The document provides specifications for engines including the 3.0L/3.0LX model. Key specifications listed include displacement of 181 CID (3.0L), cylinder bore diameter of 3.9995-4.0025 inches, piston clearance of 0.0025-0.0035 inches, crankshaft diameter of 2.2979-2.294 inches, connecting rod journal diameter of 2.09980-20995 inches, camshaft lobe lift of 0.2529 inches intake and exhaust, and cylinder head gasket surface flatness of 0.003-0.008 inches over 6 inches or 0.007 inches overall maximum. Tools, lubricants, sealants, and torque specifications
This is the Highly Detailed factory service repair manual for theBOBCAT 325 COMPACT EXCAVATOR, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.BOBCAT 325 COMPACT EXCAVATOR Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
Models Covers:
S/N 511820001 & Above
Service Repair Manual Covers:
Preventive maintenance
Hydraulic system
Drive system
Upper works & swing section
Main frame & tracks
Electrical system
Engine service
Technical data
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader
NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to haveBOBCAT 325 COMPACT EXCAVATOR Service Repair Workshop Manual.
Looking for some other Service Repair Manual,please check:
https://www.aservicemanualpdf.com/
Thanks for visiting!
This is the Highly Detailed factory service repair manual for theBOBCAT 325 COMPACT EXCAVATOR, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.BOBCAT 325 COMPACT EXCAVATOR Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
Models Covers:
S/N 511820001 & Above
Service Repair Manual Covers:
Preventive maintenance
Hydraulic system
Drive system
Upper works & swing section
Main frame & tracks
Electrical system
Engine service
Technical data
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader
NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to haveBOBCAT 325 COMPACT EXCAVATOR Service Repair Workshop Manual.
Looking for some other Service Repair Manual,please check:
https://www.aservicemanualpdf.com/
Thanks for visiting!
What Exactly Is The Common Rail Direct Injection System & How Does It WorkMotor Cars International
Learn about Common Rail Direct Injection (CRDi) - the revolutionary technology that has made diesel engines more efficient. Explore its workings, advantages like enhanced fuel efficiency and increased power output, along with drawbacks such as complexity and higher initial cost. Compare CRDi with traditional diesel engines and discover why it's the preferred choice for modern engines.
Comprehensive program for Agricultural Finance, the Automotive Sector, and Empowerment . We will define the full scope and provide a detailed two-week plan for identifying strategic partners in each area within Limpopo, including target areas.:
1. Agricultural : Supporting Primary and Secondary Agriculture
• Scope: Provide support solutions to enhance agricultural productivity and sustainability.
• Target Areas: Polokwane, Tzaneen, Thohoyandou, Makhado, and Giyani.
2. Automotive Sector: Partnerships with Mechanics and Panel Beater Shops
• Scope: Develop collaborations with automotive service providers to improve service quality and business operations.
• Target Areas: Polokwane, Lephalale, Mokopane, Phalaborwa, and Bela-Bela.
3. Empowerment : Focusing on Women Empowerment
• Scope: Provide business support support and training to women-owned businesses, promoting economic inclusion.
• Target Areas: Polokwane, Thohoyandou, Musina, Burgersfort, and Louis Trichardt.
We will also prioritize Industrial Economic Zone areas and their priorities.
Sign up on https://profilesmes.online/welcome/
To be eligible:
1. You must have a registered business and operate in Limpopo
2. Generate revenue
3. Sectors : Agriculture ( primary and secondary) and Automative
Women and Youth are encouraged to apply even if you don't fall in those sectors.
What Does the PARKTRONIC Inoperative, See Owner's Manual Message Mean for You...Autohaus Service and Sales
Learn what "PARKTRONIC Inoperative, See Owner's Manual" means for your Mercedes-Benz. This message indicates a malfunction in the parking assistance system, potentially due to sensor issues or electrical faults. Prompt attention is crucial to ensure safety and functionality. Follow steps outlined for diagnosis and repair in the owner's manual.
Fleet management these days is next to impossible without connected vehicle solutions. Why? Well, fleet trackers and accompanying connected vehicle management solutions tend to offer quite a few hard-to-ignore benefits to fleet managers and businesses alike. Let’s check them out!
Things to remember while upgrading the brakes of your carjennifermiller8137
Upgrading the brakes of your car? Keep these things in mind before doing so. Additionally, start using an OBD 2 GPS tracker so that you never miss a vehicle maintenance appointment. On top of this, a car GPS tracker will also let you master good driving habits that will let you increase the operational life of your car’s brakes.
𝘼𝙣𝙩𝙞𝙦𝙪𝙚 𝙋𝙡𝙖𝙨𝙩𝙞𝙘 𝙏𝙧𝙖𝙙𝙚𝙧𝙨 𝙞𝙨 𝙫𝙚𝙧𝙮 𝙛𝙖𝙢𝙤𝙪𝙨 𝙛𝙤𝙧 𝙢𝙖𝙣𝙪𝙛𝙖𝙘𝙩𝙪𝙧𝙞𝙣𝙜 𝙩𝙝𝙚𝙞𝙧 𝙥𝙧𝙤𝙙𝙪𝙘𝙩𝙨. 𝙒𝙚 𝙝𝙖𝙫𝙚 𝙖𝙡𝙡 𝙩𝙝𝙚 𝙥𝙡𝙖𝙨𝙩𝙞𝙘 𝙜𝙧𝙖𝙣𝙪𝙡𝙚𝙨 𝙪𝙨𝙚𝙙 𝙞𝙣 𝙖𝙪𝙩𝙤𝙢𝙤𝙩𝙞𝙫𝙚 𝙖𝙣𝙙 𝙖𝙪𝙩𝙤 𝙥𝙖𝙧𝙩𝙨 𝙖𝙣𝙙 𝙖𝙡𝙡 𝙩𝙝𝙚 𝙛𝙖𝙢𝙤𝙪𝙨 𝙘𝙤𝙢𝙥𝙖𝙣𝙞𝙚𝙨 𝙗𝙪𝙮 𝙩𝙝𝙚 𝙜𝙧𝙖𝙣𝙪𝙡𝙚𝙨 𝙛𝙧𝙤𝙢 𝙪𝙨.
Over the 10 years, we have gained a strong foothold in the market due to our range's high quality, competitive prices, and time-lined delivery schedules.
Ever been troubled by the blinking sign and didn’t know what to do?
Here’s a handy guide to dashboard symbols so that you’ll never be confused again!
Save them for later and save the trouble!
In this presentation, we have discussed a very important feature of BMW X5 cars… the Comfort Access. Things that can significantly limit its functionality. And things that you can try to restore the functionality of such a convenient feature of your vehicle.
5 Warning Signs Your BMW's Intelligent Battery Sensor Needs AttentionBertini's German Motors
IBS monitors and manages your BMW’s battery performance. If it malfunctions, you will have to deal with an array of electrical issues in your vehicle. Recognize warning signs like dimming headlights, frequent battery replacements, and electrical malfunctions to address potential IBS issues promptly.
Why Is Your BMW X3 Hood Not Responding To Release CommandsDart Auto
Experiencing difficulty opening your BMW X3's hood? This guide explores potential issues like mechanical obstruction, hood release mechanism failure, electrical problems, and emergency release malfunctions. Troubleshooting tips include basic checks, clearing obstructions, applying pressure, and using the emergency release.
Symptoms like intermittent starting and key recognition errors signal potential problems with your Mercedes’ EIS. Use diagnostic steps like error code checks and spare key tests. Professional diagnosis and solutions like EIS replacement ensure safe driving. Consult a qualified technician for accurate diagnosis and repair.
"Trans Failsafe Prog" on your BMW X5 indicates potential transmission issues requiring immediate action. This safety feature activates in response to abnormalities like low fluid levels, leaks, faulty sensors, electrical or mechanical failures, and overheating.
3. MECHANICAL INFORMATION - 3A-190-8065359840 893
Engine Identification
4 Cylinder
73584
a
a Location of G.M. Engine Code
MCM (Stern Drive) Code Rotation
3.0L RM,RJ
LH3.0LX RN,RK LH
V-6
72312
a - Location of GM Engine Code
a
MCM
(Stern Drive)
Code Rotation
4.3L Alpha LG
LH4.3LX Alpha LH LH
V-8
72312
a - Location of GM Engine Code
a
MCM (Stern Drive) Code Rotation
5.0L Alpha ZC
5.0LX Alpha ZD
5.0L Bravo ZC LH
5.7L Alpha MB
5.7L Bravo CD,MD
350Magnum Alpha
(See Note)
CD,MD
MIE (Inboard) Code Rotation
5 7L
NN LH
5.7L NR RH
5 7L Competition Ski
MB LH
5.7L Competition Ski MR RH
350 Magnum Tournament
Ski (See Note)
CD,MD LH
Note; Engines with roller lifters and steel camshaft
MCM (Stern Drive) Code Rotation
7.4L XW
LH454 Magnum XA LH
502Magnum EFI HJ
MIE (Inboard) Code Rotation
7.4L XY
LH8.2L FH LH
454 EFI Ski UA
INDEX
4. 3A-2 - MECHANICAL INFORMATION 90-806535940 893
3.0L and 3.0LX
Tools/Lubricants/Sealants
MERCURY MARINE SPECIAL TOOLS
91-24697 Piston Ring Expander
91-63209 Torch Lamp
KENT MOORE SPECIAL TOOLS
J5892 Valve Spring Compressor (Head on)
J8062 Valve Spring Compressor (Head off)
J23738-A Valve Stem Seal Tester
J8101 Valve Guide Cleaner
J8814 Valve Guide Reamer (Standard)
J5830-02 Valve Guide Reamer (.015 in. oversize)
J5802-01 Rocker Arm Stud Remover
J6880 Rocker Arm Stud Installer
J5715 Stud Bore Reamer (.003 in. oversize)
J6036 Stud Bore Reamer (.013 in. oversize)
J8089 Carbon Remover Brush
J5910-04 Piston Support Tool
J24086-B Piston Pin Tool
J3936-03 Piston Ring Groove Cleaner
J8037 Piston Ring Compressor
J5239 Connecting Rod Guide Tool (3/8 -24)
J8087 Cylinder Bore Checker
J8369 Oil Pump Suction Pipe Installer
J23042-B Timing Cover Seal Aligner
J8520 Cam Lobe Lift Indicator
J6098-01 Camshaft Bearing Installer/Remover Tool
J9534-01 Distributor Shaft Lower Bearing Installer/Remover
J6978-E Pulley Hub Puller
J5590 Pulley Hub Installer
J24420 Universal Torsional Damper Remover
LUBRICANTS/SEALANTS
92-34227--1 Quicksilver Perfect Seal
92-86154A1 Quicksilver 2-C-4 Marine Lubricant
92–91601-1 Quicksilver RTV Sealer
INDEX
5. MECHANICAL INFORMATION - 3A-390-8065359840 893
Torque Specifications
Fastener Location Lb. Ft. (N⋅m) Lb. In. (N⋅m)
Camshaft Sprocket Bolts 80 (9)
Connecting Rod Cap Nuts 45 (61)
Cylinder Head Bolts 90 (122) See Note 1
Distributor Clamp 20 (27)
Engine Coupler to Flywheel 35 (47)
Flywheel Housing to Block 21 (28)
Flywheel to Crankshaft Bolts 65 (88)
Front Cover Bolts 30 (3.4)
Front Mount to Block 21 (28)
Main Bearing Cap Bolts 65 (88)
Manifold to Head 23 (31) See Note 2
Oil Pan Bolts-Crankcase 80 (9)
Oil Pan Bolts -to Front Cover 45 (5)
Oil Pan Studs to Oil Seal Retainer
or Crankcase
15 (1.7)
Oil Pump Cover 72 (8)
Oil Pump to Block 120 (14)
Oil Pump Pickup 60 (7)
Rocker Arm Cover and Bolts 40 (4.5)
Rear Crankshaft Oil Seal Retainer
Nuts
135 (15)
Spark Plugs 22 (30)
Starter Motor to Block 37 (50)
Timing Gear Cover 72 (8)
Torsional Damper Bolt 50 (68)
Water Pump to Block 15 (20)
Note 1: Retorque after first 20 hours of operation.
Note 2: Retorque after first start up.
INDEX
6. 3A-4 - MECHANICAL INFORMATION 90-806535940 893
Engine Specifications
Model 3.0L/3.0LX
Displacement 181 CID (3.0L)
CYLINDER BORE
Diameter 3.9995-4.0025(101.588-101.790)
Out of Round
Production .0005(0.012) Max
Out of Round Service .002(0.05) Max
Taper Production
Thrust Side .0005(0.012) Max
Taper Production Relief Side .0005(0.012) Max
Service .001(0.02) Max
PISTON CLEARANCE
Production .0025-.0035(0.064-0.088) Max
Service .0035(0.08) Max
PISTON RING: COMPRESSION
Groove Clearance Production
Top
0012 0029(0 030 0 073)Groove Clearance Production 2nd .0012-.0029(0.030-0.073)
Service .003(0.09) Max
Gap Production
Top
010 020(0 254 0 762)Gap Production 2nd .010-.020(0.254-0.762)
Service .035(0.88) Max
PISTON RING: OIL
Groove
Clearance
Production .001-.006(0.026-0.152)
Clearance Service Limit .007(0.17) Max
Gap
Production .010-.030(0.254-0.762) Max
Gap Service Limit .040(1.01) Max
PISTON PIN
Diameter .9270-.9271(23.546-23.550)
Clearance
Production .0003–.0006(0.008-0.016)
Clearance Service Limit .001(0.02) Max
Fit in Rod .0008-.0019(0.020-0.050) Interference
UNIT OF MEASUREMENT
in. (mm)
INDEX
7. MECHANICAL INFORMATION - 3A-590-8065359840 893
CRANKSHAFT
Diameter 2.2979-2.294(58.367-58.404)
Taper
Production .0002(0.005) Max
Main Journal
Taper Service .001(0.02) Max
Out of Round
Production .0002(0.005) Max
Out of Round Service .001(0.02) Max
Production No.1-No.4 .001-.0024(0.025-0.060)
Main Bearing
Service No.5 .0016-.0035(0.041-0.088)
Main Bearing
Clearance Production No.1-No.4 .001-.0025(0.03-0.06)
Service No.5 .002-.0035(0.05-0.08)
Crankshaft End Play .002-.006(0.05-0.15)
Diameter 2.09980-20995(53.289-53.327)
Taper
Production .0003(0.007) Max
Crankpin
Taper Service .001(0.02) Maxp
Out of Round
Production .0002(0.51) Max
Out of Round Service .001(0.02) Max
Rod Bearing
Clearance
Production .0017-.0027(0.044-0.0686)
Clearance Service
Rod Size Clearance .006-.017(0.153-0.4318) Max
CAMSHAFT
Lobe Lift (Max )
Intake .2529(6.425)
Lobe Lift (Max.) Exhaust .2529(6.425)
Journal Diameter 1.8677-18697(47.440-47.490)
Camshaft End Play .003-.008(0.08-0.2032) Max
CYLINDER HEAD
Gasket Surface Flatness .003-.008in any 6 in.(152)
or .007(0.15) Overall Max
INDEX
8. 3A-6 - MECHANICAL INFORMATION 90-806535940 893
VALVE SYSTEM
Lifter Hydraulic
Rocker Arm Ratio 1.75 to 1
Collapsed Tappet Gap Half to 1 Turn Down from Zero Lash
Face Angle
Intake 45°
Face Angle Exhaust 45°
Seat Angle (Intake & Exhaust) 46°
Seat Runout (Intake & Exhaust) .002(0.05) Max
Seat Width
Intake 1/16 (.0625)in. (1.16 mm)
Seat Width Exhaust 1/16-5/64 [.0625-.07812] in. (1.6-2.0 mm)
Production
Intake .0010-.0027(0.025-0.069)
Stem
Production Exhaust .0007-.0027(0.018-0.069)
Stem
Clearance
Service
Intake .003(0.09) Max
Service Exhaust .004(0.11) Max
Free Length 2-1/16(52)
Pressure
Valve Closed 100-110 lb. (136-149 N) at 1-19/32 in. (41 mm)
Spring
Pressure Valve Open 208-220 lb. (282-300 N) at 1-7/32 in. (31 mm)p g
Installed
Height±
Intake
(1/32)1.6562(42)Height±
.031(8) Exhaust
(1/32)1.6562(42)
Internal Damper None
INDEX
9. MECHANICAL INFORMATION - 3A-790-8065359840 893
4.3L and 4.3LX
Tools/Lubricants/Sealants
MERCURY MARINE SPECIAL TOOLS
91-24697 Piston Ring Expander
91-35547 Engine Coupler Wrench
92-823089 Quicksilver Loctite A
92-34227 Quicksilver Perfect Seal
92-91601-1 Quicksilver RTV Sealer
Obtain Locally General Motors Cam and Lifter Prelude
SNAP-ON SPECIAL TOOLS
TA360 Torque Angle Gauge (Degree Wheel Torquing)
KENT-MOORE SPECIAL TOOLS
J5982 Valve Spring Compressor (Head On)
J8062 Valve Spring Compressor (Head Off)
J8056 Valve Spring Tester
J8101 Valve Guide Cleaner
J5830-2 Valve Guide Reamer
J7049 Valve Guide Reamer
J8089 Carbon Remover Brush
J24086-B Piston Pin Remover Kit
J3936-03 Piston Ring Groove Cleaner
J8037 Piston Ring Compressor
J5239 Connecting Rod Bolt Guide Set (3/8-24)
J21882 Oil Pump Suction Pipe Installer
J6098-01 Camshaft Bearing Remover and Installer Set
J8520-1 Ball Socket Adapter Tool Kit (Lift Indicator)
J23523-E Torsional Damper Remover and Installer
J35468 Crankcase Front Cover Seal Installer
J5825-A Crankcase Gear and Sprocket Puller
J5590 Crankcase Gear and Sprocket Installer
J23590 Air Adapter
J8080 Main Bearing Remover and Installer
J26817-A Rear Main Seal Installer
J26941 Balance Shaft Rear Bearing Remover
J38834 Balance Shaft Bearing Remover and Installer
INDEX
10. 3A-8 - MECHANICAL INFORMATION 90-806535940 893
Torque Specifications
Fastener Location Lb. Ft. (N.m) Lb. In. (N.m)
Alternator Brace to Alternator 192(28)
Alternator Brace to Engine 30(41)
Alternator to Mounting Bracket 35(48)
Alternator Mounting Bracket 30(41)
Balance Shaft Drive Gear Retaining Stud 120(16)
Balance Shaft Driven Gear Bolt (Torque Plus 35°) 15(20)
Balance Shaft Thrust Plate 120(14)
Camshaft Sprocket 20(27)
Camshaft Thrust Plate 106(12)
Carburetor 132(15)
Connecting Rod Cap Nuts (Torque Plus 60°) 20(27)
Coupler/Flywheel(MCM) 35(48)
Crankcase Front Cover 124(14)
Crankshaft Pulley Bolt (Cast Aluminum) 40(54)
Cylinder Head 65(88)
Distributor Hold Down 25(34)
Exhaust Manifold 20(27)
Flywheel 75(100)
Flywheel Housing to Block 30(41)
Flywheel Housing Cover 80(9)
Front Mount Bracket 30(41)
Fuel Filter Bracket Bolt 25(34)
Fuel Pump Bracket Bolt 25(34)
Fuel Pump Inlet Fitting (Large Diameter See Note) 96(10.8)
Fuel Pump Inlet Fitting (Small Diameter See Note) 84(9.5)
Intake Manifold 35(48)
Main Bearing Cap 75(100)
Oil Filter Adapter Bolts 15(20)
Oil Pan Drain Plug 15(20)
Note : Hold Fuel Pump using wrench on flat surface at outlet before tightening brass fitting
INDEX
11. MECHANICAL INFORMATION - 3A-990-8065359840 893
Fastener Location Lb. Ft. (N⋅m) Lb. In. (N⋅m)
OIl Pan Screw (1/4-20) 80(9)
Oil Pan Nuts (5/16-20) 165(19)
OIl Pump 65(68)
Oil Pump Cover 80(9)
Power Steering Pump Brace to Block 30(41)
Power Steering Pump Bracket 30(41)
Rear Crankshaft Oil Seal Retainer Screws and Nuts 133(15)
Rear Mount (MCM) 40(54)
Rocker Arm Cover 50(5.5)
Rocker Arm Nuts 20(27)
Roller Lifter Restrictor Plate 12(16) 144(16)
Seawater Pump Brace (if equipped) 30(41)
Seawater Pump Bracket (if equipped) 30(41)
Spark Plugs 15(20) 180(20)
Starter Motor 50(68)
Thermostat Housing 30(41)
Torsional Damper 40(54)
Water Circulating Pump 30(41)
Water Temperature Sender 20(27)
INDEX
12. 3A-10 - MECHANICAL INFORMATION 90-806535940 893
Engine Specification
Unit of Measurement
in. (mm)
Engine Model 4.3L/43LX
Displacement 262 CID (4.3 Litre)
Bore 4.00(101.6)
Stoke 3.48(88.39)
Compression Ratio 9.05:1
Heads Cast Iron
Intake Manifold Cast Iron
Block Cast Iron (2 Bolt Main Bearing Caps)
Rods Forged Steel
Pistons Cast Aluminum
Crankshaft Cast Iron
Camshaft Steel
72976
LH ROTATION
FRONT
Firing Order
1-6-5-4-3-2
INDEX
13. MECHANICAL INFORMATION - 3A-1190-8065359840 893
Model 4.3L/4.3LX
Displacement 262 CID (4.3L)
CYLINDER BORE
Diameter 4.000-4.001(101.617-101.643)
Out of Round
Production .001(0.025) Max
Out of Round Service .002(0.05) Max
Taper Production
Thrust Side .0005(0.012) Max
Taper Production Relief Side .001(0.02) Max
Service .001(0.02) Over Production
PISTON CLEARANCE
Production .0007-.0017(0.017-0.043) Max
Service .0027(0.07) Max
PISTON RING: COMPRESSION
Production
Top
.0012-.0032(0.030-0.081)
Groove Clearance
Production
2nd
.0012-.0032(0.030-0.081)
Service High Limit Production+.001(0.025)
Gap Production
Top .010-.020(0.254-0.508)
Gap Production 2nd .010-.025(.0254-.0635)
Service High Limit Production + .010(0.25)
PISTON RING: OIL
Groove
Clearance
Production .002-.007(0.051-0.177)
Clearance Service High Limit Production + .001(0.025)
Gap
Production .015-.055(0.381-1.397)
Gap Service Limit High Limit Production + .010(0.254)
PISTON PIN
Diameter .9270-.9273(23.546-23.553)
Clearance
Production .0002–.0007(0.005-0.017)
Clearance Service Limit .001(0.02) Max
Fit in Rod .0008-.0016(0.020-0.0406) Interference
INDEX
14. 3A-12 - MECHANICAL INFORMATION 90-806535940 893
CRANKSHAFT
Diameter
No.1 2.4484-2.4493(62.198-62.212)
Diameter No. 2, 3 2.4481-2.4490(62.181-62.204)
M i
No.4 2.4479-2.4488(62.176-62.199)
Main
Journal Taper
Production .0002(0.005) Max
Journal Taper Service .001(0.02) Max
Out of Round
Production .0002(0.005) Max
Out of Round Service .001(0.005) Max
Production
No.1 .0008-.0020(0.020-0.050)
Production No.2, 3 .0011-.0023(0.027-0.058)
Main Bearing
Cl
No.4 .0017-.0032(0.043-0.081)g
Clearance
Service
No.1 .0010-.0015(0.03)
Service No.2, 3 .0010-.0025(0.03-0.06)
No.4 .0025-.0035(0.07-0.08)
Crankshaft End Play .002-.006(0.05-0.15)
Diameter 2.2487-2.2497(57.117-57.142)
Connecting Rod Taper
Production .0005(0.021) Max
Connecting Rod
Journal
Taper Service .001(0.02) Max
Out of Round
Production .0005(0.021) Max
Out of Round Service .001(0.02) Max
Rod Bearing Clearance
Production .0013-.0035(0.033-0.088)
Rod Bearing Clearance Service .003(0.07) Max
Rod Side Clearance .006–.014(0.15-0.35)
Crankshaft Runout .0015(0.038) Max
INDEX
15. MECHANICAL INFORMATION - 3A-1390-8065359840 893
VALVE SYSTEM
Lifter Hydraulic
Rocker Arm Ratio 1.70 to 1
Valve Lift
Intake .394(10.00)
Valve Lift Exhaust .404(10.26)
Valve Lash (Intake and Exhaust) Fixed Lash
Face Angle (Intake & Exhaust) 45°
Seat Angle (Intake & Exhaust) 46°
Seat Runout (Intake & Exhaust) .002(0.05) Max
Seat Width
Intake 1/32-1/16 [.03125-.0625] in. (0.79-1.58 mm)
Seat Width Exhaust 1/16-3/32 [.0625-.09375] in. (1.58-2.38 mm)
Production
Intake .0010-.0027(0.025-0.069)
Stem Clear-
Production Exhaust .0010-.0027(0.025-0.069)
Stem Clear-
ance
Service
Intake .0037(0.09) Max
Service Exhaust .0047(0.11) Max
Stem Diameter
Intake .341(8.66)
Stem Diameter Exhaust .372(9.45)
Valve Margin Intake and Exhaust 1/32 (0.79)
VALVE SPRING
Free Length 2.03(51.6)
Valve Spring Pressure
Valve Closed 76-84 Lb. (338-374 N) at1.785 [1-45/64](43.16)
Valve Spring Pressure Valve Open 194-204 Lb. (863-916 N) at 1.250[1-1/4](31.75)
Installed Height 1.70 [1-45/64](47.24)
Damper Free Length 1.86 [1-55/64](47)
Approximate Number of Coils 4
NOTE: Test spring pressure with damper removed
INDEX
16. 3A-14 - MECHANICAL INFORMATION 90-806535940 893
CAMSHAFT AND DRIVE
Lobe Lift ±
002(0 051)
Intake .269(6.89)
.002(0.051) Exhaust .273(6.93)
Journal Diameter 1.8682-1.8692(47.452-47.478)
Journal Out of Round .001(0.025) Max
Camshaft Runout .002(0.051) Max
Camshaft End Play .004-.012(0.11-0.30)
Timing Chain Deflection .375(9.5) from taut position [total .75 (19)]
FLYWHEEL
Runout .008(0.203) Max
CYLINDER HEAD
Gasket Surface Flatness .004(0.10) Overall Maximum
BALANCE SHAFT
Front Bearing Journal 1.1812-1.1815(30.002-30.010)
Rear Bearing Journal 1.4209-1.4215(36.091-36.106)
Rear Bearing Inside Diameter Assembled Production 1.501-1.503(37.525-37.575)
Rear Bearing Outside Diameter Production 1.875-1.876(46.875-46.900)
Rear Cylinder Block Housing Bore Production 1.873-1.874(46.825-46.850)
INDEX
17. MECHANICAL INFORMATION - 3A-1590-8065359840 893
305/5.0L/350/5.7L
Tools/Lubricants/Sealants
MERCURY MARINE SPECIAL TOOLS
91-24697 Piston Ring Expander
91-35547 Engine Coupler Wrench
91-66273 Rocker Stopper
92-32609-1 Quicksilver Loctite
92-34227 Quicksilver Perfect Seal
92-42649A1 Quicksilver Needle Bearing Assembly Grease
92-91601-1 Quicksilver RTV Sealer
Obtain Locally General Motors Cam and Lifter Prelube or Equivalent
KENT-MOORE SPECIAL TOOLS
J5892 Valve Spring Compressor (Head on)
J8062 Valve Spring Compressor (Head off)
J8056 Valve Spring Tester
J8101 Valve Guide Cleaner
J7049 Valve Guide Reamer (Standard)
J5830-02 Valve Guide Reamer (.015 in. oversize)
J5802-01 Rocker Arm Stud Remover
J6880 Rocker Arm Stud Installer
J5715 Stud Bore Reamer (.003 in. oversize)
J6036 Stud Bore Reamer (.013 in. oversize)
J8089 Carbon Remover Brush
J24086-B Piston Pin Tool
J3936-03 Piston Ring Groove Cleaner
J8037 Piston Ring Compressor
J5239 Connecting Rod Guide Tool (3/8 -24)
J21882 Oil Pump Suction Pipe Installer
J6098-01 Camshaft Bearing Installer/Remover Tool
J8520-1 Ball Socket Adapter
J23523-E Torsional Damper Remover and Installer
J35468 Crankcase Front Cover Seal Installer
J5825-A Crankshaft Gear and Sprocket Puller
J5590 Crankshaft Gear and Sprocket Installer
J23590 Air Adapter
INDEX
18. 3A-16 - MECHANICAL INFORMATION 90-806535940 893
KENT-MOORE SPECIAL TOOLS
J8080 Main Bearing Remover and Installer
J26817-A Rear Main Seal Installer
Torque Specifications
Fastener Location Lb. Ft. (N.m) Lb. In. (N.m)
Alternator Brace to Alternator 192(28)
Alternator Brace to Engine 30(41)
Alternator to Mounting Bracket 35(48)
Alternator Mounting Bracket 30(41)
Camshaft Sprocket Gear 18(24) 216(24)
Carburetor 132(15)
Connecting Rod Cap Nuts 45(61)
Coupler/Flywheel(MCM) 35(48)
Crankshaft Pulley 35(48)
Cylinder Head 65(88)
Distributor Hold Down 25(34)
Exhaust Manifold 20(27)
Filter Adapter (5/16-18) 20(27)
Flywheel 75(100)
Flywheel Drive Plate (MIE) 35(48)
Flywheel Housing to Block 30(41)
Flywheel Housing Cover 80(9)
Front Mount Bracket 30(41)
Fuel Pump 25(34)
Intake Manifold 35(48)
Main Bearing Cap 80(109)
Oil Baffle Nuts 25(34)
Oil Filter Adapter Bolts 15(20)
Oil Pan Drain Plug 15(20)
Oil Pan Screw (1/4-20) 80(9)
Oil Pan Nuts (5/16-18) 165(19)
Oil Pump 65(88)
Oil Pump Cover 80(9)
Power Steering Pump Brace to Block 30(41)
Power Steering Pump Bracket 30(41)
Rear Crankshaft Oil Seal Retainer Screws and Nuts 133(15)
Rear Mount (MCM) 40(54)
Rear Mount (MIE) 50(68)
INDEX
19. MECHANICAL INFORMATION - 3A-1790-8065359840 893
Fastener Location Lb. Ft. (N⋅m) Lb. In. (M⋅n)
Remote Oil Connector (1/2 in. x 13) 25(34)
Remote Oil Filter Adapter Nut/Fitting 20(27)
Spark Plugs 15(20)
Starter Motor 50(68)
Thermostat Housing 30(41)
Timing Chain or Gear Cover 100(11)
Torsional Damper 40(54)
Transmission To Housing 50(68)
Water Circulating Pump 30(41)
Water Temperature Sender 20(27)
Rocker Arm Cover 90(10)
Roller Lifter Restrictor Retainer Plate 12(16)
Seawater Pump Brace 30(41)
Seawater Pump Bracket 30(41)
INDEX
20. 3A-18 - MECHANICAL INFORMATION 90-806535940 893
Engine Specifications
Unit Of Measurement
In. (mm)
Engine
Model
MCM
5.0L
MCM
5.0LX
MCM
5.0L
Bravo
MCM
5.7L
Alpha
MCM
5.7L
Bravo
MCM
350
Magnum
Alpha
MIE
5.7L
MIE
5.7L
Comp.
Ski
MIE
Magnum
Tour.
Ski
Displace-
ment
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)
Com-
pression
Ratio
9.1:1
Heads Cast Iron
Intake
Manifold
Cast Iron (Magnums-High Rise-See Note 2)
Block Cast Iron (2 Bolt Main Bearing Caps)
Rods Forged Steel
Crank-
shaft
Cast Iron
Pistons Cast Aluminum
Cam-
shaft
Cast Iron Steel
(See Note 1)
Cast Iron Steel
(Note 1)
Fuel
Pump
Push
Rod
Steel
Cast Iron
(See Note 1)
Steel Cast Iron
(See
Note 1)
NOTE1: Engine with roller lifters and steel camshaft
NOTE 2: Includes- 350 Magnum Alpha,5.7L Bravo and 350Magnum Tournament Ski
7200972008
A
LH ROTATION
FRONT
B
RH ROTATION
FRONT
Firing Order
1-8-4-3-6-5-7-2
Firing Order
1-2-7-5-6-3-4-8
INDEX
21. MECHANICAL INFORMATION - 3A-1990-8065359840 893
Model 5.0L/5.0LX 5.7L/350 Magnum
Displacement 305 CID (5.0L) 350 CID (5.7L)
CYLINDER BORE
Diameter 3.7350-3.7385
(94.8690-94.9579)
3.9995-4.0025
(101.5873-101.6635)
Out of Round
Production .001(0.025) Max
Out of Round Service .002(0.05) Max
Taper Production
Thrust Side .0005(0.012) Max
Taper Production Relief Side .001(0.02) Max
Service .001(0.02) Over Production
PISTON CLEARANCE
Production .0007-.0017(0.017-0.043) Max
Service .0027(0.07) Max
PISTON RING: COMPRESSION
Production
Top
0012 0032(0 030 0 081)
Groove Clearance
Production
2nd
.0012-.0032(0.030-0.081)
Groove Clearance
Service High Limit Production + .001(0.025)
Gap Production
Top .010-.020(0.254-0.508)
010 025( 0254 0635)Gap Production 2nd .010-.025(.0254-.0635)
Service High Limit Production + .010(0.25)
PISTON RING: OIL
Groove
Clearance
Production .002-.007(0.051-0.177)
Clearance Service High Limit Production + .001(0.025)
Gap
Production .015-.055(0.381-1.397)
Gap Service Limit High Limit Production + .010(0.254)
PISTON PIN
Diameter .9269-.9271(23.545-23.553)
Clearance
Production .0002–.0007(0.005-0.017)
Clearance Service Limit .001(0.02) Max
Fit in Rod .0008-.0016(0.020-0.406) Interference
INDEX
22. 3A-20 - MECHANICAL INFORMATION 90-806535940 893
CRANKSHAFT
Diameter
No.1 2.4484-2.4493(62.198-62.212)
Diameter No. 2, 3 2.4481-2.4490(62.181-62.204)
M i
No.4 2.4479-2.4488(62.176-62.199)
Main
Journal Taper
Production .0002(0.005) Max
Journal Taper Service .001(0.02) Max
Out of Round
Production .0002(0.005) Max
Out of Round Service .001(0.005) Max
Production
No.1 .0008-.0020(0.020-0.050)
Production No.2, 3 .0011-.0023(0.027-0.058)
Main Bearing
Cl
No.4 .0017-.0032(0.043-0.081)g
Clearance
Service
No.1 .0010-.0015(0.03)
Service No.2, 3 .0010-.0025(0.03-0.06)
No.4 .0025-.0035(0.07-0.08)
Crankshaft End Play .002-.006(0.05-0.15)
Diameter 2.0988-2.0998(57.117–57.142)
Connecting Rod Taper
Production .0005(0.021) Max
Connecting Rod
Journal
Taper Service .001(0.02) Max
Out of Round
Production .0005(0.021) Max
Out of Round Service .001(0.02) Max
Rod Bearing Clearance
Production .0013-.0035(0.033-0.088)
Rod Bearing Clearance Service .003(0.07) Max
Rod Side Clearance .006–.014(0.15-0.35)
Crankshaft Runout .0015(0.0381) Max
INDEX
23. MECHANICAL INFORMATION - 3A-2190-8065359840 893
VALVE SYSTEM
Engine 5.0L/5.7L 5.7L/350 Magnum
Lifter Type Flat Hydraulic
Flat Hydraulic
Lifter Type Flat Hydraulic Roller Hydraulic
Rocker Arm Ratio 1.50 to 1
Valve Lift
Intake .394(10.00)
Valve Lift Exhaust .404(10.26)
Valve Lash (Intake and Exhaust) 1 Turn Down from Zero Lash
Face Angle
Intake 45°
Face Angle Exhaust 45°
Seat Angle (Intake & Exhaust) 46°
Seat Runout (Intake & Exhaust) .002(0.05) Max
Seat Width
Intake 1/32-1/16 [.03215-.0625] in. (0.79-1.58 mm)
Seat Width Exhaust 1/16-3/32 [.0625-.09375] in. (1.58-2.38 mm)
Production
Intake .0010-.0027(0.025-0.069)
Stem Clear-
Production Exhaust .0010-.0027(0.025-0.069)
Stem Clear-
ance
Service
Intake .0037(0.09) Max
Service Exhaust .0047(0.11) Max
Stem Diameter
Intake .341(8.66)
Stem Diameter Exhaust .372(9.45)
Valve Margin Intake and Exhaust .0312(0.79)
VALVE SPRING
Free Length 2.03(51.6) (See Note 1)
Valve Spring
24 48347
Pressure
(NOTE 1)
Valve Closed 76-84 Lb. Ft.(103-113 N⋅m) at1.785(43.16)
24-48347
Lavender
(NOTE 1) Valve Open 194-204 Lb. Ft. (263-279 N⋅m) at 1.250(31.75)
Lavender
Stripe Installed
Height
Intake 1.7[1-45/64](43)
Damper
Free Length 1.86[1-55/64](47)
Damper Approximate Number of Coils 4
NOTE 1: Test spring pressure with damper removed
INDEX
24. 3A-22 - MECHANICAL INFORMATION 90-806535940 893
CAMSHAFT AND DRIVE
Engine 5.0L/5.0LX 5.7L/350 Magnum
Lobe Lift ± 002(0 051)
Exhaust
263(6 680)
.263(6.680)
Lobe Lift ± .002(0.051) Intake .263(6.680) .287(7.29) (See Note)
Duration at .050 In.(1.27mm)
Cam Lift
Exhaust
0269(6 833)
.269(6.833)
Cam Lift Intake 0269(6.833) .300(7.62) (See Note)
Journal Diameter 1.8682-1.8692(47.452-47.478)
Journal Out Of Round .001(0.025) Max
Camshaft Runout .002(0.051) Max
Timing Chain Deflection
[LH (Standard) Rotation Engine Only]
.375(9.5) from taut position [total .75(19)]
Camshaft Timing Gear Runout
[RH (Opposite) Rotation Engine Only]
.004(0.012) Max
Crankshaft Timing Gear Runout
[RH (Opposite)Rotation Engine Only]
.003(0.076) Max
Camshaft to Crankshaft Timing Gear Back-
lash[RH (Opposite)Rotation Engine Only]
.004-.006(0.102-0.152) New Gears
.004-.008(0.102-0.203) Used Gears
Note : Engines with roller lifters and steel camshaft
FLYWHEEL
Runout .008(0.203) Max
CYLINDER HEAD
Gasket Surface Flatness .004(0.10) Overall Maximum
INDEX
25. MECHANICAL INFORMATION - 3A-2390-8065359840 893
454 CID (7.4L) and 502 CID (8.2L)
Tool/Lubricants/Sealants
MERCURY MARINE SPECIAL TOOLS
91-24697 Piston Ring Expander
91-35547 Engine Coupler Wrench
92-32609-1 Quicksilver Loctite A
92-34227 Quicksilver Perfect Seal
92-91601-1 Quicksilver RTV Sealer
Obtain Locally General Motors Cam and Lifter Prelube or Equivalent
KENT-MOORE SPECIAL TOOLS
J5892 Valve Spring Compressor (Head on)
J8062 Valve Spring Compressor (Head off)
J8056 Valve Spring Tester
J8101 Valve Guide Cleaner
J8089 Carbon Remover Brush
J24086-B Piston Pin Tool
J3936-03 Piston Ring Groove Cleaner
J8037 Piston Ring Compressor
J5239 Connecting Rod Guide Tool (3/8 -24)
J35228 Connecting Rod Guide Tool (7/16-20)
J21882 Oil Pump Suction Pipe Installer
J8520 Lift Indicator Tool
J23523-E Torsional Damper Remover and Installer
J22102 Crankcase Front Cover Seal Installer
J24420-B Crankshaft Gear and Sprocket Puller
J20158-20 Crankshaft Gear and Sprocket Installer
J23590 Air Adapter (Cylinder Inflator)
J8080 Main Bearing Remover and Installer
J38841 Rear Main Seal Installer
INDEX
26. 3A-24 - MECHANICAL INFORMATION 90-806535940 893
Torque Specifications
Fastener Location Lb. Ft. (N⋅m) Lb. In. (N⋅m)
Alternator Brace to Alternator 192(28)
Alternator Brace to Engine 30(41)
Alternator to Mounting Bracket 35(48)
Alternator Mounting Bracket 30(41)
Camshaft Sprocket Gear 18(24) 216(24)
Carburetor 132(15)
Connecting Rod Caps (3/8-24) 50(68)
(7/16-20) 73(99)
Coupler/Flywheel(MCM) 35(48)
Crankcase Front Cover 120(14)
Crankshaft Pulley 35(48)
Cylinder Head 85(115)
Distributor Hold Down 20(27)
Exhaust Manifold 30(41)
Exhaust Manifold Elbow 30(41)
Filter Adapter (5/16-18) 20(27)
Flywheel 75(100)
Flywheel Drive Plate (MIE) 35(48)
Flywheel Housing to Block 30(41)
Flywheel Housing Cover 80(9)
Front Mount Bracket 30(41)
Fuel Pump 25(34)
Intake Manifold 35(48)(See Note)
Main Bearing Cap 110(149)
Oil Baffle Nuts 25(34)
Oil Filter Adapter Nuts 40(54)
Oil Pan Bolts (5/16-18) 80(9)
Oil Pan Drain Plug 15(20)
Oil Pump 70(95)
Oil Pump Cover 80(9)
Power Steering Pump Brace to Block 30(41)
Power Steering Pump Bracket 30(41)
Rear Mount (MCM) 40(54)
Rear Mount (MIE) 50(68)
Remote Oil Connector (1/2 in. x 13) 25(34)
Remote Oil Filter Adapter Nut/Fitting 20(27)
Rocker Arm Bolts 45(61)
Rocker Arm Cover 90(10)
INDEX
27. MECHANICAL INFORMATION - 3A-2590-8065359840 893
Fastener Location Lb. Ft. (N⋅m)
Seawater Pump Brace 30(41)
Seawater Pump Bracket 30(41)
Spark Plugs 15(20)
Starter Motor 50(68)
Thermostat Housing 30(41)
Torsional Damper 40(54)
Transmission To Housing 50(68)
Water Circulating Pump 35(48)
Water Temperature Sender 20(27)
INDEX
28. 3A-26 - MECHANICAL INFORMATION 90-806535940 893
454/7.4L/502/8.2L Engine Specifications
Unit of Measurement
In. (mm)
Engine Model MCM
7.4L
MIE
7.4L
MCM
7.4L
Bravo
Three
MCM 454
Mag-
num/454
Magnum
EFI
MIE 454
EFI SKI
MIE8.2L, MCM 502 Magnum
MCM 502 Magnum EFI
Displacement 454 CID(7.4L) 502 CID(8.2L)
Bore 4.25 (108) 4.46 (113.28)
Stroke 4.00 (101.6)
Compression Ratio 8.0:1 8.6:1 8.75:1
Heads Cast Iron (Oval Port) Cast Iron (Rectangular Port)
Intake Manifold Cast Iron Aluminum with Brass Inserts-High Rise (See Note)
Block Cast Iron (4 Bolt Main Bearing Caps)
Rods Forged Steel
Pistons Cast Aluminum Forged Aluminum
Crankshaft Cast Steel Forged Steel
Camshaft Cast Iron
NOTE: The 454/502 EFI Magnum is equipped with a cast aluminum intake manifold
Engine
7.4L
Bravo One
Bravo Two
7.4L Bravo
Three
454 Magnum/
454 Magnum EFI/
454 EFI Ski
502 Magnum EFI/
8.2L
CYLINDER BORE
Diameter 4.2500-4.2507
(107.950-107.967)
4.2500-4.2507
(107.950-107.967)
4.2451-4.2525
(107.826-108.013)
4.4655-4.4662
(113.423-113.441)
Out of Round Produc-
tion
.001(0.025) Max
Service .002(0.05) Max
Taper Pro-
duction
Thrust
Side
.0005(0.0127) Max
duction Relief
Side
.001(0.0254) Max
Service .001(0.02) Over Production
PISTON
Clearance
Production .0030-.0042
(0.0762-0.1066)
.0025-.0037
(0.0635-0.0939)
.0040-.0057
(0.1016-0.1447)
Service .005(0.12) Max .0075(0.15) Max .0065(0.16) Max
INDEX
29. MECHANICAL INFORMATION - 3A-2790-8065359840 893
Engine
7.4L
Bravo One
Bravo Two
7.4L Bravo
Three
454 Magnum/
454 Magnum EFI/
454 EFI Ski
502 Magnum EFI/
8.2L
PISTON RING
C
o
Groove
Side
Pro-
duction
T
o
p
.0012-.0029
(0.0305-0.0737)
.0017-.0032
(0.044-0.081)
.0017-.0032
(0.044-0.081)
o
m
p
r
Side
Clear-
ance
2
n
d
.0012-.0029
(0.0305-0.0737)
.0017-.0032
(0.044-0.081)
.0017-.0032
(0.044-0.081)
r
e Service High Production Limit +.010(0.02) Max
s
s
i
o Gap
Pro-
duction
T
o
p
.010-.018
(0.25-0.46)
.011-.021
(0.28-0.53)
o
n
Gap 2
n
d
.016-.024
(0.41-0.61)
.016-.026
(0.41-0.66)
Service High Limit Production + .010(0.25) Max
Groove
Side
Produc-
tion
.0050-.0065(0.127-0.165)
Oil
Side
Clear-
ance
Service
High Limit Production + .001(0.25) High Limit
Production
.005(0.12) Max
Oil
Gap
Produc-
tion
.010-.030
(0.254-0.762)
.020-.035
(0.508-0.889)
.010-.030
(0.254-0.76)
Gap
Service
High Limit Production + .001(0.25) High Limit
Production
.005(0.12) Max
Engine 7.4L
454 Magnum/
7.4L Bravo
Three/454 EFI
Ski/454 EFI Mag-
num
502 Magnum
502 Magnum EFI
8.2L
PISTON PIN
Diameter .9895-.9897
(25.132-25.1371)
.9895-.9898
(25.134-24.140)
Clearance In Pin
Produc-
tion
.0002-.0007
(0.0050-0.0177)
.00025-.00035
(0.0064-0.0088)
Service .001(0.025) Max
Fit In Rod
.0021-.0031
(0.0533-0.0787)
Interference
.0008-.0016(0.021-0.040)
Interference
INDEX
30. 3A-28 - MECHANICAL INFORMATION 90-806535940 893
Engine
7.4L/454 Mag-
num/454 EFI
Ski/454 EFI
Magnum
502 Magnum/502 Magnum EFI
8.2.L
CRANKSHAFT
Diameter No.1,2,3,4,5 2.7482-2.7489(69.8042-69.8220)
Main Taper
Production .0002(0.005) Max
Main
Journal
Taper Service .001(0.02) Max
Out of Round
Production .0002(0.005) Max
Out of Round Service .001(0.005) Max
Production
No.1,2,3,4 .0007-.0030(0.043-0.076)
Production No.5 .0025-.0038(0.063-0.096)
Main Bearing
Clearance
Service
No.1 .001-.003
(0.03-0.07)
.0010-.0015
(0.0254-0.0381)
Service No.2,3,4 .001-.003
(0.03-0.07)
.0010-.0025
(0.0254-0.0635)
No.5 .0025-.0040(55.8546-55.8698)
Crankshaft End Play .006-.0010(0.15-0.2)
Diameter 2.1990-2.1996(57.8546–57.8698)
Connecting Rod Taper
Production .0005(0.021) Max
Connecting Rod
Journal
Taper Service .001(0.02) Max
Out of Round
Production .0005(0.021) Max
Out of Round Service .001(0.02) Max
Rod Bearing Clearance
Production .0011-.0029(0.028-0.074)
Rod Bearing Clearance Service .003(0.076) Max
Rod Side Clearance .013-.023(0.35-0.58)
Crankshaft Runout @ No.3 main Bearing .0015(0.038)
Max
.0035(0.088) Max
INDEX
31. MECHANICAL INFORMATION - 3A-2990-8065359840 893
Engine Model 7.4L/
7.4L Bravo
Three
454 Mag-
num/454 EFI
SKI/454 EFI
Magnum
502 MagnumEFI/8.2L
VALVE SYSTEM
Lifter Roller Hydraulic
Rocker Arm Ratio 1.70 to 1
Valve Lift
Intake .394(10.00)
Valve Lift Exhaust .404(10.26)
Valve Lash (Intake and Exhaust) Fixed Lash
Face Angle (Intake & Exhaust) 45°
Seat Angle (Intake & Exhaust) 46°
Seat Runout (Intake & Exhaust) .002(0.05) Max
Seat Width
Intake 1/32-1/16 [.03125 .0625] in. (0.79-1.58 mm)
Seat Width Exhaust 1/16-3/32 [.0625-.09375] in.(1.58-2.38 mm)
Production
Intake .0010-.0027(0.025-0.069)
Stem Clear-
Production Exhaust .0012-.0029(0.0304-0.0736)
Stem Clear-
ance
Service
Intake .001(0.02) .003(0.07) .0037(0.09)
Service Exhaust .002(0.05) .004(0.10) .0049(0.12)
Stem Diameter
Intake .372(9.45)
Stem Diameter Exhaust .372(9.45)
Valve Margin Intake and Exhaust .0312(0.79)
INDEX
32. 3A-30 - MECHANICAL INFORMATION 90-806535940 893
Engine Model 7.4L
454 Magnum/502
Magnum/502 Mag-
numEFI/EFI 8.2L
VALVE SPRING
Free Length 2.12(53.9) 2.15(54.6)
Valve Spring
(Note 1)
Closed at
1.88 in. (47.8 mm)
Does Not
Apply
110Lbs.
(489N)
(Note 1)
(Note 2) Pressure
Closed at
1.80 in. (45.7 mm)
74-86 Lbs.
(329-382 N)
Does Not
Apply
Open at
1.34 in. (35.1 mm)
Does Not
Apply
316 Lbs.
(1406N)
Open at
1.40 in. (35.6 mm)
195-215 Lbs.
(867-956 N)
Does Not
Apply
Installed Height 1.875(47.6) 1.88(47.7)
Damper or Damper
Shield
Free Length Does Not
Apply
1.86(47.2)
Shield Approximate Number Of Coils Apply 4
Valve Spring Fit in Damper Shield .42-.094(1.07-2.38)
Interference
Does Not
Apply
NOTE 1: 454/502/8.2L Models Only-Test spring pressure with inner and outer spring assembled.
NOTE 2: 7.4L Models Only Test spring pressure with damper shield installed.
INDEX
33. MECHANICAL INFORMATION - 3A-3190-8065359840 893
Engine 7.4L/7.4L Bravo Three
454 Magnum/502 Mag-
num/454 Magnum EFI/502
Magnum EFI/8.2L
CAMSHAFT AND DRIVE
Lobe Lift ± 002 (0 051)
Exhaust .271(6.683) .300(7.62)
Lobe Lift ± .002 (0.051) Intake .282(7.163) .300(7.62)
Duration at .050 In.(1.27mm)
Cam Lift
Exhaust 234° 224°
Cam Lift Intake 238° 224°
Journal Diameter 1.9482-1.9492(49.485-49.509)
Journal Out Of Round .001(0.025) Max
Camshaft Runout .002(0.051) Max
Timing Chain Deflection
[LH (Standard) Rotation Engine Only]
.375(9.5) from taut position [total .75(19)]
FLYWHEEL
Runout .008(0.203) Max
CYLINDER HEAD
Gasket Surface Flatness .007(0.178) Overall Maximum
.003(0.076)within a 6 in.(152mm) Span
INDEX
34. 3A-32 - MECHANICAL INFORMATION 90-806535940 893
Cylinder Head Torque
Sequences
3.0L/3.0LX
To insure gasket sealing, torque head bolts in three
steps, following torque sequence for each step. Start
first step at, second step at , and finish with a final
torque of .
1
26
5
3
4
9
10 7
8
1. 20 lb. ft. (27 N⋅m)
2. 50 lb. ft. (68 N⋅m)
3. 90 lb. ft. (120 N⋅m)
4.3L/4.3LX
72883
a - Front
a
1. 20 lb. ft. (27 N⋅m)
2. 40 lb. ft. (54 N⋅m)
3. 65 lb. ft. (88 N⋅m)
305/5.0L/350/5.7L
72332
1. 20 lb. ft. (27 N⋅m)
2. 40 lb. ft. (54 N⋅m)
3. 65 lb. ft. (88 N⋅m)
7.4L/454/8.2L/502
72944
1. 20 lb. ft. (27 N⋅m)
2. 50 lb. ft. (68 N⋅m)
3. 85 lb. ft. (115 N⋅m)
INDEX
35. MECHANICAL INFORMATION - 3A-3390-8065359840 893
Intake Manifold Torque
Sequence
4.3L/4.3LX
Torque bolts to 35 lb. ft. (48 N•m) in sequence as
shown.
72878
a - Front
a
350/5.7L
Torque bolts to 35 lb. ft. (48 N•m) in sequence as
shown.
72327
1
2
3
5
6
7
8
9
1011
12
4
454/7.4L/502/8.2L
Torque bolts to 35 lb. ft. (48 N•m) in sequence as
shown. On 502 Magnum EFI, torque bolts to 25 lb. ft.
(34N•m).
1
2
3
5
10
11
6
7
4
8
13
15
16
14
12
9
72515
INDEX
36. 3A-34 - MECHANICAL INFORMATION 90-806535940 893
Dipstick Specifications
4.3L/4.3LX
UNIT OF MEASUREMENT
In. (mm)
72887
1/2
(13)
25-7/16
(646)
3/4
(19)
FULL
ADD
41092-1
MCM
26-7/8
(682)
INDEX
37. MECHANICAL INFORMATION - 3A-3590-8065359840 893
Dipstick Specifications (Continued)
350/5.7L
UNIT OF MEASUREMENT
In. (mm)
72341
* Engines with Plastisol Coated Oil Pans
1/2
(13)
1/2
(13)
1/2
(13)
1/2
(13)
31 (787) 13-29/32 (353) 32 (814)
33-1/2 (849)
14-25/32 (375)
16-1/4 (413)33-1/4 (845) 15-19/32 (396)
3/4
(19)
15/16
(24)
3/4
(19)
FULL FULL FULL FULL
ADD ADD ADD ADD
23/32
(18)
15297
MCM
805395
MIE
Borg-Warner
In-Line and
Hurth 630A
Transmissions*
16482
5.7L Competition
Ski and 350
Magnum
Tournament
Ski
805394
MIE
Borg-Warner
V-Drive
Transmission*
INDEX
38. 3A-36 - MECHANICAL INFORMATION 90-806535940 893
Dipstick Specifications (Continued)
454/7.4L/502/8.2L
UNIT OF MEASUREMENT
In. (mm)
72341
1/2
(13)
1/2
(13)
1/2
(13)
33-1/2
(849)
15-1/8
(384)
19-7/64
(485)
35-1/4
(895)
17-13/64
(437)
1/2
(13)
19/32
(15)
59/64
(23)
FULL FULL FULL
ADD ADD ADD
805567
MCM
821503-3
MIE
Borg-Warner
In-Line
Transmissions
821503-4
MIE
All Transmissions
Except
Borg-Warner
In-Line
16-43/64
(423)
INDEX
39. MECHANICAL INFORMATION - 3A-3790-8065359840 893
Diagrams for Tool Usage
IMPORTANT: Check for specific Tool,Torque
Specification and Measurements under the En-
gine Specifications.
Valve Spring Removal With Head On
72306
a - Valve Spring Compressor
b - Rocker Arm Nut
b
a
Valve Spring Removal With Head Off
72333
a - Valve Spring Compressor
a
Valve Guide Cleaner
72335
a - Valve Guide Cleaner
a
Checking For Cylinder Head Flatness
72307
a - Straight Edge
b - Feeler Gauge
c - Take Measurements Diagonally Across Head
(Both Ways) and Straight Down Center Head
b
a
INDEX
40. 3A-38 - MECHANICAL INFORMATION 90-806535940 893
Rocker Arm Stud Replacement
1. Place large sleeve, flat washer and nut over stud,
then turn nut until it bottoms out on stud
threads.
72309
a - Large Sleeve
b - 3/8-24. Nut - Turn until Nut Bottoms Out on
Stud Threads, Then Remove Nut Using Rocker Arm
Stud Remover
ba
2. Remove nut and install small sleeve on stud. Turn
nut to remove stud.
00000
72310
a - Nut
b - Small Sleeve
c - Large Sleeve
b
c
a
3. Ream stud hole, whenever installing an oversize
stud, using appropriate reaming tool.
4. Install new stud with rocker arm stud installer.
72311
a - Rocker Arm Stud Installer
a
INDEX
41. MECHANICAL INFORMATION - 3A-3990-8065359840 893
Checking Valve Spring Height
Check installed height of valve springs. Measure from
spring seat to top of valve spring, as shown. If mea-
surement exceeds specified height, install a valve
spring shim and recheck. DO NOT shim valve springs
to give an installed height less than the minimum spe-
cified.
05037
Cutaway Scale
72339
a - Valve Spring Installed Height
a
Checking Valve Spring Pressure
Using valve spring tester, as shown, check valve
spring tension with dampers removed. Refer to
“Specifications.”
IMPORTANT: Springs should be replaced if not
within 10 Lb.(44 N) of specified tension.
72308
a - Valve Spring Tester
b - Torque Wrench
b
a
INDEX
42. 3A-40 - MECHANICAL INFORMATION 90-806535940 893
Checking For Valve Guide Wear
If clearance exceeds specifications, it will be neces-
sary to ream valve guides for oversized valves, as
outlined under “Valve Guide Bore Repair.”
72336
a - Valve Stem
b - Dial Indicator
c - Valve Guide
b
c
a
Valve Guide Bore Repair
Measure valve stem diameter of old valve being re-
placed and select proper size valve guide reamer.
Ream valve guide bores, as shown.
72337
INDEX
43. MECHANICAL INFORMATION - 3A-4190-8065359840 893
Removing The Torsional Damper
72345
a - Torsional Damper Remover
a
Installing torsional damper on crankshaft by turning
nut until it bottoms out.
72346
a - Torsional Damper Remover
a
Installing Oil Seal In Cover With
Cover Still On Engine
72348
b
a
a - Crankcase Front Cover Seal Installer
b - Support (to Prevent Distorting Cover)
Installing New Seal With Cover
Removed
72347
a
a - Crankcase Front Cover Seal Installer
INDEX
44. 3A-42 - MECHANICAL INFORMATION 90-806535940 893
Flywheel Runout - .008 In. (0.203 mm)
72353
a - .008 in. (0.203 mm) Max. Runout
b - Push Flywheel and Crankshaft Forward as Far
as It Will Go when Taking Reading
a
b
Rear Main Seal Removal
IMPORTANT: Remove seal by using a screwdriver
to pry it out of retainer as shown.
72355
a - Rear Seal
b - Seal Retainer
c - Slots (Three)
b
c
a
Using Rear Main Seal Installer.
72356
a - Rear Main Seal Installer (P/N J-26817-A)
a
INDEX
45. MECHANICAL INFORMATION - 3A-4390-8065359840 893
Checking Clearance On Crankshaft
Journals
IMPORTANT: Do not turn crankshaft when gaug-
ing crankshaft journals.
Place a piece of gauging plastic the full width of the
bearing (parallel to the crankshaft) on the journal as
shown.
72357
a - Gauging Plastic
b - Journal
b
a
Checking Clearance On Rod Journals
IMPORTANT: Do not turn crankshaft when gaug-
ing rod journals.
72361
a - Gauging Plastic
a
Without removing the gauging plastic, measure its
compressed width (at the widest point) with the grad-
uations on the gauging plastic envelope.
Measuring Crankshaft End Play
Measure crankshaft end play by forcing the crank-
shaft to the extreme front position. Measure at the
front end of the rear main bearing with a feeler gauge
as shown.
72360
a
a - Force Crankshaft to Extreme Forward Position
Measuring Piston Ring Gap
Measure gap between ends of ring with a feeler
gauge as shown.
72372
INDEX
46. 3A-44 - MECHANICAL INFORMATION 90-806535940 893
Position Of Piston Rings On Pistons
IMPORTANT: Be sure ring gaps are properly posi-
tioned as shown.
72373
Ring Gap Location
ENGINE LEFT ENGINE RIGHTENGINE FRONT
A - Oil Ring Spacer Gap (Tang in Hole or Slot within Arc)
B - Oil Ring Rail Gaps
C - 2nd Compression Ring Gap
D - Top Compression Ring Gap
1-3-5-7 Cylinders 2-4-6-8 Cylinders
Piston Orientation
Notch on piston must be positioned correctly for en-
gine that is being repaired.
72369a - Notch
a
72370
a - Notch - Toward Front in MCM and MIE (LH)
Rotation Engines; Toward Rear in MIE (RH)
Rotation Engines
a
INDEX
47. MECHANICAL INFORMATION - 3A-4590-8065359840 893
V-6 and V-8 Piston Installation
IMPORTANT: Be sure to install new pistons in same
cylinders for which they were fitted, and used pistons
in same cylinder from which they were removed. Each
connecting rod and bearing cap should be marked, be-
ginning at front of engine (1, 3, 5 and 7 in left bank and
2, 4, 6 and 8 in right bank). Numbers on connecting rod
and bearing cap must be on same side when installed
in cylinder bore. If a connecting rod is ever transposed
from one block or cylinder to another, new bearings
should be fitted and connecting rod should be num-
bered to correspond with new cylinder number.
72374
a - Piston Ring Compressor
a
Cylinder Wall Inspection And
Measurement
Measure cylinder walls for taper, out-of-round or ex-
cessive ridge at top of ring travel. This should be done
with a dial indicator or inside micrometer. Carefully
work gauge up and down cylinder to determine taper
and turn it to different points around cylinder wall to
determine out-of-round condition. If cylinders exceed
specifications, boring and/or honing will be neces-
sary.
72385
“A” = At right angle to centerline of engine
“B” = Parallel to centerline of engine
“Out-of-Round” = Difference between “A” and “B”
“Taper” = Difference between measurement “A”
at top of cylinder bore and “A”
measurement at bottom of cylinder bore
Cylinder Measurement
INDEX
48. 3A-46 - MECHANICAL INFORMATION 90-806535940 893
72386
Measuring Cylinder Bore
72387
Measuring Cylinder Bore
Checking Deck Surface
If surfaces are warped more than .003 in. (0.07 mm)
in a 6 in. area or .007 in. (0.2 mm) overall, block must
be resurfaced
72388
a - Machinist’s Straight-Edge
b - Feeler Gauge
b
a
INDEX
49. MECHANICAL INFORMATION - 3A-4790-8065359840 893
Camshaft Gear And Sprocket
Installer
72377
a - Crankshaft Gear and Sprocket Installer
(P/N J-5590)
a
Checking Timing Chain Deflection
The deflection is the difference between these two
measurements. If the deflection exceeds 3/4 in. (19
mm), timing chain should be replaced.
72376
a - Reference Point
a
Alignment Of Timing Marks
NOTE: .Flat lifter timing gear is shown. Roller lifter gears
have similar timing marks.
72376
a - Timing Marks Aligned
b - Locating Pin
b
a
Standard (Left Hand) Rotation Shown
Measuring Lobe Lift
Position indicator with ball socket adaptor tool on
push rod. Be sure that push rod is in lifter socket.
72380
a - Ball Socket Adaptor Tool
a
INDEX