ENGINES 3 A MECHANICAL INFORMATION

Transcription

1 ENGINES 3 A MECHANICAL INFORMATION

2 Tble of Contents Pge Engine Identifiction A-1 4 Cylinder A-1 V A-1 V A-1 3.0LX A-2 Specil Tools A-2 Lubricnts/Selers/Adhesives A-3 3.0LX Torque Specifictions A-3 4.3L nd 4.3LX A-7 Specil Tools A-7 Lubricnts/Selers/Adhesives A-8 4.3L/4.3LX Torque Specifictions A-8 305/5.0L/350/5.7L A-15 Specil Tools A-15 Lubricnts/Selers/Adhesives A /5.0L/350/5.7L Torque Specifictions. 3A /7.4L nd 502/8.2L A-25 Specil Tools A-25 Lubricnts/Selers/Adhesives A /7.4L/502/8.2L Torque Specifictions. 3A-26 Cylinder Hed Torque Sequences A LX A L/4.3LX A /5.0L/350/5.7L A L/454/8.2L/ A-34 Intke Mnifold Torque Sequence A L/4.3LX A /5.7L A /7.4L/502/8.2L A-35 Dipstick Specifictions A L/4.3LX A /5.7L A /7.4L/502/8.2L A-38 Pge Digrms for Tool Usge A-39 Vlve Spring Removl With Hed On.... 3A-39 Vlve Spring Removl With Hed Off.... 3A-39 Vlve Guide Clener A-39 Checking For Cylinder Hed Fltness... 3A-39 Rocker Arm Stud Replcement A-40 Checking Vlve Spring Height A-41 Checking Vlve Spring Pressure A-41 Checking For Vlve Guide Wer A-42 Vlve Guide Bore Repir A-42 Removing The Torsionl Dmper A-43 Instlling Oil Sel In Cover With Cover Still On Engine A-43 Instlling New Sel With Cover Removed A-43 Flywheel Runout A-44 Rer Min Sel Removl A-44 Using Rer Min Sel Instller A-44 Checking Clernce On Crnkshft Journls A-45 Checking Clernce On Rod Journls... 3A-45 Mesuring Crnkshft End Ply A-45 Mesuring Piston Ring Gp A-45 Position Of Piston Rings On Pistons.... 3A-46 Piston Orienttion A-46 V-6 nd V-8 Piston Instlltion A-47 Cylinder Wll Inspection And Mesurement A-47 Checking Deck Surfce A-48 Cmshft Ger And Sprocket Instller... 3A-49 Checking Timing Chin Deflection A-49 Alignment Of Timing Mrks A-49 Mesuring Lobe Lift A-49 3A-0 - MECHANICAL INFORMATION

3 Engine Identifiction V-8 4 Cylinder Loction of GM Engine Code Loction of G.M. Engine Code MCM (Stern Drive) Code Rottion 3.0LX RN,RK LH V-6 MCM (Stern Drive) Code Rottion 5.0L Alph ZC 5.0LX Alph ZD 5.0L Brvo ZC 5.7L Alph MB 5.7L Brvo CD,MD 350Mgnum Alph LH (See Note) 350 Alph EFI (See Note) 350 Brvo EFI (See Note) CD,MD 350 Mgnum EFI/MP Brvo (See Note) - Loction of GM Engine Code MCM Code (Stern Drive) 4.3L Alph LG 4.3LX Alph LH Rottion LH MIE (Inbord) Code Rottion 57L 5.7L NN LH NR RH 5.7L Competition Ski MB LH MR RH 350 Mgnum Tournment Ski (See Note) 350 Mgnum EFI/MP CD,MD LH Tournment Ski (See Note) Note: Engines with roller lifters nd steel cmshft MCM (Stern Drive) Code Rottion 7.4L XW 7.4L Brvo Three UB,XX 454 Mgnum XA LH 454 Mgnum EFI XA 502Mgnum EFI HJ MIE (Inbord) Code Rottion 7.4L XY 8.2L FH LH 454 EFI Ski UA MECHANICAL INFORMATION - 3A-1

4 3.0LX Specil Tools MERCURY MARINE SPECIAL TOOLS Description Piston Ring Expnder Torch Lmp KENT MOORE SPECIAL TOOLS Description Vlve Spring Compressor (Hed on) J5892 Vlve Spring Compressor (Hed off) J8062 Vlve Stem Sel Tester J23738-A Vlve Guide Clener J8101 Vlve Guide Remer (Stndrd) J8814 Vlve Guide Remer (.015 in. oversize) J Rocker Arm Stud Remover J Rocker Arm Stud Instller J6880 Stud Bore Remer (.003 in. oversize) J5715 Stud Bore Remer (.013 in. oversize) J6036 Crbon Remover Brush J8089 Piston Support Tool J Piston Pin Tool J24086-B Piston Ring Groove Clener J Piston Ring Compressor J8037 Connecting Rod Guide Tool (3/8-24) J5239 Cylinder Bore Checker J8087 Oil Pump Suction Pipe Instller J8369 Timing Cover Sel Aligner J23042-B Cm Lobe Lift Indictor J8520 Cmshft Bering Instller/Remover Tool J Distributor Shft Lower Bering Instller/Remover J Pulley Hub Puller J6978-E Pulley Hub Instller J5590 Universl Torsionl Dmper Remover J24420 Prt Number Prt Number 3A-2 - MECHANICAL INFORMATION

5 Lubricnts/Selers/Adhesives Description Quicksilver Perfect Sel Prt Number A2 Quicksilver 2-C-4 Mrine Lubricnt Quicksilver RTV Seler 3.0LX Torque Specifictions Description Lb. In. Lb. Ft. N m Cmshft Sprocket Bolts 80 9 Connecting Rod Cp Nuts Cylinder Hed Bolts 90 See Note See Note 1 Distributor Clmp Engine Coupler to Flywheel Flywheel Housing to Block Flywheel to Crnkshft Bolts Front Cover Bolts Front Mount to Block Min Bering Cp Bolts Mnifold to Hed 23 See Note 2 31 See Note 2 Oil Pn Bolts-Crnkcse 80 9 Oil Pn Bolts -to Front Cover 45 5 Oil Pn Studs to Oil Sel Retiner or Crnkcse Oil Pump Cover 72 8 Oil Pump to Block Oil Pump Pickup 60 7 Rocker Arm Cover nd Bolts Rer Crnkshft Oil Sel Retiner Nuts Sprk Plugs Strter Motor to Block Timing Ger Cover 72 8 Torsionl Dmper Bolt Wter Pump to Block Note 1: Retorque fter first 20 hours of opertion. Note 2: Retorque fter first strt up. MECHANICAL INFORMATION - 3A-3

6 3.0LX Engine Specifictions UNIT OF MEASUREMENT in. (mm) Displcement CYLINDER BORE Model 3.0LX 181 CID (3.0L) Dimeter ( ).0005(0.012) Mx Out of Round.002(0.05) Mx Thrust Side.0005(0.012) Mx Tper Relief Side.0005(0.012) Mx.001(0.02) Mx PISTON CLEARANCE ( ) Mx.0035(0.08) Mx PISTON RING: COMPRESSION Groove Clernce Gp Top 2nd Top 2nd ( ) 0029( ).003(0.09) Mx ( ) 020( (0.88) Mx PISTON RING: OIL Groove Clernce Gp PISTON PIN ( ) Limit.007(0.17) Mx ( ) Mx Limit.040(1.01) Mx Dimeter ( ) ( ) Clernce Limit.001(0.02) Mx Fit in Rod ( ) Interference 3A-4 - MECHANICAL INFORMATION

7 3.0LX Engine Specifictions CRANKSHAFT Min Journl Tper Out of Round Dimeter ( ).0002(0.005) Mx.001(0.02) Mx.0002(0.005) Mx.001(0.02) Mx No.1-No ( ) Min Bering No ( ) Clernce No.1-No ( ) Crnkpin Rod Bering Clernce CAMSHAFT No ( ) Crnkshft End Ply ( ) Tper Out of Round Dimeter ( ).0003(0.007) Mx.001(0.02) Mx.0002(0.51) Mx.001(0.02) Mx ( ) Rod Size Clernce Lobe Lift (Mx.) CYLINDER HEAD ( ) Mx Intke.2529(6.425) Exhust.2529(6.425) Journl Dimeter ( ) Cmshft End Ply ( ) Mx Gsket Surfce Fltness in ny 6 in.(152) or.007(0.15) Overll Mx MECHANICAL INFORMATION - 3A-5

8 3.0LX Engine Specifictions VALVE SYSTEM Lifter Hydrulic Rocker Arm Rtio 1.75 to 1 Collpsed Tppet Gp 3/4 Turn Down from Zero Lsh Fce Angle Intke 45 Exhust 45 Set Angle (Intke & Exhust) 46 Set Runout (Intke & Exhust).002(0.05) Mx Set Width Intke 1/16 (.0625)in. (1.16 mm) Exhust 1/16-5/64 [ ] in. ( mm) Intke ( ) Stem Exhust ( ) Clernce Intke.003(0.09) Mx Exhust.004(0.11) Mx Free Length 2-1/16(52) Vlve Closed lb. ( N) t 1-19/32 in. (41 mm) Pressure Spring Vlve Open lb. ( N) t 1-7/32 in. (31 mm) Instlled Intke Height± (1/32)1.6562(42).031(8) Exhust Internl Dmper None 3A-6 - MECHANICAL INFORMATION

9 4.3L nd 4.3LX Specil Tools MERCURY MARINE SPECIAL TOOLS Description Piston Ring Expnder Engine Coupler Wrench Prt Number TA360 Description SNAP-ON SPECIAL TOOLS Prt Number Torque Angle Guge (Degree Wheel Torquing) KENT-MOORE SPECIAL TOOLS Description Vlve Spring Compressor (Hed On) J5982 Vlve Spring Compressor (Hed Off) J8062 Vlve Spring Tester J8056 Vlve Guide Clener J8101 Vlve Guide Remer J Vlve Guide Remer J7049 Crbon Remover Brush J8089 Piston Pin Remover Kit J24086-B Piston Ring Groove Clener J Piston Ring Compressor J8037 Connecting Rod Bolt Guide Set (3/8-24) J5239 Oil Pump Suction Pipe Instller J21882 Cmshft Bering Remover nd Instller Set J Bll Socket Adpter Tool Kit (Lift Indictor) J Torsionl Dmper Remover nd Instller J23523-E Crnkcse Front Cover Sel Instller J35468 Crnkcse Ger nd Sprocket Puller J5825-A Crnkcse Ger nd Sprocket Instller J5590 Air Adpter J23590 Min Bering Remover nd Instller J8080 Rer Min Sel Instller J26817-A Blnce Shft Rer Bering Remover J26941 Blnce Shft Bering Remover nd Instller J38834 Prt Number MECHANICAL INFORMATION - 3A-7

10 Lubricnts/Selers/Adhesives Description Quicksilver Loctite Quicksilver Perfect Sel Quicksilver RTV Seler Generl Motors Cm nd Lifter Prelude Obtin Loclly 4.3L/4.3LX Torque Specifictions Prt Number Description Lb. In. Lb. Ft. N.m Alterntor Brce to Alterntor Alterntor Brce to Engine Alterntor to Mounting Brcket Alterntor Mounting Brcket Blnce Shft Drive Ger Retining Stud Blnce Shft Driven Ger Bolt (Torque Plus 35 ) Blnce Shft Thrust Plte Cmshft Sprocket Cmshft Thrust Plte Crburetor Connecting Rod Cp Nuts (Torque Plus 60 ) Coupler/Flywheel(MCM) Crnkcse Front Cover Crnkshft Pulley Bolt (Cst Aluminum) Cylinder Hed Distributor Hold Down Exhust Mnifold Flywheel Flywheel Housing to Block Flywheel Housing Cover 80 9 Front Mount Brcket Fuel Filter Brcket Bolt Fuel Pump Brcket Bolt Fuel Pump Inlet Fitting (Lrge Dimeter See Note) Fuel Pump Inlet Fitting (Smll Dimeter See Note) Intke Mnifold Min Bering Cp Oil Filter Adpter Bolts Oil Pn Drin Plug Note : Hold Fuel Pump using wrench on flt surfce t outlet before tightening brss fitting 3A-8 - MECHANICAL INFORMATION

11 4.3L/4.3LX Torque Specifictions Description Lb. In. Lb. Ft. N m Oil Pn Screw (1/4-20) 80 9 Oil Pn Nuts (5/16-20) Oil Pump Oil Pump Cover 80 9 Power Steering Pump Brce to Block Power Steering Pump Brcket Rer Crnkshft Oil Sel Retiner Screws nd Nuts Rer Mount (MCM) Rocker Arm Cover Rocker Arm Nuts Roller Lifter Restrictor Plte Sewter Pump Brce (if equipped) Sewter Pump Brcket (if equipped) Sprk Plugs Strter Motor Thermostt Housing Torsionl Dmper Wter Circulting Pump Wter Temperture Sender MECHANICAL INFORMATION - 3A-9

12 4.3L/4.3LX Engine Specifiction Unit of Mesurement in. (mm) Engine Model 4.3L/43LX Displcement 262 CID (4.3 Litre) Bore 4.00(101.6) Stoke 3.48(88.39) Compression Rtio 9.05:1 Heds Cst Iron Intke Mnifold Cst Iron Block Cst Iron (2 Bolt Min Bering Cps) Rods Forged Steel Pistons Cst Aluminum Crnkshft Cst Iron Cmshft Steel LH ROTATION FRONT Firing Order A-10 - MECHANICAL INFORMATION

13 4.3L/4.3LX Engine Specifiction Unit of Mesurement in. (mm) Displcement CYLINDER BORE Model 4.3L/4.3LX 262 CID (4.3L) Dimeter ( ).001(0.025) Mx Out of Round.002(0.05) Mx Thrust Side.0005(0.012) Mx Tper Relief Side.001(0.02) Mx.001(0.02) Over PISTON CLEARANCE PISTON RING: COMPRESSION Groove Clernce Gp PISTON RING: OIL ( ) Mx.0027(0.07) Mx Top ( ) 0032( ) 2nd High Limit +.001(0.025) Top ( ) 2nd ( ) High Limit +.010(0.25) Groove ( ) Clernce High Limit +.001(0.025) Gp ( ) Limit High Limit +.010(0.254) PISTON PIN Dimeter ( ) ( ) Clernce Limit.001(0.02) Mx Fit in Rod ( ) Interference MECHANICAL INFORMATION - 3A-11

14 4.3L/4.3LX Engine Specifiction Unit of Mesurement in. (mm) CRANKSHAFT No ( ) Dimeter No. 2, ( ) No ( ) Min.0002(0.005) Mx Journl Tper.001(0.02) Mx Out of Round.0002(0.005) Mx.001(0.005) Mx No ( ) No.2, ( ) Min Bering No ( ) Clernce No (0.03) No.2, ( ) No ( ) Crnkshft End Ply ( ) Dimeter ( ).0005(0.021) Mx Connecting Rod Tper.001(0.02) Mx Journl.0005(0.021) Mx Out of Round.001(0.02) Mx Rod Bering Clernce ( ).003(0.07) Mx Rod Side Clernce ( ) Crnkshft Runout.0015(0.038) Mx 3A-12 - MECHANICAL INFORMATION

15 4.3L/4.3LX Engine Specifiction Unit of Mesurement in. (mm) VALVE SYSTEM Lifter Roller Hydrulic Rocker Arm Rtio 1.70 to 1 Vlve Lift Intke.394(10.00) Exhust.404(10.26) Vlve Lsh (Intke nd Exhust) Fixed Lsh Fce Angle (Intke & Exhust) 45 Set Angle (Intke & Exhust) 46 Set Runout (Intke & Exhust).002(0.05) Mx Set Width Intke 1/32-1/16 [ ] in. ( mm) Exhust 1/16-3/32 [ ] in. ( mm) Intke ( ) Stem Exhust ( ) Clernce Intke.0037(0.09) Mx Exhust.0047(0.11) Mx Stem Dimeter Intke.341(8.66) Exhust.372(9.45) Vlve Mrgin Intke nd Exhust 1/32 (0.79) VALVE SPRING Free Length 2.03(51.6) Vlve Closed Lb. ( N) t1.785 [1-45/64](43.16) Pressure Vlve Spring Vlve Open Lb. ( N) t 1.250[1-1/4](31.75) Instlled Height 1.70 [1-45/64](47.24) Dmper Free Length 1.86 [1-55/64](47) Approximte Number of Coils 4 NOTE: Test spring pressure with dmper removed MECHANICAL INFORMATION - 3A-13

16 4.3L/4.3LX Engine Specifiction Unit of Mesurement in. (mm) CAMSHAFT AND DRIVE FLYWHEEL Lobe Lift ± Intke.269(6.89).002(0.051) Exhust.273(6.93) Journl Dimeter ( ) Journl Out of Round Cmshft Runout.001(0.025) Mx.002(0.051) Mx Cmshft End Ply ( ) Timing Chin Deflection.375(9.5) from tut position [totl.75 (19)] Runout.008(0.203) Mx CYLINDER HEAD Gsket Surfce Fltness BALANCE SHAFT.004(0.10) Overll Mximum Front Bering Journl ( ) Rer Bering Journl ( ) Rer Bering Inside Dimeter Assembled ( ) Rer Bering Outside Dimeter ( ) Rer Cylinder Block Housing Bore ( ) 3A-14 - MECHANICAL INFORMATION

17 305/5.0L/350/5.7L Specil Tools MERCURY MARINE SPECIAL TOOLS Description Piston Ring Expnder Engine Coupler Wrench Rocker Stopper KENT-MOORE SPECIAL TOOLS Description Vlve Spring Compressor (Hed on) J5892 Vlve Spring Compressor (Hed off) J8062 Vlve Spring Tester J8056 Vlve Guide Clener J8101 Vlve Guide Remer (Stndrd) J7049 Vlve Guide Remer (.015 in. oversize) J Rocker Arm Stud Remover J Rocker Arm Stud Instller J6880 Stud Bore Remer (.003 in. oversize) J5715 Stud Bore Remer (.013 in. oversize) J6036 Crbon Remover Brush J8089 Piston Pin Tool J24086-B Piston Ring Groove Clener J Piston Ring Compressor J8037 Connecting Rod Guide Tool (3/8-24) J5239 Oil Pump Suction Pipe Instller J21882 Cmshft Bering Instller/Remover Tool J Bll Socket Adpter J Torsionl Dmper Remover nd Instller J23523-E Crnkcse Front Cover Sel Instller J35468 Crnkshft Ger nd Sprocket Puller J5825-A Crnkshft Ger nd Sprocket Instller J5590 Air Adpter J23590 Min Bering Remover nd Instller J8080 Rer Min Sel Instller J26817-A Prt Number Prt Number MECHANICAL INFORMATION - 3A-15

18 Lubricnts/Selers/Adhesives Description Quicksilver Loctite Quicksilver Perfect Sel Quicksilver Needle Bering Assembly Lubricnt A1 Quicksilver RTV Seler Generl Motors Cm nd Lifter Prelube or Equivlent Obtin Loclly Prt Number 305/5.0L/350/5.7L Torque Specifictions Description Lb. In. Lb. Ft. N m Alterntor Brce to Alterntor Alterntor Brce to Engine Alterntor to Mounting Brcket Alterntor Mounting Brcket Cmshft Sprocket Ger Crburetor Connecting Rod Cp Nuts Coupler/Flywheel(MCM) Crnkshft Pulley Cylinder Hed Distributor Hold Down Exhust Mnifold Filter Adpter (5/16-18) Flywheel Flywheel Drive Plte (MIE) Flywheel Housing to Block Flywheel Housing Cover 80 9 Front Mount Brcket Fuel Pump Intke Mnifold Min Bering Cp Oil Bffle Nuts Oil Filter Adpter Bolts Oil Pn Drin Plug Oil Pn Screw (1/4-20) 8 9 Oil Pn Nuts (5/16-18) Oil Pump A-16 - MECHANICAL INFORMATION

19 305/5.0L/350/5.7L Torque Specifictions (Continued) Description Lb. In. Lb. Ft. N m Oil Pump Cover 80 9 Power Steering Pump Brce to Block Power Steering Pump Brcket Rer Crnkshft Oil Sel Retiner Screws nd Nuts Rer Mount (MCM) Rer Mount (MIE) Remote Oil Connector (1/2 in. x 13) Remote Oil Filter Adpter Nut/Fitting Sprk Plugs Strter Motor Thermostt Housing Timing Chin or Ger Cover 11 Torsionl Dmper Trnsmission To Housing Wter Circulting Pump Wter Temperture Sender Rocker Arm Cover Roller Lifter Restrictor Retiner Plte Sewter Pump Brce Sewter Pump Brcket MECHANICAL INFORMATION - 3A-17

20 305/5.0L/350/5.7L Engine Specifictions Unit Of Mesurement In. (mm) Engine Model MCM 5.0L MCM 5.0LX MCM 5.0L Brvo MCM 5.7L Alph MCM 5.7L Brvo MCM 350 Mgnum Alph Displcement 305 CID (5.0 Litre) 350 CID (5.7 Litre) Bore 3.74(95) 4.00(101.6) Stroke 3.48(88.4) 3.48(88.4) Compression Rtio 9.05:1 9.1:1 9.3:1 Heds Cst Iron Intke Mnifold Intke Mnifold Cst Iron (Mgnums-High Rise-See Note 2) Block Cst Iron (2 Bolt Min Bering Cps) Rods Forged Steel Crnkshft Cst Iron Pistons Cst Aluminum Cmshft Cst Iron Steel (See Note 1) Fuel Pump Push Rod Steel NOTE1: Engine with roller lifters nd steel cmshft NOTE 2: Includes- 350 Mgnum Alph,5.7L Brvo nd 350Mgnum Tournment Ski Cst Iron (See Note 1) 3A-18 - MECHANICAL INFORMATION

21 305/5.0L/350/5.7L Engine Specifictions Unit Of Mesurement In. (mm) Engine Model MCM 5.7L EFI Alph MCM 5.7L EFI Brvo Displcement 350 CID (5.7 Litre) Bore 4.00(101.6) Stroke 3.48(88.4) Compression Rtio 9.3:1 Heds Cst Iron Intke Mnifold Intke Mnifold Cst Iron (Mgnums-High Rise-See Note 2) Block Cst Iron (2 Bolt Min Bering Cps) Rods Forged Steel Crnkshft Cst Iron Pistons Cst Aluminum Cmshft Steel (See Note 1) Fuel Pump Push Rod Cst Iron (See Note 1) NOTE1: Engine with roller lifters nd steel cmshft MCM 350 Mgnum EFI/MP Alph NOTE 2: Includes- 350 Mgnum Tournment Ski, 350 EFI Mgnum Tournment Ski nd 350 EFI/MP Tournment Ski MECHANICAL INFORMATION - 3A-19

22 305/5.0L/350/5.7L Engine Specifictions Engine Model MIE 5.7L Unit Of Mesurement In. (mm) MIE 5.7L Competition Ski MIE 350 Mgnum Tournment Ski MIE 350 EFI Mgnum Tournment Ski Displcement 350 CID (5.7 Litre) Bore 4.00(101.6) Stroke 3.48(88.4) Compression Rtio 9.3:1 Heds Cst Iron Intke Mnifold Cst Iron (Mgnums-High Rise-See Note 2) Block Cst Iron (2 Bolt Min Bering Cps) Rods Forged Steel Crnkshft Cst Iron Pistons Cst Aluminum Cmshft Cst Iron Steel (Note 1) Fuel Pump Push Rod Steel Cst Iron (See Note 1) MIE 350 EFI/MP Mgnum Tournment Ski NOTE1: Engine with roller lifters nd steel cmshft NOTE 2: Includes- 350 Mgnum Tournment Ski, 350 EFI Mgnum Tournment Ski nd 350 EFI/MP Tournment Ski A LH ROTATION FRONT B RH ROTATION FRONT Firing Order Firing Order A-20 - MECHANICAL INFORMATION

23 305/5.0L/350/5.7L Engine Specifictions Unit Of Mesurement In. (mm) Model 5.0L/5.0LX 5.7L/350 Mgnum Displcement 305 CID (5.0L) 350 CID (5.7L) CYLINDER BORE Dimeter Out of Round Thrust Side Tper Relief Side PISTON CLEARANCE PISTON RING: COMPRESSION ( ).001(0.025) Mx.002(0.05) Mx.0005(0.012) Mx.001(0.02) Mx.001(0.02) Over ( ) ( ) Mx.0027(0.07) Mx Groove Clernce Gp PISTON RING: OIL Top 2nd ( ) 0032( ) High Limit +.001(0.025) Top ( ) 2nd ( ) 025( ) High Limit +.010(0.25) Groove ( ) Clernce High Limit +.001(0.025) Gp ( ) Limit High Limit +.010(0.254) PISTON PIN Dimeter ( ) ( ) Clernce Limit.001(0.02) Mx Fit in Rod ( ) Interference MECHANICAL INFORMATION - 3A-21

24 305/5.0L/350/5.7L Engine Specifictions Unit Of Mesurement In. (mm) CRANKSHAFT No ( ) Dimeter No. 2, ( ) No ( ) Min.0002(0.005) Mx Journl Tper.001(0.02) Mx Out of Round.0002(0.005) Mx.001(0.005) Mx No ( ) No.2, ( ) Min Bering No ( ) Clernce No (0.03) No.2, ( ) No ( ) Crnkshft End Ply ( ) Dimeter ( ).0005(0.021) Mx Connecting Rod Tper.001(0.02) Mx Journl.0005(0.021) Mx Out of Round.001(0.02) Mx Rod Bering Clernce ( ).003(0.07) Mx Rod Side Clernce ( ) Crnkshft Runout.0015(0.0381) Mx 3A-22 - MECHANICAL INFORMATION

25 305/5.0L/350/5.7L Engine Specifictions Unit Of Mesurement In. (mm) VALVE SYSTEM Engine 5.0L/5.7L 5.7L/350 Mgnum Lifter Type Flt Hydrulic Flt Hydrulic Roller Hydrulic Rocker Arm Rtio 1.50 to 1 Vlve Lift Intke.394(10.00) Exhust.404(10.26) Vlve Lsh (Intke nd Exhust) 1 Turn Down from Zero Lsh Fce Angle Intke 45 Exhust 45 Set Angle (Intke & Exhust) 46 Set Runout (Intke & Exhust) Stem Clernce Set Width Stem Dimeter Intke Exhust.002(0.05) Mx 1/32-1/16 [ ] in. ( mm) 1/16-3/32 [ ] in. ( mm) Intke ( ) Exhust ( ) Intke Exhust.0037(0.09) Mx.0047(0.11) Mx Intke.341(8.66) Exhust.372(9.45) Vlve Mrgin Intke nd Exhust.0312(0.79) VALVE SPRING Free Length 2.03(51.6) (See Note 1) Vlve Spring Pressure Vlve Closed Lb. Ft.( N m) t1.785(43.16) (NOTE 1) Vlve Open Lb. Ft. ( N m) t 1.250(31.75) Lvender Instlled Stripe Intke 1.7[1-45/64](43) Height Free Length 1.86[1-55/64](47) Dmper Approximte Number of Coils 4 NOTE 1: Test spring pressure with dmper removed MECHANICAL INFORMATION - 3A-23

26 305/5.0L/350/5.7L Engine Specifictions Unit Of Mesurement In. (mm) CAMSHAFT AND DRIVE Engine 5.0L/5.0LX 5.7L/350 Mgnum Lobe Lift ±.002(0.051) 051) Exhust.263(6.680).263(6.680) 680) Intke.287(7.29) (See Note) Durtion t.050 In.(1.27mm) Exhust.269(6.833) 0269(6.833) Cm Lift Intke.300(7.62) (See Note) Journl Dimeter ( ) Journl Out Of Round.001(0.025) Mx Cmshft Runout.002(0.051) Mx Timing Chin Deflection [LH (Stndrd) Rottion Engine Only].375(9.5) from tut position [totl.75(19)] Cmshft Timing Ger Runout [RH (Opposite) Rottion Engine Only].004(0.012) Mx Crnkshft Timing Ger Runout [RH (Opposite)Rottion Engine Only].003(0.076) Mx Cmshft to Crnkshft Timing Ger Bcklsh[RH (Opposite)Rottion Engine Only] Note : Engines with roller lifters nd steel cmshft FLYWHEEL ( ) New Gers ( ) Used Gers Runout.008(0.203) Mx CYLINDER HEAD Gsket Surfce Fltness.004(0.10) Overll Mximum 3A-24 - MECHANICAL INFORMATION

27 454/7.4L nd 502/8.2L Specil Tools MERCURY MARINE SPECIAL TOOLS Description Piston Ring Expnder Engine Coupler Wrench KENT-MOORE SPECIAL TOOLS Description Vlve Spring Compressor (Hed on) J5892 Vlve Spring Compressor (Hed off) J8062 Vlve Spring Tester J8056 Vlve Guide Clener J8101 Crbon Remover Brush J8089 Piston Pin Tool J24086-B Piston Ring Groove Clener J Piston Ring Compressor J8037 Connecting Rod Guide Tool (3/8-24) J5239 Connecting Rod Guide Tool (7/16-20) J35228 Oil Pump Suction Pipe Instller J21882 Lift Indictor Tool J8520 Torsionl Dmper Remover nd Instller J23523-E Crnkcse Front Cover Sel Instller J22102 Crnkshft Ger nd Sprocket Puller J24420-B Crnkshft Ger nd Sprocket Instller J Air Adpter (Cylinder Infltor) J23590 Min Bering Remover nd Instller J8080 Rer Min Sel Instller J38841 Lubricnts/Selers/Adhesives Description Quicksilver Loctite Quicksilver Perfect Sel Quicksilver RTV Seler Generl Motors Cm nd Lifter Prelube or Equivlent Obtin Loclly Prt Number Prt Number Prt Number MECHANICAL INFORMATION - 3A-25

28 454/7.4L/502/8.2L Torque Specifictions Description Lb. In. Lb. Ft. N m Alterntor Brce to Alterntor Alterntor Brce to Engine Alterntor to Mounting Brcket Alterntor Mounting Brcket Cmshft Sprocket Ger Crburetor Connecting Rod Cps (3/8-24) (7/16-20) Coupler/Flywheel(MCM) Crnkcse Front Cover Crnkshft Pulley Cylinder Hed Distributor Hold Down Exhust Mnifold Exhust Mnifold Elbow Filter Adpter (5/16-18) Flywheel Flywheel Drive Plte (MIE) Flywheel Housing to Block Flywheel Housing Cover 80 9 Front Mount Brcket Fuel Pump Intke Mnifold (See Note) Min Bering Cp Oil Bffle Nuts Oil Filter Adpter Nuts Oil Pn Bolts (5/16-18) 80 9 Oil Pn Drin Plug Oil Pump Oil Pump Cover 80 9 Power Steering Pump Brce to Block Power Steering Pump Brcket Rer Mount (MCM) Rer Mount (MIE) Remote Oil Connector (1/2 in. x 13) Rocker Arm Cover Rocker Arm Bolts 7.4L/ Mgnum/ A-26 - MECHANICAL INFORMATION

29 454/7.4L/502/8.2L Torque Specifictions Description Lb. Ft. N m Remote Oil Filter Adpter Nut/Fitting Sewter Pump Brce Sewter Pump Brcket Sprk Plugs Strter Motor Thermostt Housing Torsionl Dmper Trnsmission To Housing Wter Circulting Pump Wter Temperture Sender MECHANICAL INFORMATION - 3A-27

30 454/7.4L/502/8.2L Engine Specifictions Engine Model MCM 7.4L MIE 7.4L Unit of Mesurement In. (mm) MCM 7.4L Brvo Three MCM 454 Mgnum/454 Mgnum EFI/MP MIE 454 Mgnum EFI/MP Ski MIE8.2L, MCM 502 Mgnum MCM 502 Mgnum EFI/MP Displcement 454 CID(7.4L) 502 CID(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 Aluminum with Brss Inserts-High Rise (See Note) Block Cst Iron (4 Bolt Min Bering Cps) Rods Forged Steel Pistons Cst Aluminum Forged Aluminum Crnkshft Cst Steel Forged Steel Cmshft Cst Iron NOTE: The 454/502 Mgnum EFI/MP is equipped with cst luminum intke mnifold CYLINDER BORE Engine Dimeter Out of Round Thrust Pro- Side Tper duction Relief Side PISTON 7.4L Brvo One Brvo Two ( ) 7.4L Brvo Three.001(0.025) Mx.002(0.05) Mx.0005(0.0127) Mx.001(0.0254) Mx 454 Mgnum/ 454 Mgnum EFI/ MP 454 EFI/MP Ski ( ).001(0.02) Over 502 Mgnum EFI/MP 8.2L ( ) Clernce ( ) ( ) ( ).005(0.12) Mx.0075(0.15) Mx.0065(0.16) Mx 3A-28 - MECHANICAL INFORMATION

31 454/7.4L/502/8.2L Engine Specifictions PISTON RING Unit of Mesurement In. (mm) Engine 7.4L Brvo One Brvo Two 7.4L Brvo Three 454 Mgnum/ 454 Mgnum EFI/MP 454 EFI/MP Ski e s s i o n Oil Gp ( ) ( ) High Limit +.010(0.25) Mx ( ) High Limit +.001(0.25) ( ) ( ) High Limit +.001(0.25) 502 Mgnum EFI/MP 8.2L ( ) ( ) ( ) ( ) High Limit.005(0.12) Mx ( ) High Limit.005(0.12) Mx PISTON PIN Engine 7.4L Dimeter Clernce In Pin Fit In Rod T o Groove ( ) ( ) Pro- p C Side duction 2 o Clernce ( ) ( ) n m d p r High Limit +.010(0.02) Mx T o Pro- p Gp duction 2 n d Side Groove Clernce ( ) ( ) ( ) Interference 454 Mgnum/ 7.4L Brvo Three/454 EFI/MP Ski/454 Mgnum EFI/MP ( ) ( ).001(0.025) Mx 502 Mgnum 502 Mgnum EFI 8.2L ( ) Interference MECHANICAL INFORMATION - 3A-29

32 454/7.4L/502/8.2L Engine Specifictions CRANKSHAFT Min Journl Min Bering Clernce Engine Unit of Mesurement In. (mm) 7.4L/454 Mgnum 454 EFI/MP Ski 454 Mgnum EFI/MP 502 Mgnum 502 Mgnum EFI/MP 8.2.L Dimeter No.1,2,3,4, ( ) Tper.0002(0.005) Mx.001(0.02) Mx Out of Round.0002(0.005) Mx.001(0.005) Mx No.1,2,3, ( ) No ( ) No.1 No.2,3, ( ) ( ) ( ) ( ) No ( ) Crnkshft End Ply ( ) Dimeter ( ).0005(0.021) Mx Connecting Tper.001(0.02) Mx Rod Journl.0005(0.021) Mx Out of Round.001(0.02) Mx Rod Bering Clernce ( ).003(0.076) Mx Rod Side Clernce ( ) Crnkshft No.3 min Bering.0015(0.038) Mx.0035(0.088) Mx 3A-30 - MECHANICAL INFORMATION

33 454/7.4L/502/8.2L Engine Specifictions VALVE SYSTEM Unit of Mesurement In. (mm) Engine Model 7.4L/ 7.4L Brvo Three 454 Mgnum 454 Mgnum EFI/ MP SKI/454 EFI 502 MgnumEFI/ MP/8.2L Lifter Hydrulic Rocker Arm Rtio 1.70 to 1 Vlve Lift Intke.461(11.709).510(12.954) Exhust.479(12.167).510(12.954) Vlve Lsh (Intke nd Exhust) Fixed Lsh Fce Angle (Intke & Exhust) 45 Set Angle (Intke & Exhust) 46 Set Runout (Intke & Exhust).002(0.05) Mx Set Width Intke 1/32-1/16 [ ] in. ( mm) Exhust 1/16-3/32 [ ] in.( mm) Intke ( ) Stem Exhust ( ) Clernce Intke.001(0.02).003(0.07).0037(0.09) Exhust.002(0.05).004(0.10).0049(0.12) Stem Dimeter Intke.372(9.45) Exhust.372(9.45) Vlve Mrgin Intke nd Exhust.0312(0.79) MECHANICAL INFORMATION - 3A-31

34 454/7.4L/502/8.2L Engine Specifictions VALVE SPRING Vlve Spring (Note 1) (Note 2) Unit of Mesurement In. (mm) Engine Model 7.4L 454 Mgnum/454 Mgnum/EFI/502 Mgnum/502 Mgnum EFI/MP 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 Lbs. ( N) Does Not Apply Lbs. ( N) 110Lbs. (489N) Does Not Apply 316 Lbs. (1406N) 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 Number Of Coils Apply 4 Dmper or Dmper Shield Vlve Spring Fit in Dmper Shield ( ) Interference NOTE 1: 454/502/8.2L Models Only-Test spring pressure with inner nd outer spring ssembled. NOTE 2: 7.4L Models Only Test spring pressure with dmper shield instlled. Does Not Apply 3A-32 - MECHANICAL INFORMATION

35 454/7.4L/502/8.2L Engine Specifictions CAMSHAFT AND DRIVE Unit of Mesurement In. (mm) Engine 7.4L/7.4L Brvo Three 454 Mgnum/502 Mgnum/454 Mgnum EFI/MP 502 Mgnum EFI/MP/8.2L Lobe Lift ±.002 (0.051) 051) Exhust.271(6.683).300(7.62) Intke.282(7.163).300(7.62) Durtion t.050 In.(1.27mm) Exhust Cm Lift Intke Journl Dimeter ( ) Journl Out Of Round Cmshft Runout Timing Chin Deflection [LH (Stndrd) Rottion Engine Only] FLYWHEEL.001(0.025) Mx.002(0.051) Mx.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.(152mm) Spn MECHANICAL INFORMATION - 3A-33

36 Cylinder Hed Torque Sequences 305/5.0L/350/5.7L 3.0LX To insure gsket seling, torque hed bolts in three steps, following listed torque sequence for ech step lb. ft. (27 N m) lb. ft. (54 N m) lb. ft. (88 N m) lb. ft. (27 N m) lb. ft. (68 N m) lb. ft. (120 N m) 7.4L/454/8.2L/ L/4.3LX Front lb. ft. (27 N m) lb. ft. (68 N m) lb. ft. (115 N m) lb. ft. (27 N m) lb. ft. (54 N m) lb. ft. (88 N m) 3A-34 - MECHANICAL INFORMATION

37 Intke Mnifold Torque Sequence 4.3L/4.3LX Torque bolts to 35 lb. ft. (48 N m) in sequence s shown. 454/7.4L/502/8.2L Torque bolts to 35 lb. ft. (48 N m) in sequence s shown. On 502 Mgnum EFI, torque bolts to 25 lb. ft. (34N m) Front 350/5.7L Torque bolts to 35 lb. ft. (48 N m) in sequence s shown MECHANICAL INFORMATION - 3A-35

38 Dipstick Specifictions 4.3L/4.3LX UNIT OF MEASUREMENT In. (mm) 1/2 (13) 25-7/16 (646) 26-7/8 (682) FULL ADD 3/4 (19) MCM A-36 - MECHANICAL INFORMATION

39 Dipstick Specifictions (Continued) 350/5.7L UNIT OF MEASUREMENT In. (mm) 1/2 (13) 1/2 (13) 1/2 (13) 1/2 (13) 31 (787) 13-29/32 (353) 32 (814) 14-25/32 (375) 33-1/4 (845) 15-19/32 (396) 33-1/2 (849) FUL FUL FUL FUL 3/4 15/1 3/4 L L L L (19) 6 (19) ADD ADD ADD ADD (24) 23/3 2 (18) 16-1/4 (413) MCM MIE Borg-Wrner In-Line nd Hurth 630A Trnsmissions* L Competition Ski nd 350 Mgnum Tournment Ski MIE Borg-Wrner V-Drive Trnsmission* * Engines with Plstisol Coted Oil Pns MECHANICAL INFORMATION - 3A-37

40 Dipstick Specifictions (Continued) 454/7.4L/502/8.2L UNIT OF MEASUREMENT In. (mm) 1/2 (13) 1/2 (13) 1/2 (13) 33-1/2 (849) 35-1/4 (895) 15-1/8 (384) 17-13/64 (437) 16-43/6 4 (423) 19-7/64 (485) FUL FUL FUL 1/2 19/3 L L L (13) 2 ADD ADD ADD (15) 59/64 (23) MCM MIE Borg-Wrner In-Line Trnsmissions MIE All Trnsmissions Except Borg-Wrner In-Line A-38 - MECHANICAL INFORMATION

41 Digrms for Tool Usge IMPORTANT: Check for specific Tool,Torque Specifiction nd Mesurements under the Engine Specifictions. Vlve Guide Clener Vlve Spring Removl With Hed On b Vlve Spring Compressor b - Rocker Arm Nut Vlve Spring Removl With Hed Off - Vlve Guide Clener Checking For Cylinder Hed Fltness Tke mesurements digonlly cross hed (both wys) nd stright down center hed. b Stright Edge b - Feeler Guge - Vlve Spring Compressor MECHANICAL INFORMATION - 3A-39

42 Rocker Arm Stud Replcement 1. Plce lrge sleeve, flt wsher nd nut over stud, then turn nut until it bottoms out on stud threds. Then remove nut using rocker rm stud remover. 4. Instll new stud with rocker rm stud instller. b Lrge Sleeve b - 3/8-24. Nut 2. Remove nut nd instll smll sleeve on stud. Turn nut to remove stud. - Rocker Arm Stud Instller b c Nut b - Smll Sleeve c - Lrge Sleeve 3. Rem stud hole, whenever instlling n oversize stud, using pproprite reming tool. 3A-40 - MECHANICAL INFORMATION

43 Checking Vlve Spring Height Check instlled height of vlve springs. 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. Checking Vlve Spring Pressure Using vlve spring tester, s shown, check vlve spring tension with dmpers removed. Refer to Specifictions. IMPORTANT: Springs should be replced if not within 10 Lb.(4.4 N) of specified tension. Cutwy Scle b Vlve Spring Tester b - Torque Wrench Vlve Spring Instlled Height MECHANICAL INFORMATION - 3A-41

44 Checking For Vlve Guide Wer If clernce exceeds specifictions, it will be necessry to rem vlve guides for oversized vlves, s outlined under Vlve Guide Bore Repir. Vlve Guide Bore Repir Mesure vlve stem dimeter of old vlve being replced nd select proper size vlve guide remer. Rem vlve guide bores, s shown. b c Vlve Stem b - Dil Indictor c - Vlve Guide 3A-42 - MECHANICAL INFORMATION

45 Removing The Torsionl Dmper Instlling Oil Sel In Cover With Cover Still On Engine b Torsionl Dmper Remover Instlling torsionl dmper on crnkshft by turning nut until it bottoms out. - Crnkcse Front Cover Sel Instller b - Support (to Prevent Distorting Cover) Instlling New Sel With Cover Removed Crnkcse Front Cover Sel Instller - Torsionl Dmper Remover MECHANICAL INFORMATION - 3A-43

46 Flywheel Runout In. (0.203 mm) Using Rer Min Sel Instller. b Rer Min Sel Instller (PN J A) in. (0.203 mm) Mx. Runout b - Push Flywheel nd Crnkshft Forwrd s Fr s It Will Go when Tking Reding Rer Min Sel Removl IMPORTANT: Remove sel by using screwdriver to pry it out of retiner s shown. c b Rer Sel b - Sel Retiner c - Slots (Three) 3A-44 - MECHANICAL INFORMATION

47 Checking Clernce On Crnkshft Journls IMPORTANT: Do not turn crnkshft when guging crnkshft journls. Plce piece of guging plstic the full width of the bering (prllel to the crnkshft) on the journl s shown. Mesuring Crnkshft End Ply Mesure crnkshft end ply by forcing the crnkshft to the extreme front position. Mesure t the front end of the rer min bering with feeler guge s shown. b Guging Plstic b - Journl Checking Clernce On Rod Journls IMPORTANT: Do not turn crnkshft when guging rod journls. - Force Crnkshft to Extreme Forwrd Position Mesuring Piston Ring Gp Mesure gp between ends of ring with feeler guge s shown Guging Plstic Without removing the guging plstic, mesure its compressed width (t the widest point) with the grdutions on the guging plstic envelope MECHANICAL INFORMATION - 3A-45

48 Position Of Piston Rings On Pistons IMPORTANT: Be sure ring gps re properly positioned s shown. Piston Orienttion Notch on piston must be positioned correctly for engine tht is being repired. ENGINE LEFT ENGINE FRONT ENGINE RIGHT Cylinders Ring Gp Loction Cylinders Notch A - Oil Ring Spcer Gp (Tng in Hole or Slot within Arc) B - Oil Ring Ril Gps C - 2nd Compression Ring Gp D - Top Compression Ring Gp Notch - Towrd Front in MCM nd MIE (LH) Rottion Engines; Towrd Rer in MIE (RH) Rottion Engines 3A-46 - MECHANICAL INFORMATION

49 V-6 nd V-8 Piston Instlltion 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 bering cp should be mrked, beginning t front of engine (1, 3, 5 nd 7 in left bnk nd 2, 4, 6 nd 8 in right bnk). Numbers on connecting rod nd bering cp must be on sme side when instlled in cylinder bore. If connecting rod is ever trnsposed from one block or cylinder to nother, new berings should be fitted nd connecting rod should be numbered to correspond with new cylinder number. Cylinder Wll Inspection And Mesurement Mesure cylinder wlls for tper, out-of-round or excessive ridge t top of ring trvel. This should be 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, boring nd/or honing will be necessry Piston Ring Compressor Cylinder Mesurement A = At right ngle to centerline of engine B = Prllel to centerline of engine Out-of-Round = Difference between A nd B Tper =Difference between mesurement A t top of cylinder bore nd A mesurement t bottom of cylinder bore MECHANICAL INFORMATION - 3A-47

50 Checking Deck Surfce If surfces re wrped more thn.003 in. (0.07 mm) in 6 in. re or.007 in. (0.2 mm) overll, block must be resurfced Mesuring Cylinder Bore b Mchinist s Stright-Edge b - Feeler Guge Mesuring Cylinder Bore 3A-48 - MECHANICAL INFORMATION

51 Cmshft Ger And Sprocket Instller Alignment Of Timing Mrks NOTE:Flt lifter timing ger is shown. Roller lifter gers hve similr timing mrks. b Crnkshft Ger nd Sprocket Instller (PN J-5590) Checking Timing Chin Deflection The deflection is the difference between these two mesurements. If the deflection exceeds 3/4 in. (19 mm), timing chin should be replced. Stndrd (Left Hnd) Rottion Shown - Timing Mrks Aligned b - Locting Pin Mesuring Lobe Lift Position indictor with bll socket dptor tool on push rod. Be sure tht push rod is in lifter socket Reference Point - Bll Socket Adptor Tool MECHANICAL INFORMATION - 3A-49