Mx Groove Production.0050-.0065 (0.127-0.165) Side Clernce Service High Limit Production +.001 (0.25) Gp Production.010-.030 (0.254-0.762).020-.035 (0.508-0.889) Service High Limit Production +.001 (0.25) 502 MAGNUM 8.2L.0017-.0032 (0.044-0.081).0017-.0032 (0.044-0.081).011-.021 (0.28-0.53).016-.026 (0.41-0.66) High Limit Production.005 (0.12) Mx.010-.030 (0.254-0.76) High Limit Production.005 (0.12) Mx PISTON PIN ENGINE 7.4L 454 MAGNUM Dimeter Clernce In Pin Fit In Rod Production Service.9895-.9897 (25.132-25.1371).0002-.0007 (0.0050-0.0177).0021-.0031 (0.0533-0.0787) Interference 502 MAGNUM 8.2L.9895-.9898 (25.134-24.140).00025-.00035 (0.0064-0.0088).001 (0.025) Mx.0008-.0016 (0.021-0.040) Interference 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A-5

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.1,2,3,4,5 2.7482-2.7489 (69.8042-69.8220) 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.1,2,3,4.0007-.0030 (0.043-0.076) No.5.0025-.0038 (0.063-0.096) Service No.1 No.2,3,4.001-.003 (0.03-0.07).001-.003 (0.03-0.07).0010-.0015 (0.0254-0.0381).0010-.0025 (0.0254-0.0635) No.5.0025-.0040 (.0635-.1016) Crnkshft End Ply.006-.0010 (0.15-0.2) Dimeter 2.1990-2.1996 (55.8546-55.8698) 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.0011-.0029 (0.028-0.074) Service.003 (0.076) Mx Rod Side Clernce.013-.023 (0.35-0.58) Crnkshft Runout @ No.3 Min Bering.0015 (0.038) Mx.0035 (0.088) Mx 3A-6-454 C.I.D. (7.4L) / 502 C.I.D. (8.2L) 90-823224--2 796

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 [.03125.0625] in. (0.79-1.58 mm) 1/16-3/32 [.0625-.09375] in. (1.58-2.38 mm) Intke.0010-.0027 (0.025-0.069) Exhust.0012-.0029 (0.0304-0.0736) 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 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A-7

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 74-86 Ls. (329-382 N) Does Not Apply 195-215 Ls. (867-956 N) 110 Ls. (489 N) Does Not Apply 316 Ls. (1406 N) Does Not Apply Instlled Height 1.875 (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.42-.094 (1.07-2.38) 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-8-454 C.I.D. (7.4L) / 502 C.I.D. (8.2L) 90-823224--2 796

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 234 224 Cm Lift Intke 238 224 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 209 227 Cm Lift Intke 209 211 FLYWHEEL Journl Dimeter 1.9482-1.9492 (49.485-49.509) 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 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A-9

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 4.2500-4.2507 (107.950-107.968) 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.0018-.0030 (0.0457-0.0762) Service.0018 (0.0457) Mx 3A-10-454 C.I.D. (7.4L) / 502 C.I.D. (8.2L) 90-823224--2 796

7.4L Gen VI Engine Specifictions Unit of Mesurement In. (mm) PISTON RING Production 2nd.0012-.0029 (0.0304-0.0737) Groove C Side o Clernce Service High Production Limit +.010 (0.0254) Mx m p r Top.010-.018 (0.254-0.457) e s Production s i Gp 2nd.016-.024 (0.406-0.6096) o n Service High Limit Production +.010 (0.254) Mx Oil Groove Side Clernce Production Service.0050-.0065 (0.1270-0.1651) High Limit Production +.001 (0.254) Gp Production.010-.030 (0.254-0.762) Service High Limit Production +.001 (0.254) PISTON PIN Dimeter.9895-.9897 (25.132-25.1371) Clernce In Piston Production.0002-.0007 (0.0051-0.0177) Service.001 (0.0254) Mx Fit In Rod.0031-.0021 (0.0180-0.0787) Interference 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A-11

7.4L Gen VI Engine Specifictions Unit of Mesurement In. (mm) CRANKSHAFT Dimeter No. 1, 2, 3, 4, 5 2.7482-2.7489 (69.8040-69.8220) 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. 1.0017-.0030 (0.043-0.076) No. 1, 2, 3, 4.0011-.0024 (.0279-.0610) Min Bering Clernce Production No. 5.0025-.0038 (0.0635-0.0965) Service No. 1, 2, 3, 4.0010-.0030 (0.0254-0.0762) No. 5.0025-.0040 (.0635-.1016) Crnkshft End Ply.005-.0011 (0.1270-0.2794) Dimeter 2.1990-2.1996 (55.8546-55.8698) 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.0011-.0029 (0.0279-0.0736) Service.001 (0.0254) Mx Rod Side Clernce.013-.023 (0.330-0.5842) 3A-12-454 C.I.D. (7.4L) / 502 C.I.D. (8.2L) 90-823224--2 796

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.0300-.0600 (0.7620-1.5240) Exhust.0600-.0950 (1.5240-2.4130) Production Intke.0010-.0029 (0.0254-0.0737) Exhust.0012-.0031 (0.0300-0.0787) 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 1.838 in. (46.6850 mm) t 71-79 Ls. (316-351 N) Open 1.3470 in. (34.2130 mm) t 238-262 Ls. (1059-1165N) Instlled Height 1.8380 (46.6850) ±.07937 (47.6) 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A-13

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 1.9482-1.9492 (49.485-49.509) 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-14-454 C.I.D. (7.4L) / 502 C.I.D. (8.2L) 90-823224--2 796

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. 72913 454 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. 72312 - 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 72914 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A-15

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. 72001 - 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-16-454 C.I.D. (7.4L) / 502 C.I.D. (8.2L) 90-823224--2 796

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. 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A-17

Bering Filures 70436 Scrtched By Dirt 70436 - Scrtches - Dirt Imedded In Bering Mteril Rdius Ride - Worn Are 70436 Tpered Journl - Overly Gone From Entire Surfce Improper Seting - Bright Or Polished Sections 70436 Lck Of Oil - Overly Worn Off 70436 Ftigue Filure - Crters or Pockets 70436 3A-18-454 C.I.D. (7.4L) / 502 C.I.D. (8.2L) 90-823224--2 796

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 72424 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 72314 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. 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A-19

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 72425 Detontion Dmge 72317 Front Mount - All MCM (Stern Drive) Models c d 72318 Rer Mount/Flywheel Housing - All MCM (Stern Drive) Models - Sprk Occurs - Comustion Begins c - Comustion Continues d - Detontion Occurs 72315 3A-20-454 C.I.D. (7.4L) / 502 C.I.D. (8.2L) 90-823224--2 796

Engine Mounts (Continued) Flywheel Housing - All MIE (Inord) Models 73055 71789 Rer Mount Assemly - MIE 7.4L/8.2L with Hurth Down Angle nd V-Drive Trnsmission 73056 Rer Mount Assemly - MIE 7.4L/8.2L with Borg-Wrner In-Line Trnsmission 72319 72319 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 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A-21

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. 72928 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-22-454 C.I.D. (7.4L) / 502 C.I.D. (8.2L) 90-823224--2 796

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 72514 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. 14 16 15 4 1 5 13 6 7 - Exhust Crossover Port Opening in Gsket - Intke Vlve Port c - Coolnt Pssges! WARNING 72514 Be sure to red nd follow pckge lel directions when using ellows dhesive. 12 11 3 2 10 8 9 Intke Mnifold Torque Sequence 72515 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A-23

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) 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 72030 9 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 72031 3A-24-454 C.I.D. (7.4L) / 502 C.I.D. (8.2L) 90-823224--2 796

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 72329 72340 - Roller Lifter Restrictor - Roller Lifter 5. Remove lifter restrictors on roller lifters models. 6. Remove vlve lifters. 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A-25

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 72516 4. 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 72149 IMPORTANT: Do not turn crnkshft while vlve springs, retiners, nd locks re removed or vlves will fll into cylinder. 3A-26-454 C.I.D. (7.4L) / 502 C.I.D. (8.2L) 90-823224--2 796

Vlve Assemly (Exploded View) 1 1 2 3 4 1 1 2 3 4 5 5 6 6 7 7 8 8 9 7.4L 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 72279 454 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 72278 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A-27

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. 72149 3. 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 72516 6. 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)]. 72149 4. 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-28-454 C.I.D. (7.4L) / 502 C.I.D. (8.2L) 90-823224--2 796

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 72944 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. 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A-29

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) 72567 5. Thoroughly clen vlve guides with vlve guide clener. 72564 - Vlve Guide Clener (J-8101) 72565 - 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-30-454 C.I.D. (7.4L) / 502 C.I.D. (8.2L) 90-823224--2 796

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 72566 72563 - 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. 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A-31

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-7049 2. 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 72927 3. 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 -.060-.090 in (1.52-2.29 mm) Exhust -.060-.090 in (1.52-2.29 mm) 50668 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 72308 Mesuring Vlve Set Concentricity 72568 3A-32-454 C.I.D. (7.4L) / 502 C.I.D. (8.2L) 90-823224--2 796

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 72565 - Vlve Spring Compressor (J-8062) Exhust - 372 In. (9.45 mm) - 1/32 [.031] In. (0.79 mm) Min. Intke - 372 In. (9.45 mm) - 1/32 [.031] In. (0.79 mm) Min. 50695 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A-33

5. Slowly relese tool, mking sure vlve locks set properly in grooves of vlve stem. 1 2 3 4 1 1 1 2 3 4 5 5 6 6 7 8 9 7 8 7.4L 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 72279 454 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 72278 3A-34-454 C.I.D. (7.4L) / 502 C.I.D. (8.2L) 90-823224--2 796

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. 50037 72562 Cutwy Scle - Cut Awy This Portion (1/2 Inch) - Vlve Spring Instlled Height 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A-35

Dipstick Specifictions All Engines UNIT OF MEASUREMENT In. (mm) c 1/2 (13) 1/2 (13) 1/2 (13) 33-1/2 (849) 15-1/8 (384) 16-43/64 (423) 35-1/4 (895) 17-13/64 (437) 19-7/64 (485) FULL 1/2 FULL 19/32 FULL ADD (13) ADD (15) ADD 59/64 (23) 72341 - MCM Engines (805567) - MIE Velvet Drive In Line Trnsmissions (821503-3) c - MIE All Trnsmissions Except Velvet Drive (821503-4) 3A-36-454 C.I.D. (7.4L) / 502 C.I.D. (8.2L) 90-823224--2 796

Oil Pn Removl 1. Drin crnkcse oil. 2. Remove dipstick nd tue, or tues, if equipped with two. Note shpe of port nd strord tues s shown following to id in ressemly. On High Output (H.O.) Engine only, disconnect outlet hose of sewter pump. IMPORTANT: Quicksilver RTV Seler sets up in out 15 minutes. Be sure to complete ssemly promptly. IMPORTANT: On Genertion V engines DO NOT move or distur the orienttion of fitting on ottom of pn or incorrect oil level redings my e otined. - Joints Of Rer Sel Retiner - Joints Of Front Cover 72544 c 3. Instll oil pn gsket in position s shown. NOTE:A one-piece oil pn gsket my e re-used if it is still plile nd is not crcked, torn or otherwise dmged. 71308 Genertion V MIE Engine Oil Pn - Fctory Positioned Fitting For Tues (Do Not Move) - Port Tue c - Strord Tue 3. Remove oil pn. Instlltion 1. Clen seling surfces of engine lock nd oil pn. 2. Apply smll mount of Quicksilver RTV Seler to joints of rer sel retiner nd joints of front cover. - Oil Pn Gsket 72545 4. Instll oil pn. Strting from the center nd working outwrd in ech direction, tighten 5/16-18 threded fsteners to 165 l. in. (19 N m). 5. Instll dipstick tue(s) nd dipstick(s). Be certin, if equipped with two tues, tht they re fitted where they were removed, nd positioned s shown following. 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A-37

IMPORTANT: DO NOT move or distur the orienttion of fitting on ottom of pn or incorrect oil level redings my e otined. The oil pump consists of two gers nd pressure regultor vlve enclosed in two-piece housing. Oil pump is driven y distriutor shft which is driven y helicl ger on cmshft. c Removl 1. Remove oil pn s outlined. 2. Remove gsket crefully s the one-piece gsket for the oil pn my e reused if still plile nd not crcked, torn, etc. 3. Remove ffle. Genertion V MIE Engine Oil Pn - Fctory Positioned Fitting For Tues (Do Not Move) - Port Tue c - Strord Tue 71308 6. Fill crnkcse with required quntity of oil of specified viscosity. See Section 1B - Mintennce. Oil Pump c 3 5 6 7 8 9 72545 10 - Nuts (5) - Bffle c - Oil Pump 4 11 4. Remove oil pump. 1 2 Oil Pump Assemly 1 - Extension Shft 2 - Shft Coupling 3 - Pump Body 4 - Drive Ger nd Shft 5 - Idler Ger 6 - Pickup Screen nd Pipe 7 - Pump Cover 8 - Pressure Regultor Vlve 9 - Pressure Regultor Spring 10- Retining Pin 11- Screws 72277 Disssemly 1. Remove pump cover. IMPORTANT: Mrk ger teeth for ressemly with sme teeth indexing. 2. Remove idler ger nd drive ger from pump ody. 3. Remove retining pin, spring, nd pressure regultor vlve from pump cover. 3A-38-454 C.I.D. (7.4L) / 502 C.I.D. (8.2L) 90-823224--2 796

Clening nd Inspection 1. Wsh ll prts in clening solvent nd dry with compressed ir. 2. Inspect pump ody nd cover for crcks or excessive wer. 3. Inspect pump gers for dmge nd excessive wer. 4. Check for loose drive ger shft in pump ody. 5. Inspect inside of pump cover for wer tht would permit oil to lek pst ends of gers. 6. Inspect pickup screen nd pipe ssemly for dmge to screen nd pipe. 7. Check pressure regultor vlve for fit. IMPORTANT: Oil pump is not servicele. If ny prts re worn or dmged, replcement of entire pump ssemly nd pickup tue is necessry. Ressemly IMPORTANT: Oil internl prts lierlly efore instlltion. 1. Instll pressure regultor vlve nd relted prts. 2. Instll drive ger in pump ody. 3. Instll idler ger in pump ody with smooth side of ger towrd pump cover opening. Align mrks mde in disssemly. 4. Fill ger cvity with engine oil. 5. Instll pump cover nd torque ttching screws to 80 l. in. (9 N m). 6. Turn extension shft y hnd to check for smooth opertion. Instlltion 1. Instll pump, with extension shft, to rer min ering, ligning extension shft with distriutor drive shft. 2. Instll ffle. Tighten ffle nuts to 25 l. ft. (34 N m). Tighten oil pump olt to 70 l. ft. (95 N m). - Nuts (5) - Bffle c - Oil Pump c 72545 3. Instll oil pn s outlined. The one-piece gsket for the oil pn my e reused if still plile nd not crcked, torn, etc. Torsionl Dmper Removl 1. Remove drive elts. 2. Remove drive pulley nd wter pump pulley, then remove torsionl dmper retining olt. 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A-39

IMPORTANT: Do not use universl clw type puller to remove torsionl dmper (in next step) s outside ring of torsionl dmper is onded in ruer to the hu nd use of clw type puller my rek the ond. 3. Remove torsionl dmper with Torsionl Dmper Remover nd Instller. IMPORTANT: Be sure to instll threded rod in crnkshft t lest 1/2 in. (13 mm) to prevent dmge to threds.. Instll plte, thrust ering, wsher nd nut on rod. c. Instll torsionl dmper on crnkshft y turning nut until it ottoms out. 72346 72345 - Torsionl Dmper Remover nd Instller (J-23523-E) Instlltion IMPORTANT: The inerti weight section of torsionl dmper is ssemled to the hu with ruer type mteril. The instlltion procedure (with proper tool) must e followed or movement of the inerti weight on the hu will destroy the tuning of the torsionl dmper. 1. Replce key in crnkshft if it is dmged. 2. Cot sel surfce of torsionl dmper with engine oil. 3. Instll torsionl dmper on crnkshft, using Torsionl Dmper Remover nd Instller s follows:. Instll pproprite end of threded rod into crnkshft. - Torsionl Dmper Remover nd Instller (J-23523-E) d. Remove tool from crnkshft. e. To prevent oil lekge, pply Quicksilver RTV selnt to keywy. f. Instll torsionl dmper olt. Torque to 90 l. ft. (122 N m). 4. Instll drive pulley nd wter pump pulley. Torque olts to 35 l. ft. (48 N m). 5. Instll nd djust drive elts. 3A-40-454 C.I.D. (7.4L) / 502 C.I.D. (8.2L) 90-823224--2 796

Crnkcse Front Cover/ Oil Sel 2. Instll new sel with open end of sel inwrd (lip of sel towrd inside of engine), using crnkcse front cover sel instller. Drive sel in until it just ottoms out. Do not use excessive force. Oil Sel Replcement (Without Removing Front Cover) REMOVAL 1. Remove torsionl dmper. 2. Pry sel out of cover from the front with lrge screwdriver, eing creful not to distort front cover or dmge crnkshft. INSTALLATION IMPORTANT: Correct rottion oil sel must e used to prevent oil lek. - Crnkcse Front Cover Sel Instller (J-22102) 3. Reinstll torsionl dmper s outlined. 72560 Crnkcse Front Cover Front Sel WITHOUT Helicl Grooves - Sel Lip Towrd Inside of Engine 73123 Removl 1. Remove engine from ot. 2. Remove torsionl dmper nd oil pn. 3. Remove wter circulting pump. 4. Remove crnkcse front cover. 5. If dmged, drive oil sel out of front cover (from the rer) using punch. Clening nd Inspection Front Sel WITH Helicl Grooves 73124 - Sel Lip Towrd Inside Of Engine - Rottion Of Crnkcse As Viewed From Front End Looking Towrd Flywheel End. 1. Apply Quicksilver Perfect Sel to sel retiner mting surfce nd pply grese to sel lips. IMPORTANT: The Gen VI front cover is cst luminum tht hs molded o-ring style gsket. This gsket is retined in cst groove. It must e replced if dmged. 1. Clen front cover in solvent nd dry with compressed ir. 2. Clen old gsket mteril nd seler from mting surfces on cover nd cylinder lock. 3. Check gsket surfce on front cover for distortion, nd true if necessry. Surfces must e clen nd flt or oil lekge my result. 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A-41

Instlltion 1. Instll oil sel in cover with lip of sel towrd inside of engine, using crnkcse front cover sel instller. Support cover round sel re with pproprite tool s shown. Flywheel Removl 1. Remove engine from ot. 2. Remove trnsmission, if so equipped. 3. Refer to Flywheel Housing description in this section nd remove flywheel housing nd relted prts. 4. Remove MCM coupler or MIE drive plte. 5. Remove flywheel. - Crnkcse Front Cover Sel Instller (J-22102) - Support (To Prevent Distorting Cover) 72945 2. Cot oth sides of front cover gsket with Quicksilver Perfect Sel nd plce in position on engine. 3. Instll front cover, mking sure holes in cover lign with dowel pins in lock. Torque front cover ttching olts to 120 l. in. (14 N m). 4. Instll oil pn nd torsionl dmper s outlined. 5. Instll wter circulting pump. 6. Reinstll engine in ot. 7. Fill crnkcse with engine oil. 8. 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. Brvo Coupler MIE Drive Plte 72350 72351! CAUTION Ensure tht cooling wter supply is ville efore strting the engine. 9. Strt engine nd check for wter nd oil leks. 3A-42-454 C.I.D. (7.4L) / 502 C.I.D. (8.2L) 90-823224--2 796

c. Mximum runout -.008 in. (0.203 mm). Drive Shft Extension Coupler 72352 Inspection 1. Inspect splines in drive plte or coupler for wer. 2. Check flywheel ring ger for worn nd missing teeth. Instlltion NOTE:If crnkshft is to e replced, ut old pilot ushing is to e reused, ushing cn e removed without dmge y filling pilot ushing cvity with grese, then inserting n old trnsmission input shft in ore of ushing nd hitting it with hmmer. This will crete hydrulic pressure in pilot ushing cvity which should force ushing out. 1. Clen mting surfces of flywheel nd crnkshft. Remove ny urrs. Mting surfces must e clen re metl. 2. Aligning dowel hole in flywheel with dowel in crnkshft, instll flywheel. Torque olts to 70 l. ft. (95 N m). 3. Check flywheel runout s follows:. Attch dil indictor to engine lock.. Tke redings round outer edge of flywheel. Push in on flywheel to remove crnkshft end ply. 72353 -.008 in. (0.203 mm) Mx. Runout - Pus Flywheel And Crnkshft Forwrd As Fr As It Will Go When Tking Reding 4. Instll drive coupler or drive plte. Torque olts to 35 l. ft. (48 N m). 5. Instll flywheel housing nd relted prts. Torque olts to 30 l. ft. (41 N m). 6. Instll flywheel housing cover. Torque olts to 80 l. in. (9 N m). 7. Instll trnsmission (MIE). Torque olts to 50 l. ft. (68 N m). 8. Refer to Section 2 Removl nd Instlltion nd instll engine. 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A-43

Rer Min Oil Sel The rer crnkshft oil sel cn e replced without removing the oil pn or rer min ering cp from engine. Removl Remove sel y using screwdriver to pry it out of engine lock s shown. Clening nd Inspection Clen crnkshft/sel running surfce nd sel retiner. IMPORTANT: Correct rottion oil sel must e used to prevent oil lek. - Rer Min Sel (Crnkshft Oil Sel) 72559 IMPORTANT: Do not nick or gouge the engine lock or rer min ering cp seling surfce. Protect end of crnkshft nd crnkshft/sel running surfce from dmge, lso. Rer Sel WITHOUT Helicl Grooves - Sel Lip Towrds Inside Of Engine 73126 Rer Sel WITH Helicl Grooves - Sel Lip Towrd Inside Of Engine - Rottion of Crnkshft As Viewed From Flywheel End Looking Forwrd 72618 3A-44-454 C.I.D. (7.4L) / 502 C.I.D. (8.2L) 90-823224--2 796

Instlltion 1. Apply Quicksilver Perfect Sel to engine lock/ sel mting surfce. Apply grese to sel lips. 2. Instll sel using rer min sel instller or suitle device. Checking Clernces To otin ccurte mesurements while using Plstigge, or its equivlent, engine must e out of the ot nd upside down so crnkshft will rest on the upper erings nd totl clernce cn e mesured etween lower ering nd journl. To ssure the proper seting of the crnkshft, ll ering cp olts should e t their specified torque. In ddition, preprtory to checking fit of erings, the surfce of the crnkshft journl nd ering should e wiped clen of oil. 72356 - Suitle Device Shown (Rer Min Sel Instller (J-38841) Not Shown IMPORTANT: Inspect ering cps for orienttion mrks prior to removl. If no mrkings exist, mke suitle mrks efore disssemly so tht they cn e reinstlled in their originl loctions. 1. With the oil pn nd oil pump removed, mke suitle mrks, if required, on ering cp(s) to e inspected. Remove ering cp(s) s needed. Wipe oil from journl nd ering cp to e inspected. 2. Plce piece of guging plstic the full width of the ering (prllel to the crnkshft) on the journl s shown. Min Berings IMPORTANT: Before removing min ering cps or connecting rod cps, mrk them for ressemly in their originl loctions. Min erings re of the precision insert type nd do not use shims for djustment. If clernces re found to e excessive, new ering, oth upper nd lower hlves, will e required. Service erings re ville in stndrd size nd.001 in.,.002,.010 in. nd.020 in. undersize. IMPORTANT: Do not rotte the crnkshft while the guging plstic is etween the ering nd journl. Inspection In generl, the lower hlf of the ering (except No. 1 ering) shows greter wer nd the most distress from ftigue. If, upon inspection, the lower hlf is suitle for use, it cn e ssumed tht the upper hlf is lso stisfctory. If the lower hlf shows evidence of wer or dmge, oth upper nd lower hlves should e replced. Never replce one hlf without replcing the other hlf. - Guging Plstic - Journl 72558 3. Instll the ering cp nd evenly torque the retining olts to specifictions. Bering cp MUST e torqued to specifiction in order to ssure proper reding. Vritions in torque ffect the compression of the plstic guge. 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A-45

4. Remove ering cp. The flttened guging plstic will e found dhering to either the ering cp or journl. 5. On the edge of the guging plstic envelope there is grduted scle which is correlted in thousndths of n inch. Without removing the guging plstic, mesure its compressed width (t the widest point) with the grdutions on the guging plstic envelope s shown. 8. Proceed to the next ering. After ll erings hve een checked, rotte the crnkshft to see tht there is no excessive drg. When checking No. 1 min ering, loosen ccessory drive elts so s to prevent tpered reding with plstic guge. 9. Mesure crnkshft end ply (see Specifictions ) y forcing the crnkshft to the extreme front position. Mesure t the front end of the rer min ering with feeler guge s shown. 72557 - Compressed Guging Plstic - Grduted Scle NOTE:Normlly min ering journls wer evenly nd re not out of round. However, if ering is eing fitted to n out-of-round journl (.001 in. mx.), e sure to fit to the mximum dimeter of the journl: If the ering is fitted to the minimum dimeter, nd the journl is out of round.001 in., interference etween the ering nd journl will result in rpid ering filure. If the flttened guging plstic tpers towrd the middle or ends, there is difference in clernce indicting tper, low spot or other irregulrity of the ering or journl. Be sure to mesure the journl with micrometer if the flttened guging plstic indictes more thn.001 in. difference. 6. If the ering clernce is within specifictions, the ering insert is stisfctory. If the clernce is not within specifictions, replce the insert. Alwys replce oth upper nd lower inserts s unit. 7. A stndrd, or.001 in., undersize ering my produce the proper clernce. If not, it will e necessry to regrind the crnkshft journl for use with the next undersize ering. After selecting new ering, recheck clernce. 72543 - Mesuring Crnkshft End Ply - (Force Crnkshft To Extreme Forwrd Position ) Replcement NOTE:Min erings my e replced with or without removing crnkshft. Min Bering Inserts - Lower Bering Insert (Instll In Cp) - Upper Bering Insert (Instll In Block) c - Oil Groove c 72359 3A-46-454 C.I.D. (7.4L) / 502 C.I.D. (8.2L) 90-823224--2 796

WITH CRANKSHAFT REMOVED 1. Remove nd inspect the crnkshft s outlined. 2. Remove the min erings from the cylinder lock nd min ering cps. 3. Cot ering surfces of new, correct size, min erings with oil nd instll in the cylinder lock nd min ering cps. 4. Instll the crnkshft. WITHOUT CRANKSHAFT REMOVED IMPORTANT: Inspect ering cps for orienttion mrks prior to removl. If no mrkings exist, mke suitle mrks efore disssemly so tht they cn e reinstlled in their originl loctions. 1. With oil pn, oil pump nd sprk plugs removed, mke suitle mrks on cp nd remove cp on min ering requiring replcement. Remove ering from cp. 2. Instll min ering remover/instller in oil hole in crnkshft journl. If such tool is not ville, cotter pin my e ent, s shown, to do the jo. 3. Rotte the crnkshft clockwise s viewed from the front of engine. This will roll upper ering out of lock. 4. Oil new selected size upper ering nd insert plin (no notched) end etween crnkshft nd indented or notched side of lock. Rotte the ering into plce nd remove tool from oil hole in crnkshft journl. 5. Oil new lower ering nd instll in ering cp. 6. Instll min ering cp with mrks mde on disssemly (or rrows, if present) pointing towrd front of engine. 7. Torque ll min ering cps, EXCEPT THE REAR MAIN CAP, to 110 l. ft. (149 N m). Torque rer min ering cp to 10-12 l. ft. (14-16 N m); then tp end of crnkshft, first rerwrd then forwrd with led hmmer. This will line up rer min ering nd crnkshft thrust surfces. Torque rer min ering cp to 110 l. ft. (149 N m). Connecting Rod Berings Connecting rod erings re of the precision insert type nd do not use shims for djustment. DO NOT FILE RODS OR ROD CAPS. If clernces re found to e excessive, new ering will e required. Service erings re ville in stndrd size nd.001 in. nd.002 in. undersize for use with new nd used stndrd size crnkshfts, nd in.010 in. nd.020 in. undersize for use with reconditioned crnkshfts. Inspection nd Replcement - Min Bering Remover / Instller (J-8080) - Cotter Pin 72556 IMPORTANT: Before you remove the connecting rod cp, mrk the side of the rod nd cp with the cylinder numer to ssure mtched ressemly of rod nd cp. 1. With oil pn nd oil pump removed, mrk the side of the rod nd cp with the cylinder numer nd remove the connecting rod cp nd ering. 2. Inspect the ering for evidence of wer nd dmge. Do not reinstll worn or dmged ering. 3. Wipe oth upper nd lower ering shells nd crnk pin clen of oil. 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A-47

4. Mesure the crnkpin for out-of-round or tper with micrometer. If not within specifictions, replce or recondition the crnkshft. If within specifictions nd new ering is to e instlled, mesure the mximum dimeter of the crnkpin to determine new ering size required. 5. If within specifictions, mesure new or used ering clernces with guging plstic or its equivlent. If ering is eing fitted to n out-of-round crnkpin, e sure to fit to the mximum dimeter of the crnkpin. If the ering is fitted to the minimum dimeter, nd the crnkpin is out of round.001 in., interference etween the ering nd crnkpin will result in rpid ering filure.. Plce piece of guging plstic, the length of the ering (prllel to the crnkshft), on the crnkpin or ering surfce s shown. Position the guging plstic in the middle of the ering shell. (Berings re eccentric nd flse redings could occur if plced elsewhere.) IMPORTANT: Do not turn the crnkshft with the guging plstic instlled. 72362 6. If the clernce exceeds specifictions, select new, correct size ering nd mesure the clernce. Be sure to check wht size ering is eing removed in order to determine proper replcement size ering. If clernce cnnot e rought to within specifictions, the crnkpin will hve to e ground undersize. If the crnkpin is lredy t mximum undersize, replce crnkshft. 7. Cot the ering surfce with oil, instll the rod cp nd torque nuts 3/8 in. nuts 50 l. ft. (68 N m) 7/16 in. nuts 73 l. ft. (99 N m). 72361 - Guging Plstic. Instll the ering in the connecting rod nd cp. c. Instll the ering cp nd evenly torque nuts. Refer to Specifictions. d. Remove the ering cp nd using the scle on the guging plstic envelope, mesure the guging plstic width t the widest point s shown. 3A-48-454 C.I.D. (7.4L) / 502 C.I.D. (8.2L) 90-823224--2 796

8. When ll connecting rod erings hve een instlled, tp ech rod lightly (prllel to the crnkpin) to mke sure they hve clernce. 9. Mesure ll connecting rod side clernces (see Specifictions ) etween connecting rod cps s shown. IMPORTANT: Before ridge nd/or deposits re removed, turn crnkshft until piston is t ottom of stroke nd plce cloth on top of piston to collect cuttings. After ridge nd/or deposits re removed, turn crnkshft until piston is t top of stroke, then remove cloth nd cuttings. 3. Mrk connecting rods nd ering cps (left nk 1, 3, 5 nd 7; right nk 2, 4, 6 nd 8 from front to rer on sme side s piston thrust). 4. Remove connecting rod cp nd instll connecting rod olt guide (3/8-24 or 7/16-20) on olts. Push connecting rod nd piston ssemly out of top of cylinder lock. NOTE:It will e necessry to turn crnkshft slightly to disconnect nd remove some connecting rod nd piston ssemlies. 72555 Connecting Rod/Piston Assemly Removl 1. Remove s outlined:. Oil pn nd dipstick tue.. Bffle nd oil pump. c. Distriutor nd intke mnifold. d. Cylinder heds. 2. Use ridge remer to remove ny ridge nd/or deposits from upper end of cylinder ore. 72572 - Connecting Rod Bolt Guide 3/8-24 (J-5239) or 7/16-20 (J-35228) 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A-49

Disssemly Disssemle piston from connecting rod using piston pin remover s shown. Follow instructions supplied with kit. 5. Slip outer surfce of new top nd second compression ring into respective piston ring groove nd roll ring entirely round the groove to mke sure tht ring is free s shown. If inding occurs t ny point, determine cuse. If cused y ring groove, remove y dressing with fine cut file. If inding is cused y distorted ring, recheck with nother ring. c d - Piston Pin Remover nd Instller Kit (J-24086-C) - Arched Bse c - Piston d - Connecting Rod e - Rod Support e 72365 72366 Clening nd Inspection CONNECTING RODS 1. Wsh connecting rods in clening solvent nd dry with compressed ir. 2. Check for twisted nd ent rods nd inspect for nicks nd crcks. Replce dmged connecting rods. PISTONS NOTE:Cylinder ore nd tper must e within specifictions efore pistons cn e considered for re-use. 1. Clen vrnish from piston skirts with clening solvent. DO NOT WIRE BRUSH ANY PART OF PISTON. Clen ring grooves with groove clener nd mke sure oil ring holes re clen. 2. Inspect piston for crcked ring lnds, skirts nd pin osses, wvy worn ring lnds, scuffed or dmged skirts, nd eroded res t top of piston. Replce pistons which re dmged or show signs of excessive wer. 3. Inspect grooves for nicks nd urrs tht might cuse rings to hng up. 4. Mesure piston skirt nd check clernce s outlined under Piston Selection. 6. Proper clernce of piston ring in its piston ring groove is very importnt to provide proper ring ction nd reduce wer. Therefore, when fitting new rings, clernces etween ring nd groove surfces should e mesured. See Specifictions. 72367 3A-50-454 C.I.D. (7.4L) / 502 C.I.D. (8.2L) 90-823224--2 796

PISTON PINS 1. Piston pin clernce is designed to mintin dequte clernce under ll engine operting conditions. Becuse of this, piston nd piston pin re mtched set nd not serviced seprtely. 2. Inspect piston pin ores nd piston pins for wer. Piston pin ores nd piston pins must e free of vrnish nd scuffing when mesured. Mesure piston pin with micrometer nd piston pin ore with dil ore guge or inside micrometer. If clernce is in excess of the.001 in. (0.025 mm) wer limit, replce piston nd piston pin ssemly. Notch or vlve relief in piston must e positioned correctly for engine tht is eing repired. Ressemly IMPORTANT: When ressemling pistons nd connecting rods, the following must e kept in mind. Piston nd pin re mchine fitted to ech other nd must remin together s mtched set. Do not intermix pistons nd pins. If originl pistons nd/or connecting rods re eing used, e sure to ssemle pistons nd connecting rods so they cn e reinstlled in sme cylinder from which they were removed. Connecting rod ering tngs re lwys towrd outside of cylinder lock. 7.4L Engine - Notch - Towrd Front Of Engine 72554 454 Mgnum / 502 Mgnum / 8.2L - Vlve Relief - Towrd Center Of Engine 72553 72368 - Rod Bering Tngs 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A-51

1. Assemle piston to connecting rod using piston pin remover s shown. Follow instructions supplied with kit. 3. Mesure gp etween ends of ring with feeler guge s shown. 72372 - Piston Pin Remover (J-24086-C) 72371 2. Once ssemled, check piston for freedom of movement (ck-nd-forth nd up-nd-down) on connecting rod. Piston should move freely in ll directions. If it does not, piston pin ore is tight nd piston/pin ssemly must e replced. 3. If new connecting rod hs een instlled, mrk connecting rod nd cp (on side of rod nd cp with slots for connecting rod ering tngs) with cylinder numer in which it will e instlled. PISTON RINGS All compression rings re mrked on upper side of ring. When instlling compression rings, mke sure tht mrked side is towrd top of piston. Oil control rings re three-piece type, consisting of two rings nd spcer. 1. Select rings comprle in size to cylinder ore nd piston size. 2. Slip compression ring in cylinder ore, then press ring down into cylinder ore out 1/4 in. (6 mm) (elow ring trvel). Be sure tht ring is squre with cylinder wll. 4. If gp etween ends of ring is elow specifictions, remove ring nd try nother for fit. 5. Fit ech compression ring to cylinder in which it is going to e used. 6. Clen nd inspect pistons, if not previously done. 7. Instll piston rings s follows:. Instll oil ring spcer in groove nd insert ntirottion tng in oil hole.. Hold spcer ends utted nd instll lower steel oil ring ril with gp properly locted. c. Instll upper steel oil ring ril with gp properly locted. d. Flex the oil ring ssemly to mke sure ring is free. If inding occurs t ny point, the cuse should e determined nd, if cused y ring groove, removed y dressing groove with fine cut file. If inding is cused y distorted ring, use new ring. IMPORTANT: Use piston ring expnder (91-24697) for compression ring instlltion. e. Instll lower compression ring with mrked side up, using ring expnder. f. Instll top compression ring with mrked side up, using ring expnder. 3A-52-454 C.I.D. (7.4L) / 502 C.I.D. (8.2L) 90-823224--2 796

Instlltion IMPORTANT: Cylinder ores must e clen efore piston instlltion. Clen with light honing, s necessry. Then clen with hot wter nd detergent wsh. After clening, sw ores severl times with light engine oil nd clen cloth, then wipe with clen dry cloth. 1. Luricte connecting rod erings nd instll in rods nd rod cps. 2. Lightly cot pistons, rings nd cylinder wlls with light engine oil. 3. With ering cps removed, instll connecting rod olt guide (3/8-24, use tool J-5239 or 7/16-20, use tool J-35228) on connecting rod olts. IMPORTANT: Be sure ring gps re properly positioned s shown. IMPORTANT: Be sure to instll new pistons in sme cylinders for which they were fitted, nd used pistons in sme cylinder from which they were removed. Ech connecting rod nd ering cp should e mrked, eginning t front of engine (1, 3, 5 nd 7 in left nk nd 2, 4, 6 nd 8 in right nk). Numers on connecting rod nd ering cp must e on sme side when instlled in cylinder ore. If connecting rod is ever trnsposed from one lock or cylinder to nother, new erings should e fitted nd connecting rod should e numered to correspond with new cylinder numer. 1 2 3 c d c d 72552 - Piston Ring Compressor (J-8037) Ring Gp Loction 1 - Port Side 2 - Engine Front 3 - Strord Side - Oil Ring Spcer Gp (Tng In Hole Or Slot Within Arc) - Oil Ring Gps c - 2nd Compression Ring Gp d - Top Compression Ring Gp 72373 4. Instll ech connecting rod nd piston ssemly in its respective ore. Instll with connecting rod ering tngs towrd outside of cylinder lock. Use piston ring compressor to compress rings. Guide connecting rod into plce on crnkshft journl with connecting rod olt guide. Use hmmer hndle with light lows to instll piston into ore. Hold ring compressor firmly ginst cylinder lock until ll piston rings hve entered cylinder ore. 5. Remove connecting rod olt guide. 6. Instll ering cps nd evenly torque nuts. Refer to Specifictions. 7. Check connecting rod side clernce s previously descried. NOTE:If ering replcement is required, refer to Connecting Rod Berings. 8. Instll s previously outlined:. Oil pump nd ffle.. Dipstick nd oil pn. c. Cylinder heds. d. Intke mnifold. e. Distriutor. 9. Fill crnkcse with oil. Refer to Section 1 - Mintennce. 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A-53

Crnkshft Removl 1. Remove engine from ot. 2. Drin crnkcse oil. 3. Remove s outlined:. Strter.. Flywheel housing. c. Drive coupler/plte nd flywheel. d. Belts. e. Wter pump. f. Crnkshft pulley nd torsionl dmper. g. Sprk plugs. h. Oil pn nd dipstick tue. i. Bffle nd oil pump. j. Timing chin/ger cover. 4. Turn crnkshft to lign timing mrk with cmshft mrk. 5. Remove cmshft sprocket or ger. 6. Remove rer min sel. IMPORTANT: Inspect ering cps for orienttion mrks prior to removl. If no mrkings exist, mke suitle mrks efore disssemly so tht they cn e reinstlled in their originl loctions. 7. Mke sure ll ering cps (min nd connecting rods) re mrked so they cn e reinstlled in their originl loctions. 8. Remove connecting rod ering cps, then push piston nd rod ssemlies towrd heds. 9. Remove min ering cps nd crefully lift crnkshft out of cylinder lock. 10. If new min nd/or connecting rod erings re to e instlled, remove min ering inserts from cylinder lock nd ering cps, nd/or connecting rod ering inserts from connecting rod nd cps. Instll new erings following procedures outlined. Clening nd Inspection 1. Wsh crnkshft in solvent nd dry with compressed ir. 2. Mesure min ering journls nd crnkpin dimensions with micrometer for out-of-round, tper or undersize (see Specifictions ). 3. Check crnkshft for runout (y supporting t front nd rer min erings journls in V-locks) nd check t front nd rer intermedite journls with dil indictor (see Specifictions ). 4. Replce or recondition crnkshft if not within specifictions. Instlltion 1. If new crnkshft is eing instlled, proceed s follows:. Remove timing sprocket or ger from old crnkshft nd reinstll on new crnkshft s outlined.. On models with drive shft extension, if old pilot ushing is to e reused, ushing cn e removed without dmge y filling pilot ushing cvity with grese, then inserting n old trnsmission input shft in ore of ushing nd hitting it with hmmer. This will crete hydrulic pressure in pilot ushing cvity which should force ushing out. IMPORTANT: Be sure tht ll erings nd crnkshft journls re clen. 2. Instll min erings in engine lock s follows. Min Bering Inserts - Lower Bering Insert (Instll In Cp) - Upper Bering Insert (Instll In Block) c - Oil Groove c 72359 3A-54-454 C.I.D. (7.4L) / 502 C.I.D. (8.2L) 90-823224--2 796

3. Crefully lower crnkshft into plce. Be creful not to dmge ering surfce. 4. Check clernce of ech min ering, following procedure outlined under Min Berings. If ering clernces re stisfctory, pply engine oil to journls nd erings. 5. Instll min ering cps. Torque olts to 110 l. ft. (149 N m). When tightening rer min ering cp, follow procedure outlined under Min Berings. 6. Check crnkshft end ply s outlined. 7. Check clernce for ech connecting rod ering, following procedure under Connecting Rod Berings. If ering clernces re stisfctory, pply engine oil to journls nd erings. 8. Instll rod cps nd evenly torque nuts. Refer to Specifictions. 9. Turn crnkshft so mrk on timing sprocket or ger is fcing cmshft. 10. Instll s outlined:. Timing chin nd sprocket or ger on cmshft -lign mrks with crnkshft.. Timing chin/ger cover. c. Oil pump nd ffle. d. Dipstick tue nd oil pn. e. Sprk plugs. f. Torsionl dmper nd crnkshft pulley. g. Wter pump. h. Belts. i. Flywheel nd drive coupler/plte. j. Flywheel housing. k. Strter. 11. Instll new oil filter. Fill crnkcse with oil. Timing Chin nd Sprocket Removl 1. Remove torsionl dmper, oil pn nd crnkcse front cover s outlined. 2. Turn crnkshft until timing mrks on crnkshft nd cmshft sprockets re in lignment s shown. - Timing Mrks Aligned - Locting Pin 72946 3. Remove cmshft sprocket nd timing chin. (If sprocket does not come off esily, light tp on the lower edge of the sprocket, using plstic mllet, should dislodge it.) 4. If crnkshft sprocket requires replcement, remove s outlined. 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A-55

Clening nd Inspection 1. Clen ll prts in solvent nd dry with compressed ir. 2. Inspect timing chin for wer nd dmge. 3. Inspect sprockets for wer nd dmge. Instlltion 1. Using crnkshft ger nd sprocket instller, s shown, instll sprocket on crnkshft. Instlltion 1. If crnkshft sprocket ws removed, instll s outlined in Crnkshft Sprocket. 2. Instll timing chin on cmshft sprocket. Hold sprocket verticl with chin hnging down. Align mrks on cmshft nd crnkshft sprockets. IMPORTANT: Do not ttempt to drive sprocket on cmshft, s welsh plug t rer of engine cn e dislodged. 3. Instll sprocket on cmshft. Torque olts to 25 l. ft. (34 N m). 4. Luricte timing chin with engine oil. Instll crnkcse front cover nd torsionl dmper s outlined. Crnkshft Sprocket Removl 1. Remove torsionl dmper nd crnkcse front cover s outlined. 2. Remove cmshft timing chin s outlined. 3. Remove crnkshft sprocket using crnkshft ger nd sprocket puller (J-24420-B). - Crnkshft Ger And Sprocket Instller (J-1058-20) 72550 2. Instll timing chin s outlined. 3. Instll crnkcse cover nd torsionl dmper s outlined. Checking Timing Chin Deflection With timing chin nd sprockets instlled, check timing chin deflection, s follows: 1. Rotte cmshft (in either direction) to plce tension on one side of the chin. 2. Estlish reference point on the lock (on tut side of chin) nd mesure from this point to the chin. 3. Rotte cmshft in the opposite direction to slcken the chin, then force chin out with fingers nd gin mesure the distnce etween reference point nd timing chin. 3A-56-454 C.I.D. (7.4L) / 502 C.I.D. (8.2L) 90-823224--2 796

4. The deflection is the difference etween these two mesurements. If the deflection exceeds 3/4 in. (19 mm), timing chin should e replced. 1. Remove vlve mechnism s outlined. 2. Adpt dil indictor to cylinder hed y temporrily instlling suitle stud in olt hole. Position indictor with ll socket dptor tool, from Lift Indictor Tool Kit, on push rod. Be sure tht push rod is in lifter socket. - Reference Point 72946 5. Instll torsionl dmper nd crnkcse front cover. Cmshft Mesuring Loe Lift NOTE:Procedure is similr to checking vlve timing. If improper vlve opertion is indicted, mesure lift of ech push rod in consecutive order nd record redings. - Lift Indictor Tool Kit (J-8520) 72551 3. Rotte torsionl dmper slowly in direction of rottion until lifter is on heel of cm loe. At this point, push rod will e in its lowest position. 4. Set dil indictor on zero, then rotte dmper slowly (or ttch n uxiliry strter switch nd ump engine over) until push rod is in fully rised position. 5. Compre totl lift, recorded from dil indictor, with Specifictions. 6. Continue to rotte engine until indictor reds zero. This will e check on ccurcy of originl indictor reding. 7. If cmshft redings for ll loes re within specifictions, remove dil indictor ssemly nd hrdwre. 8. Instll nd torque vlve mechnism to specifictions. 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A-57

Removl 1. Remove vlve lifters s outlined. 2. Remove crnkcse front cover s outlined. 3. Remove cmshft s follows:. Remove timing chin nd sprocket or timing gers s outlined.. Instll two 5/16-18 x 5 in. olts in cmshft olt holes nd crefully remove cmshft s shown. Also check cmshft for lignment with V-locks nd dil indictor which indictes exct mount cmshft is out of true. If out more thn.002 in. (0.051 mm) (dil indictor reding) cmshft should e replced. 72382 Checking Cmshft Alignment Inspection 72549 Mesure cmshft ering journls with micrometer for out-of-round condition. If journls exceed.001 in. (0.025 mm) out-of-round, cmshft should e replced. Instlltion 1. Instll cmshft s follows:. Instll two 5/16-18 x 5 in. olts in cmshft olt holes, then luricte cmshft journls with engine oil nd instll cmshft, eing creful not to dmge erings.. Luricte cmshft loes with Generl Motors Cm nd Lifter Prelue or equivlent. c. Instll timing chin or gers s outlined. 2. Instll crnkcse front cover nd vlve lifters s outlined. Cmshft Berings Removl Cmshft erings cn e replced while engine is disssemled for overhul or without complete disssemly. To replce erings without complete disssemly, remove cmshft nd crnkshft, leving cylinder heds ttched nd pistons in plce. Before removing crnkshft, fsten connecting rods ginst sides of engine so tht they will not interfere while replcing cmshft erings. 1. With cmshft nd crnkshft removed, drive cmshft rer plug from cylinder lock. NOTE:This procedure is sed on removl of erings from center of engine first, thus requiring minimum mount of turns to remove ll erings. 3A-58-454 C.I.D. (7.4L) / 502 C.I.D. (8.2L) 90-823224--2 796

2. Using cmshft ering remover nd instller set (J-6098-01) (with nut nd thrust wsher instlled to end of threds), position pilot in front cmshft ering nd instll puller screw through pilot. 3. Instll tool with shoulder towrd ering. Be sure sufficient mount of threds re engged. 4. Using two wrenches, hold puller screw while turning nut. When ering hs een pulled from ore, remove tool nd ering from puller screw. 5. Remove remining erings (except front nd rer) in sme mnner. It will e necessry to position pilot in rer cmshft ering to remove rer intermedite ering. c d - Index Point - Puller Screw c - Driver d - Bering 72571 6. Assemle driver on driver hndle nd remove front nd rer cmshft erings y driving towrd center of cylinder lock. - Driver - Driver Hndle c - Bering c 72548 Inspection Clen cmshft ering ores in cylinder lock with solvent nd low out with compressed ir. Be sure grooves nd drilled oil pssges re clen. Instlltion Front nd rer erings must e instlled lst s pilot will not fit into ering ores if erings re instlled. Luricte outer surfce of new cmshft erings with engine oil to ese instlltion. IMPORTANT: All cmshft erings re not the sme. Be sure to instll erings in proper loctions (Indicted y ering mnufcturer) nd to position erings s follows (directionl references re in reference to engine in its norml operting position): Front ering must e positioned so tht oil holes re equl distnce from 6 o clock position in the lock. Intermedite nd center erings must e positioned so tht oil holes re t the 5 o clock position (towrd left side of lock nd t position even with ottom of cylinder ore). Rer ering must e positioned so tht oil hole is t the 12 o clock position. 1. Instlling intermedite nd center erings:. Instll nut nd thrust wsher ll the wy onto puller screw, then position pilot in front cmshft ering ore nd insert screw through pilot.. Index center cmshft ering, then position pproprite size remover nd instller tool in ering nd thred puller screw into tool. Be sure t lest 1/2 in. (13 mm) of threds re engged. c. Using two wrenches, hold puller screw nd turn nut until ering hs een pulled into position. Remove the remover nd instller tool nd check to ensure tht oil hole(s) in ering re positioned correctly. d. Instll intermedite erings in sme mnner eing sure to index erings correctly. It will e necessry to position pilot in rer cmshft ering ore to instll rer intermedite ering. 2. Instlling front nd rer erings:. Instll pproprite size remover nd instller tool on drive hndle. 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A-59

. Index front ering (s explined in Importnt ove), nd drive it into position with tool. Check position of oil hole(s) in ering to ensure ering is positioned correctly. c. Instll rer ering in sme mnner, eing sure to index ering correctly. 3. Instll new cmshft rer plug. IMPORTANT: Plug must e instlled flush to 1/32 in. (0.8 mm) deep nd must e prllel with rer surfce of cylinder lock. 4. Instll crnkshft nd cmshft s outlined. 7. Mesure cylinder wlls for tper, out-of-round or excessive ridge t top of ring trvel. This should e done with dil indictor or inside micrometer. Crefully work guge up nd down cylinder to determine tper nd turn it to different points round cylinder wll to determine out-of-round condition. If cylinders exceed specifictions, oring nd/or honing will e necessry. Cylinder Block Clening nd Inspection 1. Remove ll engine components s previously outlined. 2. Wsh cylinder lock thoroughly in clening solvent nd clen ll gsket surfces. 3. Remove oil gllery plugs nd clen ll oil pssges. 4. Remove expnsion plugs. NOTE:These plugs my e removed with shrp punch, or they my e drilled nd pried out. 5. Clen nd inspect wter pssges in cylinder lock. 6. Inspect cylinder lock for crcks in cylinder wlls, wter jcket vlve lifter ores nd min ering wes. Cylinder Mesurement 72385 - Equl To Right Angle To Centerline Of Engine - Prllel to Centerline Of Engine Out Of Round Equls The Difference Between A nd B At Top Of Cylinder Bore nd A Mesurement At Bottom Of Cylinder Bore Mesuring Cylinder Bore 72570 3A-60-454 C.I.D. (7.4L) / 502 C.I.D. (8.2L) 90-823224--2 796

72569 Mesuring Cylinder Bore 8. Check cylinder hed gsket surfces for wrpge with mchinist s stright-edge nd feeler guge, s shown. Tke mesurements digonlly cross surfces (oth wys) nd stright down center. If surfces re wrped more thn.003 in. (0.07 mm) in 6 in. re or.007 in. (0.2 mm) overll, lock must e resurfced y n utomotive mchine shop. - Mchinist s Stright Edge - Feeler Guge 72566 CYLINDER CONDITIONING 1. Performnce of the following opertion depends upon engine condition t time of repir. 2. If cylinder lock inspection indictes tht lock is suitle for continued use (except for out-of-round or tpered cylinders), they cn e conditioned y honing or oring. 3. If cylinders hve less thn.005 in. (0.127 mm) tper or wer, they cn e conditioned with hone nd fitted with high limit stndrd size piston. A cylinder ore of more thn.005 in. wer or tper my not clen up entirely when fitted to high limit piston. To entirely clen up the ore, it will e necessry to ore for n oversize piston. If more thn.005 in. tper or wer, ore nd hone to smllest oversize tht will permit complete resurfcing of ll cylinders. 4. When pistons re eing fitted nd honing is not necessry, cylinder ores my e clened with hot wter nd detergent wsh. After clening, sw cylinder ores severl times with light engine oil nd clen cloth, then wipe with clen dry cloth. CYLINDER BORING 1. Before using ny type oring r, file off top of cylinder lock to remove dirt or urrs. This is very importnt to prevent oring r tilt, with result tht ored cylinder wll is not t right ngles to crnkshft. 2. Mesure piston to e fitted with micrometer, mesuring t center of piston skirt nd t right ngles to piston pin. Bore cylinder to sme dimeter s piston nd hone to give specified clernce. NOTE:Hone cylinders s outlined under Cylinder Honing nd Piston Selection, following. 3. Crefully oserve instructions furnished y mnufcturer of equipment eing used. CYLINDER HONING 1. Follow hone mnufcturer s recommendtions for use of hone nd clening nd luriction during honing. 2. Occsionlly, during the honing opertion, thoroughly clen cylinder ore nd check piston for correct fit in cylinder. 3. When finish-honing cylinder ore to fit piston, move hone up nd down t sufficient speed to otin very fine uniform surfce finish mrks in crosshtch pttern of pproximtely 30 degrees to cylinder ore. Finish mrks should e clen ut not shrp, free from imedded prticles nd torn or folded metl. 4. Permnently mrk piston (for cylinder to which it hs een fitted) nd proceed to hone cylinders nd fit remining pistons. 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A-61

IMPORTANT: Hndle pistons with cre nd do not ttempt to force them through cylinder until cylinder is honed to correct size, s this type piston cn e distorted y creless hndling. 5. Thoroughly clen cylinder ores with hot wter nd detergent. Scru well with stiff ristle rush nd rinse thoroughly with hot wter. It is extremely essentil tht good clening opertion e performed. If ny rsive mteril remins in cylinder ores, it will rpidly wer new rings nd cylinder ores in ddition to erings luricted y the contminted oil. Sw ores severl times with light engine oil on clen cloth, then wipe with clen dry cloth. Cylinder should not e clened with kerosene or gsoline. Clen reminder of cylinder lock to remove excess mteril spred during honing opertion. PISTON SELECTION 1. Check used piston to cylinder ore clernce s follows:. Mesure cylinder ore dimeter with telescope guge 2-1/2 in. (64 mm) from top of cylinder ore s follows.. Mesure piston dimeter t skirt cross center line of piston pin s shown. 72624 c. Sutrct piston dimeter from cylinder ore dimeter to determine piston-to-ore clernce. d. Determine if piston-to-ore clernce is in cceptle rnge shown in Specifictions. 2. If used piston is not stisfctory, determine if new piston cn e selected to fit cylinder ore within cceptle rnge. 3. If cylinder ore must e reconditioned, mesure new piston dimeter (cross centerline of piston pin), then hone cylinder ore to correct clernce (preferle rnge). 4. Mrk piston to identify cylinder for which it ws fitted. 72570 3A-62-454 C.I.D. (7.4L) / 502 C.I.D. (8.2L) 90-823224--2 796

Oil Filter By-Pss Vlve nd Adptor! CAUTION Any Gen V or Gen VI engine with front mounted verticl oil cooler MUST hve 30 PSI oil pressure relief vlve instlled. Severe engine dmge or filure will occur if not instlled. 6. Wipe out vlve chmer in cylinder lock to remove ny foreign mteril. 7. Instll y-pss vlve (if replced) nd connector. Torque dptor nut to 20 l. ft. (27 N m). 8. Luricte dptor sel with engine oil. Instll hose fitting nd torque to specifictions. 9. Apply Perfect Sel to hose threds. Instll nd tighten securely. Inspection nd/or Replcement Oil y-pss vlve nd dptor should e inspected whenever engine is disssemled for mjor repir or whenever indequte oil filtrtion is suspected. Refer to Engine Prts List when ordering prts for oil filter y-pss vlve, dptor ssemly or remote oil filter prts. 1. Remove oil hoses from dptor. 2. Remove hose fitting nd sel from dptor. 3. Remove connector. 4. Clen prts in solvent nd low dry with compressed ir. 5. Inspect fier vlves for crcks or other dmge. Check tht vlves fit tightly ginst sets. Push ech vlve down nd relese it. Vlves should return freely to their sets. If vlve opertion is questionle, y-pss vlve should e replced. Typicl By-Pss Vlve nd Adptor 72546 - Fier Vlves (Ensure Tht Vlves Fit Tightly Aginst Their Sels 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A-63

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THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 3A-66-454 C.I.D. (7.4L) / 502 C.I.D. (8.2L) 90-823224--2 796

THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 90-823224--2 796 454 CID (7.4L) / 502 CID (8.2L) - 3A-67