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ENGINES
MECHANICAL INFORMATION
INDEX
3A-0 - MECHANICAL INFORMATION 90-806535940 893
Table of Contents
Page
Engine Identification 3A-1. . . . . . . . . . . . . . . . . . . . . .
4 Cylinder 3A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
V-6 3A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V-8 3A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.0L and 3.0LX 3A-2. . . . . . . . . . . . . . . . . . . . . . . . . .
Tools/Lubricants/Sealants 3A-2. . . . . . . . . . . . . . .
Torque Specifications 3A-3. . . . . . . . . . . . . . . . . .
Engine Specifications 3A-4. . . . . . . . . . . . . . . . . .
4.3L and 4.3LX 3A-7. . . . . . . . . . . . . . . . . . . . . . . . . .
Tools/Lubricants/Sealants 3A-7. . . . . . . . . . . . . . .
Torque Specifications 3A-8. . . . . . . . . . . . . . . . . .
Engine Specification 3A-10. . . . . . . . . . . . . . . . . .
305/5.0L/350/5.7L 3A-15. . . . . . . . . . . . . . . . . . . . . . .
Tools/Lubricants/Sealants 3A-15. . . . . . . . . . . . . .
Torque Specifications 3A-16. . . . . . . . . . . . . . . . .
Engine Specifications 3A-18. . . . . . . . . . . . . . . . .
454 CID (7.4L) and 502 CID (8.2L) 3A-23. . . . . . . .
Tool/Lubricants/Sealants 3A-23. . . . . . . . . . . . . . .
Torque Specifications 3A-24. . . . . . . . . . . . . . . . .
454/7.4L/502/8.2L Engine Specifications 3A-26.
Cylinder Head Torque Sequences 3A-32. . . . . . . . .
3.0L/3.0LX 3A-32. . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3L/4.3LX 3A-32. . . . . . . . . . . . . . . . . . . . . . . . . . .
305/5.0L/350/5.7L 3A-32. . . . . . . . . . . . . . . . . . . .
7.4l/454/8.2L/502 3A-32. . . . . . . . . . . . . . . . . . . . .
Intake Manifold Torque Sequence 3A-33. . . . . . . . .
4.3L/4.3LX 3A-33. . . . . . . . . . . . . . . . . . . . . . . . . . .
350/5.7L 3A-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
454/7.4L/502/8.2L 3A-33. . . . . . . . . . . . . . . . . . . .
Dipstick Specifications 3A-34. . . . . . . . . . . . . . . . . . .
4.3L/4.3LX 3A-34. . . . . . . . . . . . . . . . . . . . . . . . . . .
350/5.7L 3A-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
454/7.4L/502/8.2L 3A-36. . . . . . . . . . . . . . . . . . . .
Diagrams for Tool Usage 3A-37. . . . . . . . . . . . . . . . .
Valve Spring Removal With Head On 3A-37. . . .
Valve Spring Removal With Head Off 3A-37. . . .
Valve Guide Cleaner 3A-37. . . . . . . . . . . . . . . . . .
Checking For Cylinder Head Flatness 3A-37. . .
Rocker Arm Stud Replacement 3A-38. . . . . . . . .
Checking Valve Spring Height 3A-39. . . . . . . . . .
Checking Valve Spring Pressure 3A-39. . . . . . . .
Checking For Valve Guide Wear 3A-40. . . . . . . .
Valve Guide Bore Repair 3A-40. . . . . . . . . . . . . .
Removing The Torsional Damper 3A-41. . . . . . .
Installing Oil Seal In Cover With Cover
Still On Engine 3A-41. . . . . . . . . . . . . . . . . . . . . . .
Installing New Seal With Cover
Removed 3A-41. . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel Runout 3A-42. . . . . . . . . . . . . . . . . . . . .
Rear Main Seal Removal 3A-42. . . . . . . . . . . . . .
Using Rear Main Seal Installer. 3A-42. . . . . . . . .
Checking Clearance On Crankshaft
Journals 3A-43. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Clearance On Rod Journals 3A-43. . .
Measuring Crankshaft End Play 3A-43. . . . . . . .
Measuring Piston Ring Gap 3A-43. . . . . . . . . . . .
Position Of Piston Rings On Pistons 3A-44. . . .
Piston Orientation 3A-44. . . . . . . . . . . . . . . . . . . .
V-6 and V-8 Piston Installation 3A-45. . . . . . . . . .
Cylinder Wall Inspection And
Measurement 3A-45. . . . . . . . . . . . . . . . . . . . . . . .
Checking Deck Surface 3A-46. . . . . . . . . . . . . . .
Camshaft Gear And Sprocket Installer 3A-47. . .
Checking Timing Chain Deflection 3A-47. . . . . .
Alignment Of Timing Marks 3A-47. . . . . . . . . . . .
Measuring Lobe Lift 3A-47. . . . . . . . . . . . . . . . . . .
3A - MECHANICAL INFORMATION
INDEX
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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

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  • 2. 3A-0 - MECHANICAL INFORMATION 90-806535940 893 Table of Contents Page Engine Identification 3A-1. . . . . . . . . . . . . . . . . . . . . . 4 Cylinder 3A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . V-6 3A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-8 3A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0L and 3.0LX 3A-2. . . . . . . . . . . . . . . . . . . . . . . . . . Tools/Lubricants/Sealants 3A-2. . . . . . . . . . . . . . . Torque Specifications 3A-3. . . . . . . . . . . . . . . . . . Engine Specifications 3A-4. . . . . . . . . . . . . . . . . . 4.3L and 4.3LX 3A-7. . . . . . . . . . . . . . . . . . . . . . . . . . Tools/Lubricants/Sealants 3A-7. . . . . . . . . . . . . . . Torque Specifications 3A-8. . . . . . . . . . . . . . . . . . Engine Specification 3A-10. . . . . . . . . . . . . . . . . . 305/5.0L/350/5.7L 3A-15. . . . . . . . . . . . . . . . . . . . . . . Tools/Lubricants/Sealants 3A-15. . . . . . . . . . . . . . Torque Specifications 3A-16. . . . . . . . . . . . . . . . . Engine Specifications 3A-18. . . . . . . . . . . . . . . . . 454 CID (7.4L) and 502 CID (8.2L) 3A-23. . . . . . . . Tool/Lubricants/Sealants 3A-23. . . . . . . . . . . . . . . Torque Specifications 3A-24. . . . . . . . . . . . . . . . . 454/7.4L/502/8.2L Engine Specifications 3A-26. Cylinder Head Torque Sequences 3A-32. . . . . . . . . 3.0L/3.0LX 3A-32. . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3L/4.3LX 3A-32. . . . . . . . . . . . . . . . . . . . . . . . . . . 305/5.0L/350/5.7L 3A-32. . . . . . . . . . . . . . . . . . . . 7.4l/454/8.2L/502 3A-32. . . . . . . . . . . . . . . . . . . . . Intake Manifold Torque Sequence 3A-33. . . . . . . . . 4.3L/4.3LX 3A-33. . . . . . . . . . . . . . . . . . . . . . . . . . . 350/5.7L 3A-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454/7.4L/502/8.2L 3A-33. . . . . . . . . . . . . . . . . . . . Dipstick Specifications 3A-34. . . . . . . . . . . . . . . . . . . 4.3L/4.3LX 3A-34. . . . . . . . . . . . . . . . . . . . . . . . . . . 350/5.7L 3A-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454/7.4L/502/8.2L 3A-36. . . . . . . . . . . . . . . . . . . . Diagrams for Tool Usage 3A-37. . . . . . . . . . . . . . . . . Valve Spring Removal With Head On 3A-37. . . . Valve Spring Removal With Head Off 3A-37. . . . Valve Guide Cleaner 3A-37. . . . . . . . . . . . . . . . . . Checking For Cylinder Head Flatness 3A-37. . . Rocker Arm Stud Replacement 3A-38. . . . . . . . . Checking Valve Spring Height 3A-39. . . . . . . . . . Checking Valve Spring Pressure 3A-39. . . . . . . . Checking For Valve Guide Wear 3A-40. . . . . . . . Valve Guide Bore Repair 3A-40. . . . . . . . . . . . . . Removing The Torsional Damper 3A-41. . . . . . . Installing Oil Seal In Cover With Cover Still On Engine 3A-41. . . . . . . . . . . . . . . . . . . . . . . Installing New Seal With Cover Removed 3A-41. . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel Runout 3A-42. . . . . . . . . . . . . . . . . . . . . Rear Main Seal Removal 3A-42. . . . . . . . . . . . . . Using Rear Main Seal Installer. 3A-42. . . . . . . . . Checking Clearance On Crankshaft Journals 3A-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Clearance On Rod Journals 3A-43. . . Measuring Crankshaft End Play 3A-43. . . . . . . . Measuring Piston Ring Gap 3A-43. . . . . . . . . . . . Position Of Piston Rings On Pistons 3A-44. . . . Piston Orientation 3A-44. . . . . . . . . . . . . . . . . . . . V-6 and V-8 Piston Installation 3A-45. . . . . . . . . . Cylinder Wall Inspection And Measurement 3A-45. . . . . . . . . . . . . . . . . . . . . . . . Checking Deck Surface 3A-46. . . . . . . . . . . . . . . Camshaft Gear And Sprocket Installer 3A-47. . . Checking Timing Chain Deflection 3A-47. . . . . . Alignment Of Timing Marks 3A-47. . . . . . . . . . . . Measuring Lobe Lift 3A-47. . . . . . . . . . . . . . . . . . . 3A - MECHANICAL INFORMATION INDEX
  • 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