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ENGINES

MECHANICAL INFORMATION

3A-0 - MECHANICAL INFORMATION 90-806535970 1296

Table of ContentsPage

Engine Identification 3A-1. . . . . . . . . . . . . . . . . . . . . . 4 Cylinder 3A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . V-6 3A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-8 3A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

181 CID / 3.0L 3A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools 3A-2. . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants/Sealers/Adhesives 3A-3. . . . . . . . . . . 181 CID / 3.0L Torque Specifications 3A-3. . . . . 181 CID / 3.0L Engine Specifications 3A-4. . . . .

262 CID / 4.3L Gen+ 3A-7. . . . . . . . . . . . . . . . . . . . . . Special Tools 3A-7. . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants/Sealers/Adhesives 3A-8. . . . . . . . . . . 262 CID / 4.3L Torque Specifications 3A-8. . . . . 262 CID / 4.3L Torque Specifications 3A-9. . . . . 262 CID / 4.3L Gen + Engine Specifications 3A-11. . . . . . . . . . . . . . . . . . . . . . . 262 CID / 4.3L Gen + Engine Specifications 3A-13. . . . . . . . . . . . . . . . . . . . . . .

350 CID / 5.7L 3A-15. . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools 3A-15. . . . . . . . . . . . . . . . . . . . . . . . . Lubricants/Sealers/Adhesives 3A-16. . . . . . . . . . 350 CID / 5.7L Torque Specifications 3A-16. . . . 350 CID / 5.7L Engine Specifications (Does Not Include Gen +) 3A-18. . . . . . . . . . . . . 350 CID / 5.7L Engine Specifications (Does Not Include Gen +) 3A-24. . . . . . . . . . . . . 350 Gen + Engine Specifications 3A-29. . . . . . .

454 CID / 7.4L / 502 CID / 8.2L 3A-30. . . . . . . . . . . Special Tools 3A-30. . . . . . . . . . . . . . . . . . . . . . . . . Lubricants/Sealers/Adhesives 3A-30. . . . . . . . . . 454 CID / 7.4L / 502 CID / 8.2L Torque Specifications 3A-31. . . . . . . . . . . . . . . . . 454 CID / 7.4L / 502 CID / 8.2L Torque Specifications 3A-32. . . . . . . . . . . . . . . . .

Cylinder Head Torque Sequences 3A-39. . . . . . . . . Intake Manifold Torque Sequence 3A-41. . . . . . . . .

MECHANICAL INFORMATION - 3A-190-806535970 1296

Engine Identification

4 Cylinder

73584

a

a - Location of G.M. Engine Code

MCM (Stern Drive) Code Rotation

3.0LX RK LH

V-6

72312

a - Location of GM Engine Code

a

MCM(Stern Drive) Code Rotation

4.3LX Gen + Alpha and Bravo LJ

LH4.3LXH Gen + Alpha and Bravo LK

LH

262 Magnum EFI Gen +

V-8


5.7L Bravo

MJ

LH

5.7L AlphaMJ

LH

5.7L Alpha EFIMJ

LH

5.7L Bravo EFI

LH5.7LX, Alpha5.7LX Bravo

350 Magnum AlphaMD LH

350 Magnum EFIAlpha Gen +

MH5.7L Bravo EFI Gen+ MH

350 Magnum MPI Gen + Bravo and Blackhawk

MIE (Inboard) Code Rotation

5.7L MM

LH5.7L Competition Ski MJ

LH350 Magnum Tournament SkiMH

LH

350 Magnum MPI TournamentSki (Black Scorpion)

MH


7.4L XW

LH

7.4L Bravo Three (Note) XX

LH

7.4LX EFI Bravo UJ

LH7.4LX MPI Bravo UD LH

454 Magnum XA

454 Magnum MPI UA

502 Magnum MPI HJ

MIE (Inboard) Code Rotation

7.4L XY

LH

7.4L EFI UK

LH7.4L MPI UD LH

8.2L HH

454 EFI Ski UA


181 CID / 3.0L

Special Tools

MERCURY MARINE SPECIAL TOOLS

DESCRIPTION PART NUMBER

Piston Ring Expander 91-24697

Torch Lamp 91-63209

KENT MOORE SPECIAL TOOLS


Valve Spring Compressor (Head on) J5892

Valve Spring Compressor (Head off) J8062

Valve Stem Seal Tester J23738-A

Valve Guide Cleaner J8101

Valve Guide Reamer (Standard) J8814

Valve Guide Reamer (.015 in. oversize) J5830-02

Rocker Arm Stud Remover J5802-01

Rocker Arm Stud Installer J6880

Stud Bore Reamer (.003 in. oversize) J5715


Carbon Remover Brush J8089

Piston Support Tool J5910-04

Piston Pin Tool J24086-B

Piston Ring Groove Cleaner J3936-03

Piston Ring Compressor J8037

Connecting Rod Guide Tool (3/8 -24) J5239

Cylinder Bore Checker J8087

Oil Pump Suction Pipe Installer J8369

Timing Cover Seal Aligner J23042-B

Cam Lobe Lift Indicator J8520

Camshaft Bearing Installer/Remover Tool J6098-01

Distributor Shaft Lower Bearing Installer/Remover J9534-01

Pulley Hub Puller J6978-E

Pulley Hub Installer J5590

Universal Torsional Damper Remover J24420


Lubricants/Sealers/Adhesives

PART NUMBER DESCRIPTION

Quicksilver Perfect Seal 92-34227-1

Quicksilver 2-C-4 Marine Lubricant with Teflon 92-825407A3

Quicksilver RTV Sealer 92–91601-1

181 CID / 3.0L Torque Specifications

DESCRIPTION Lb. In. Lb. Ft. N⋅mCamshaft Sprocket Bolts 80 9

Connecting Rod Cap Nuts 45 61

Cylinder Head Bolts 90 (Note 1) 122 (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 (Note 2) 31 (Note 2)

Oil Pan Bolts-Crankcase 80 9

Oil Pan Bolts - to Front Cover 45 5

Oil Pan Studs to Oil Seal Retainer orCrankcase

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.


181 CID / 3.0L Engine Specifications

UNIT OF MEASUREMENTin. (mm)

CYLINDER BORE

Diameter 3.9995-4.0025(101.588-101.790)

Out of RoundProduction .0005(0.012) Max

Out of RoundService .002(0.05) Max

TProduction

Thrust Side .0005(0.012) Max

TaperProduction

Relief Side .0005(0.012) Max

Service .001(0.02) Max

PISTON CLEARANCE

Production .0025-.0035(0.064-0.088) Max


PISTON RING: COMPRESSION

Groove ProductionTop

0012- 0029(0 030-0 073)GrooveClearance

Production2nd

.0012-.0029(0.030-0.073)Clearance


GProduction

Top010- 020(0 254-0 762)

GapProduction

2nd.010-.020(0.254-0.762)


PISTON RING: OIL

Groove ClearanceProduction .001-.006(0.026-0.152)

Groove ClearanceService Limit .007(0.17) Max

GapProduction .010-.030(0.254-0.762) Max

GapService Limit .040(1.01) Max

PISTON PIN

Diameter .9270-.9271(23.546-23.550)

ClearanceProduction .0003-.0006(0.008-0.016)

ClearanceService Limit .001(0.02) Max

Fit in Rod .0008-.0019(0.020-0.050) Interference



CRANKSHAFT

M i J l

Diameter 2.2979-2.294(58.367-58.404)

M i J lTaper

Production .0002(0.005) Max

Main JournalTaper




M i B i

Production No.1-No.4 .001-.0024(0.025-0.060)

Main BearingC

Service No.5 .0016-.0035(0.041-0.088)gClearance 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)

C k i

Diameter 2.09980-20995(53.289-53.327)

C k iTaper

Production .0003(0.007) Max

CrankpinTaper




Rod BearingClearance

Production .0017-.0027(0.044-0.0686)Clearance Service N/A

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-.008 in any 6 in.(152)or .007(0.15) Overall Maximum



VALVE SYSTEM

Lifter Hydraulic

Rocker Arm Ratio 1.75 to 1

Collapsed Tappet Gap 3/4 Turn Down from Zero Lash

Face AngleIntake 45°

Face AngleExhaust 45°

Seat Angle (Intake & Exhaust) 46°Seat Runout (Intake & Exhaust) .002(0.05) Max

Seat WidthIntake 1/16 [.0625] in. (1.16 mm)

Seat WidthExhaust 1/16-5/64 [.0625-.07812] in. (1.6-2.0 mm)

SProduction

Intake .0010-.0027(0.025-0.069)

StemC

ProductionExhaust .0007-.0027(0.018-0.069)

ClearanceService

Intake .003(0.09) MaxService

Exhaust .004(0.11) Max

S i

Free Length 2-1/16(52)

S iPressure

Valve Closed 100-110 lb. (136-149 N) at 1-19/32 in. (41 mm)

SpringPressure

Valve Open 208-220 lb. (282-300 N) at 1-7/32 in. (31 mm)p gInstalledHeight±

Intake1/32[1 6562] (42)Height±

.031(8) Exhaust1/32[1.6562] (42)

Internal Damper None


262 CID / 4.3L Gen+

Special Tools




Engine Coupler Wrench 91-35547

SNAP-ON SPECIAL TOOLS


Torque Angle Gauge (Degree Wheel Torquing) TA360

KENT-MOORE SPECIAL TOOLS


Valve Spring Compressor (Head On) J5982

Valve Spring Compressor (Head Off) J8062

Valve Spring Tester J8056


Valve Guide Reamer J5830-2

Valve Guide Reamer J7049


Piston Pin Remover Kit J24086-B



Connecting Rod Bolt Guide Set (3/8-24) J5239


Camshaft Bearing Remover and Installer Set J6098-01

Ball Socket Adapter Tool Kit (Lift Indicator) J8520-1

Torsional Damper Remover and Installer J23523-E

Crankcase Front Cover Seal Installer J35468

Crankcase Gear and Sprocket Puller J5825-A

Crankcase Gear and Sprocket Installer J5590

Air Adapter J23590

Main Bearing Remover and Installer J8080

Rear Main Seal Installer J26817-A

Balance Shaft Rear Bearing Remover J26941

Balance Shaft Bearing Remover and Installer J38834




Quicksilver Loctite 8831 92-823089-1


Quicksilver RTV Sealer 92-91601-1

General Motors Cam and Lifter Prelude Obtain Locally


DESCRIPTION Lb. In. Lb. Ft. 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 14

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 70 °) 20 27

Coupler/Flywheel(MCM) 35 48

Crankcase Front Cover 124 14

Crankshaft Pulley Bolt (Cast Aluminum) 40 54

Cylinder Head Bolts 65 88

Cylinder Head Bolts First Sequence

Angle Torque Second Sequence Short Bolt

22 30

Angle Torque Second Sequence Short Bolt

Medium Bolt55 Degrees

Medium Bolt

Long Bolt65 Degrees

Long Bolt 75 Degrees

Distributor Hold Down 25 34

Exhaust Manifold 20 27

Flywheel 75 100


Flywheel Housing Cover 80 9

Front Mount Bracket 30 41

Fuel Filter Bracket Bolt 25 25



DESCRIPTION Lb. In. Lb. Ft. N⋅mFuel Pump Bracket Bolt 25 25

Fuel Pump Inlet Fitting (Large Diameter See Note) 96 10.8

Fuel Pump Inlet Fitting (Small Diameter See Note) 84 9.6

Intake Manifold Bolts (Torque Three Steps) First Step 27 3

Second Step 106 12

Third Step 133 15

Knock Sensor 15 20

Main Bearing Cap 75 100

Oil Filter Adapter Bolts15 20

Oil Pan Drain Plug15 20

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 Block30 41

Power Steering Pump Bracket30 41

Rear Crankshaft Oil Seal Retainer Screws and Nuts 133 15

Rear Mount (MCM) 40 54

Rocker Arm Cover 106 12

Rocker Arm Nuts 20 27

Roller Lifter Restrictor Plate 144 16

Seawater Pump Brace (if equipped)30 41

Seawater Pump Bracket (if equipped)30 41

Spark Plugs 15 20

Starter Motor 50 68

Thermostat Housing 30 41

Torsional Damper 40 54

Water Circulating Pump 30 41

Water Temperature Sender 20 27

Note : Hold fuel pump using wrench on flat surface at outlet before tightening brass fitting


262 CID / 4.3L Gen+ Engine Specifications)

Unit of Measurement in. (mm)

Displacement 262 CID (4.3 Litre)

Bore 4.00(101.6)

Stoke 3.48(88.39)

Compression Ratio 9.3:1

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 ROTATIONFRONT

Firing Order1-6-5-4-3-2


262 CID / 4.3L Gen + Engine Specifications


CYLINDER BORE

Diameter 4.0007-4.0017(101.618-101.643)

Out of RoundProduction .001 (0.025) Maximum

Out of RoundService .002 (0.051) Maximum

TProduction

Thrust Side .0005 (0.012) Maximum

TaperProduction

Relief Side .001 (0.025) Maximum

Service .001 (0.025) Maximum

PISTON CLEARANCE

Production .0007-.002 (0.017-0.05)

Service .0024 (.001)

PISTON RING: COMPRESSION (MEASURED IN CYLINDER BORE)

G ClProduction

Top .02-.06 (0.51-1.52)

Groove ClearanceProduction

2nd .04-.08 (1.02-2.03)


GProduction

Top .010-.016 (0.25-0.40)

GapProduction

2nd .018-.026 (.046-.066) Maximum

Service 0.06-0.035 (1.524-0.88) Maximum

PISTON RING: OIL

Groove ClearanceProduction .002-.007 (0.51-0.20)

Groove ClearanceService 0.02-0.08 (0.51-2.032)

GapProduction .015-.050 (0.38-1.27)

GapService Limit 0.009-0.065 (0.23-1.65)

PISTON PIN

Diameter .9267-.9271 (23.545-23.548)

ClearanceProduction .0002-.0007 (0.005-0.0178)

ClearanceService Limit .001 (0.025) Maximum

Fit in Rod .0008-.0016 (0.021-0.040) Interference


262 CID / 4.3L Engine Gen + Specifications


CRANKSHAFT

M i

Di

No.1 2.4488-2.4495 (62.199-62.217)

M i

Diameter No. 2, 3 2.4485-2.4494 (62.191-62.215)

MainNo.4 2.4479-2.4489 (62.179-62.203)

Main Journal Taper

Production .0003 (0.007) MaximumJournal Taper




Main Bearing ProductionNo.1 .0008-.0020 (0.020-0.051)

Main BearingC

ProductionNo.2, 3, 4 .0010-.025 (0.025-0.635)g

ClearanceNo.2, 3, 4 .0010-.025 (0.025-0.635)

ClearanceService No 1 2 3 4 0010 0020 (0 03 0 051)Service No.1, 2, 3, 4 .0010-.0020 (0.03-0.051)Service No.1, 2, 3, 4 .0010 .0020 (0.03 0.051)

Crankshaft End Play .002-.008 (0.05-0.20)

C i R d

Diameter 2.2487-2.2497 (57.117-57.142)

Connecting Rod TaperProduction .0003 (0.007) Maximum

Connecting RodJournal

TaperService .001 (0.025) Maximum

Journal



Rod Bearing ClearanceProduction .0013-.0035 (0.033-0.088)

Rod Bearing ClearanceService .0010-.0030 (0.025-0.076)

Rod Side Clearance .006-.017 (0.15-0.43)

Crankshaft Runout .001 (0.025) Maximum




VALVE SYSTEM

Lifter Hydraulic Roller


Valve LiftIntake .414 (10.52)

Valve LiftExhaust .428 (10.87)

Valve Lash (Intake and Exhaust) Net Lash No Adjustment

Face Angle (Intake & Exhaust) 45°Seat Angle (Intake & Exhaust) 46°

Seat Runout (Intake & Exhaust) .002 (0.05) Maximum

Seat WidthIntake .035-.060 (0.89-1.52)

Seat WidthExhaust .062-.093 (1.58-2.38)

SProduction

Intake0010- 0027 (0 025-0 069)

Stem C

ProductionExhaust

.0010-.0027 (0.025-0.069)

ClearanceService

Intake .001 (0.025) MaximumService

Exhaust .002 (0.51) Maximum

Stem DiameterIntake

3400- 3407 (8 636-8 653)Stem DiameterExhaust

.3400-.3407 (8.636-8.653)

Valve Margin Intake and Exhaust .031 (0.79)

VALVE SPRING

Free Length 2.03 (51.6)

V l S i PressureValve Closed 76-84 Lb. (338-374 N) at 1.7 in (43.16 mm)

Valve Spring PressureValve Open 187-203 Lb. (832-903 N) at 1.27 in (32.25 mm)

Installed Height 1.690-1.710 in (42.93-43.43 mm)




CAMSHAFT AND DRIVE

Lobe Lift ±( )

Intake .286-.290 (7.26-7.36).002(0.051) Exhaust .292-.296 (7.42-7.52)

Journal Diameter 1.8682-1.8692 (47.452-47.478)

Journal Out of Round .001 (0.025) Maximum

Camshaft Runout .002 (0.051) Maximum

Camshaft End Play .001-.009 (0.0254-0.2286)

Timing Chain Deflection .375(9.5) from taut position [total .75 (19)]

FLYWHEEL

Runout .008 (0.203) Max

CYLINDER HEAD

Gasket Surface Flatness .010 (0.254) Overall Maximum

BALANCE SHAFT

Front Bearing Journal 2.1648-2.1654 (54.985-55.001)

Rear Bearing Journal 1.4994-1.500 (38.084-38.100)

Rear Bearing Journal Clearance .001-.0036 (.025-.091)


350 CID / 5.7L

Special Tools





Rocker Stopper 91-66273







Valve Guide Reamer (Standard) J7049

Valve Guide Reamer (.015 in. oversize) J5830-02

Rocker Arm Stud Remover J5802-01

Rocker Arm Stud Installer J6880









Camshaft Bearing Installer/Remover Tool J6098-01

Ball Socket Adapter J8520-1



Crankshaft Gear and Sprocket Puller J5825-A

Crankshaft Gear and Sprocket Installer J5590

Air Adapter J23590


Rear Main Seal Installer J26817-A






Quicksilver Needle Bearing Assembly Lubricant 92-825265A1


General Motors Cam and Lifter Prelube or Equiva-lent

Obtain Locally

350 CID / 5.7L Torque SpecificationsNOTE: Any Differences in Gen + Engines Will Be Noted With ”Gen +”.

DESCRIPTION Lb. In. Lb. Ft. N⋅mAlternator Brace to Alternator 192 28




Camshaft Sprocket Gear 216 24

Carburetor 132 15

Connecting Rod Cap Nuts 45 61

Connecting Rod Cap NutsGen +(Plus An Additional 55 Degrees) 20 27

Coupler/Flywheel(MCM)35 48

Crankshaft Pulley35 48

Cylinder Head Bolt 65 88

Cylinder Head Bolt Gen + First Sequence

A l T S d S Sh t B lt

22 30

Angle Torque Second Sequence Short BoltMedium Bolt

55 DegreesMedium BoltLong Bolt

g65 Degrees

DLong Boltg

75 Degrees


Exhaust Manifold20 27

Filter Adapter (5/16-18)20 27

Flywheel 75 100

Flywheel Drive Plate (MIE) 35 48




Fuel Pump 25 34

Intake Manifold 35 48


350 CID / 5.7L Torque Specifications (Continued)NOTE: Any Differences in Gen + Engines Will Be Noted With Gen +.

DESCRIPTION Lb. In. Lb. Ft. N⋅mIntake Manifold Bolts Gen+(Torque Three Steps) First Step

27 3

Second Step 106 12

Third Step 133 15


Main Bearing Cap Bolt Gen + 74 100

Oil Baffle Nuts 25 34

Oil Filter Adapter Bolt 15 20

Oil Pan Drain Plug 15 20

Oil Pan Corner Nut 15 20

Oil Pan Nuts (5/16-18) 106 12

Oil Pump 65 88

Oil Pump Cover 80 9

Power Steering Pump Brace to Block30 41

Power Steering Pump Bracket30 41

Rear Crankshaft Oil Seal Retainer Screws andNuts

133 15


Rear Mount (MIE) 50 68

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 50


Timing Chain or Gear Cover 106 12


Transmission To Housing 50 68




Roller Lifter Restrictor Retainer Plate 144 16

Seawater Pump Brace30 41

Seawater Pump Bracket30 41


350 CID / 5.7L Engine Specifications (Does Not Include Gen +)

Unit Of Measurement In. (mm)

EngineModel

MCM5.7L

Alpha

MCM5.7L

Bravo

MCM 350Magnum

AlphaDisplacement 350 CID (5.7 Litre)

Bore 4.00(101.6)

Stroke 3.48(88.4)


Heads Cast Iron

IntakeManifold

Cast Iron (Magnums-High Rise-See Note 2)


Rods Forged Steel



Camshaft Cast Iron Steel (See Note 1)

Fuel PumpPush Rod

Steel Cast Iron(See Note 1)

Note1: Engine with roller lifters and steel camshaft

Note 2: Includes - 350 Magnum Alpha, 5.7LX Bravo and 350 Magnum Tournament Ski




EngineModel

MCM5.7L EFI Alpha

MCM5.7L EFI Bravo


Bore 4.00(101.6)

Stroke 3.48(88.4)


Heads Cast Iron

Intake Manifold Cast Iron


Rods Forged Steel



Camshaft Steel (See Note 1)

Fuel PumpPush Rod

Cast Iron (See Note 1)

Note 1: Engine with roller lifters and steel camshaft




EngineModel

MIE5.7L

MIE5.7L

CompetitionSki

MIE350 MagnumTournament

Ski


Bore 4.00(101.6)

Stroke 3.48(88.4)


Heads Cast Iron

Intake Manifold Cast Iron (Magnum-High Rise-See Note 2)


Rods Forged Steel



Camshaft Cast Iron Steel (Note 1)

Fuel Pump Push Rod

Steel Cast Iron (Note 1)

Note1: Engine with roller lifters and steel camshaft

Note 2: Includes- 350 Magnum Tournament Ski and 350 EFI Magnum Tournament Ski. Gen + engines withan aluminum manifold.

72008

ALH ROTATION

FRONT

Firing Order1-8-4-3-6-5-7-2




CYLINDER BORE

Diameter 3.9995-4.0025(101.5873-101.6635)



TProduction


TaperProduction


Service .001(0.02) Over Production

PISTON CLEARANCE

Production .0007-.0017(0.017-0.043) Max



G ClProduction

Top0012- 0032(0 030-0 081)


2nd.0012-.0032(0.030-0.081)

Service High Limit Production + .001(0.025)

GProduction

Top .010-.020(0.254-0.508)( )Gap

Production2nd

( ).010-.025(.0254-.0635)


PISTON RING: OIL


Groove ClearanceService High Limit Production + .001(0.025)

GapProduction .015-.055(0.381-1.397)

GapService Limit High Limit Production + .010(0.254)

PISTON PIN

Diameter .9269-.9271(23.545-23.553)

ClearanceProduction .0002–.0007(0.005-0.017)






CRANKSHAFT

M i

Di

No.1 2.4484-2.4493 (62.198-62.212)

M i

Diameter No. 2, 3 2.4481-2.4490 (62.181-62.204)

MainNo.4 2.4479-2.4488 (62.176-62.199)

Main Journal Taper

Production .0002 (0.005) MaxJournal Taper

Service .001 (0.02) Max

Out of RoundProduction .0002 (0.005) Max

Out of RoundService .001 (0.005) Max

M i B i

P d i

No.1 .0008-.0020 (0.020-0.050)

M i B i

Production No. 2, 3 .0011-.0023 (0.027-0.058)

Main BearingCl

No.4 .0017-.0032 (0.043-0.081)gClearance

S i

No.1 .0010-.0015 (0.025-0.038)

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)

C i R d

Diameter 2.0988-2.0998 (57.117–57.142)

Connecting Rod TaperProduction .0005 (0.021) Max


TaperService .001 (0.02) Max

Journal

Out of RoundProduction .0005 (0.021) Max

Out of RoundService .001 (0.02) Max

Rod Bearing ClearanceProduction .0013-.0035 (0.033-0.088)

Rod Bearing ClearanceService .003 (0.07) Max

Rod Side Clearance .006-.014 (0.15-0.35)

Crankshaft Runout .0015 (0.0381) Max




VALVE SYSTEM

Lifter Type (NOTE 1)Flat Hydraulic

Lifter Type (NOTE 1)Roller Hydraulic


Valve LiftIntake .394(10.00)

Valve LiftExhaust .404(10.26)

Valve Lash (Intake and Exhaust) 1 Turn Down from Zero Lash

Face AngleIntake 45°

Face AngleExhaust 45°

Seat Angle (Intake & Exhaust) 46°Seat Runout (Intake & Exhaust) .002(0.05) Max

Seat WidthIntake .03215-.0625 (0.79-1.58)

Seat WidthExhaust .0625-.09375 (1.58-2.38)

SProduction

Intake .0010-.0027(0.025-0.069)

StemCl


ClearanceService

Intake .0037(0.09) MaxService

Exhaust .0047(0.11) Max

Stem DiameterIntake .341(8.66)

Stem DiameterExhaust .372(9.45)

Valve Margin Intake and Exhaust .0312(0.79)

VALVE SPRING

Free Length 2.03(51.6) (See Note 1)

Valve Spring24-48347

Pressure(NOTE 2)

ValveClosed

76-84 Lb. Ft.(103-113 N⋅m) at1.785(43.16)24 48347Lavender

Stripe

(NOTE 2)Valve Open 194-204 Lb. Ft. (263-279 N⋅m) at 1.250(31.75)

Stripe Installed Height Intake 1.7[1-45/64](43)

DamperFree Length 1.86[1-55/64](47)

DamperApproximate Number of Coils 4

NOTE 1: Engines are equipped either roller hydraulic or flat hydraulic depending on model designation.NOTE 2: Test spring pressure with damper removed




CAMSHAFT AND DRIVE

Lobe Lift ± 002(0 051)Exhaust .263(6.680)

Lobe Lift ± .002(0.051)Intake .287(7.29) (See Note)

Duration at .050 In.(1.27mm)C f

Exhaust .269(6.833)( )Cam Lift Intake .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 Rotation]

.375(9.5) from taut position [total .75(19)]

FLYWHEEL

Runout .008(0.203) Max

CYLINDER HEAD

Gasket Surface Flatness .004(0.1016) Overall Maximum


350 CID / 5.7L Gen+ Engine Specifications


EngineModel 350 CID / 5.7L


Bore 4.00(101.6)

Stroke 3.48(88.4)


Heads Cast Iron

Intake Manifold Cast Aluminum


Rods Powdered Metal



Camshaft Steel


350 CID Gen + Engine Specifications


NOTE: These specifications cover only Gen + engines.

CYLINDER BORE

Diameter 4.0007-4.0017(101.618-101.643)



TProduction


TaperProduction



PISTON CLEARANCE

Production .0007-.0021(0.018-0.053) Max



G ClProduction

Top0012- 0032(0 030-0 081)


2nd.0012-.0032(0.030-0.081)


GProduction

Top .010-.020(0.25-0.51)

GapProduction

2nd .018-.026(0.46-0.66)

Service High Limit Production ± .010(0.25)

PISTON RING: OIL


Groove ClearanceService High Limit Production ± .001(0.025)

GapProduction .010-.030(0.25-0.76)

GapService Limit High Limit Production ± .001(0.25)

PISTON PIN

Diameter .9270-.9271(23.545-23.548)

ClearanceProduction .0004-.0008(0.0120-0.0210)






CRANKSHAFT

Main Journal

Diameter No.1 2.4484-2.4493(62.189-62.212)

M i

DiameterNo. 2, 3, 4 2.4481-2.4490(62.182-62.205)

M i

DiameterNo.5 2.4479-2.4488(62.177-62.199)

Main TaperProduction .0002(0.005) Max

JournalTaper




M i B i

P d i

No.1 .0007-.0021(0.018-0.053)

M i B i

Production No.2, 3, 4 .0022-.00610(0.0009-0.0024)

Main BearingC

No.5 .00250-.00690(0.0010-0.0027)gClearance

S i

No.1 .0010-.0.0020(0.250-0.510)

Service No.2, 3, 4 .0010-.0025(0.0250-0.0640)

No.5 .0025-.0035(0.0760-0.0380)


C i R d

Diameter 2.0978-2.0998(53.2840-53.3340)

Connecting Rod TaperProduction .0003(0.007) Max


TaperService .001(0.025) Max

Journal



Rod Bearing ClearanceProduction .0006-.0014(0.16-0.35)

Rod Bearing ClearanceService 0.0010-0.0030(0.025-0.076)

Rod Side Clearance .006-.014(0.15-0.35)




VALVE SYSTEM

Lifter Type Roller Hydraulic


Valve LiftIntake .431(10.947)

Valve LiftExhaust .450(11.43)

Valve Lash (Intake & Exhaust) 1 Turn Down from Zero Lash


Seat Runout (Intake & Exhaust) .002(0.05) Max

Seat WidthIntake .040-.0625(1.02-1.65)

Seat WidthExhaust .065-.098(1.65-2.49)

SProduction

Intake .0010-.0027(0.025-0.069)

StemCl


ClearanceService

Intake High Limit Production + .001(0.025)Service

Exhaust High Limit Production + .0002(0.050)

VALVE SPRING

Free Length 2.02(51.3)

Valve SpringPressure

ValveClosed

76-84 Lb. Ft.(338-374 N) at 1.70(43.18)

Valve Spring Valve Open 187-203 Lb. Ft. (832-903 N) at 1.27(32.26)

Installed Height Intake 1.69-1.71(42.92-43.43)


350 Gen + Engine Specifications


CAMSHAFT

Lobe Lift ± 002(0 051)Exhaust .300(7.62)

Lobe Lift ± .002(0.051)Intake .287(7.289)


Exhaust .294(7.467)( )Cam Lift Intake .307(7.797)


End Play .011-0.030(0.004-0.0012)

Timing Chain Deflection[LH Rotation]

.375(9.5) from taut position [total .75(19)]

FLYWHEEL


CYLINDER HEAD

Gasket Surface Flatness .004(0.10) Overall Maximum


454 CID / 7.4L / 502 CID / 8.2L

Special Tools
















Connecting Rod Guide Tool (7/16-20) J35228


Lift Indicator Tool J8520



Crankshaft Gear and Sprocket Puller J24420-B

Crankshaft Gear and Sprocket Installer J20158-20

Air Adapter (Cylinder Inflator) J23590


Rear Main Seal Installer J38841






General Motors Cam and Lifter Prelubeor Equivalent

Obtain Locally


454 CID / 7.4L / 502 CID / 8.2L Torque Specifications

DESCRIPTION Lb. In. Lb. Ft. N⋅mAlternator Brace to Alternator 192 9




Camshaft Sprocket Gear 18 24

Carburetor 132 15

Connecting Rod Caps (3/8-24 Nuts) 50 68

(7/16-20 Nuts) 73 99

Coupler/Flywheel(MCM) 35 48

Crankcase Front Cover 120 14

Crankshaft Pulley 35 48

Cylinder Head 85 115


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




Fuel Pump 25 34

Intake Manifold 35 48 (See Note)


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 (MIE) 50 68

Remote Oil Connector (1/2 in. x 13) 25 34


Rocker Arm Bolts 7.4L/454/

40 54454 Magnum/502 45 61

Note: 7.4L / 454 and 502 MPI engines, Torque intake manifold fasteners to 25-30 Lb. Ft. (34-41 N·m).


454 CID / 7.4L / 502 CID / 8.2L Torque Specifications

DESCRIPTION Lb. Ft. N⋅mRemote Oil Filter Adapter Nut/Fitting 20 27

Seawater Pump Brace 30 41

Seawater Pump Bracket 30 41

Spark Plugs 15 20

Starter Motor 50 68



Transmission To Housing 50 68




454 CID / 7.4L / 502 CID / 8.2L Engine Specifications

Unit of Measurement In. (mm)

DISPLACEMENT 7.4L 454 MAGNUM 502 MAGNUM / 8.2L

Bore 4.25 (108) 4.46 (113.28)

Stroke 4.00 (101.6)

Compression 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)


Rods Forged Steel

Pistons Cast Aluminum Forged Aluminum

Crankshaft Cast Steel Forged Steel

Camshaft Cast Iron

Note: 7.4L / 454 and 502 Magnum MPI are equipped with a cast aluminum intake manifold with brass inserts.

CYLINDER BORE

ENGINE 7.4L 454 MAGNUM 502 MAGNUM/8.2L

Diameter 4.2500-4.2507(107.950-107.967)

4.2451-4.2525(107.826-108.013)

4.4655-4.4662(113.423-113.441)



TProduction


TaperProduction



PISTON

ClearanceProduction .0018-.0030

(0.0457-0.0762).0025-.0037

(0.0635-0.0939).0040-.0057

(0.1016-0.1447)Clearance

Service .0018(0.0457)Max

.0075(0.15) Max .0065(0.16) Max




PISTON RING

ENGINE 7.4L 454 MAGNUM 502 MAGNUM8.2L

C Groove Production

Top .0012-.0029(0.0305-0.0737)

.0017-.0032(0.044-0.081)

.0017-.0032(0.044-0.081)

Comp

GrooveSide

Clearance

Production

2nd .0012-.0029(0.0305-0.0737)

.0017-.0032(0.044-0.081)

.0017-.0032(0.044-0.081)

pr Service High Production Limit +.010(0.02) Max

ess

GProduction

Top .010-.018(0.25-0.46)

.011-.021(0.28-0.53)

sion

GapProduction

2nd .016-.024(0.41-0.61)

.016-.026(0.41-0.66)

nService High Limit Production + .010(0.25) Max

Oil

GrooveProduction .0050-.0065(0.127-0.165)

Oil

GrooveSide

Clearance Service High Limit Production + .001(0.25)High Limit

Production.005(0.12) Max

Oil

G

Production .010-.030(0.254-0.762)

.020-.035(0.508-0.889)

.010-.030(0.254-0.76)

GapService High Limit Production + .001(0.25)

High Limit Production

.005(0.12) Max

PISTON PIN

ENGINE 7.4L 454 MAGNUM 502 MAGNUM8.2L

Diameter .9895-.9897(25.132-25.1371)

.9895-.9898(25.134-24.140)

Clearance In PinProduc-

tion.0002-.0007

(0.0050-0.0177).00025-.00035

(0.0064-0.0088)


Fit In Rod.0021-.0031

(0.0533-0.0787)Interference

.0008-.0016(0.021-0.040)Interference




CRANKSHAFT

ENGINE 7.4L 502 MAGNUM / 8.2L 454 MAGNUM

M i

Diameter No.1,2,3,4,5 2.7482-2.7489(69.8042-69.8220)

Main TaperProduction .0004(0.010) Max .0002(0.005) Max

Main Journal


Journal



M i B i

ProductionNo.1,2,3,4 .0017-.0030

(0.043-0.076).0017-.0030

(0.043-0.076)

M i B i

No.5 .0025-.0038(0.063-0.096)

Main BearingClearance

S i

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(.0635-.1016)


.006-.0010(0.15-0.2)

C i

Diameter 2.1990-2.1996(55.8546–55.8698)

Connecting TaperProduction .0005(0.0127) Max

ConnectingRod Journal


Rod Journal



Rod Bearing ClearanceProduction .0011-.0029(0.028-0.074)

Rod Bearing ClearanceService .001(0.0254) Max .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




VALVE SYSTEM

ENGINE MODEL 7.4L 454 MAGNUM 502 MAGNUM 8.2L

Lifter Hydraulic



Seat Runout (Intake & Exhaust) .002(0.05) Max

Seat Width

Intake.0300 .0600 in.(0.7620-1.5240

mm)

.03125 .0625 in.(0.79-1.58 mm)

Seat Width

Exhaust.0600-.0950 in.(1.5240-2.4130

mm)

.0625-.09375 in.(1.58-2.38 mm)

SProduction

Intake .0010-.0029(0.0254-0.737)

.0010-.0027(0.025-0.069)

StemClearance

ProductionExhaust .0012-.0031

(0.0300-0.0787).0012-.0029(0.0304-0.0736)

ServiceIntake .001(0.02) .003(0.07) .0037(0.09)

ServiceExhaust .002(0.05) .004(0.10) .0049(0.12)

Stem DiameterIntake .372(9.45)

Stem DiameterExhaust .372(9.45)

Valve Margin Intake and Exhaust .0312(0.79)

Valve Lash (Intake and Exhaust) Fixed Lash




VALVE SPRING

ENGINE MODEL 7.4L454 MAGNUM502 MAGNUM

8.2L

V l S i

Free Length 2.12(53.9) 2.15(54.6)

V l S iP

Closed at1.88 in. (47.8 mm)

Does Not Apply

110Lbs.(489 N)

Valve Spring(Note 1) Pressure

Closed at1.838 in. (46.7 mm)

71-79 Lbs.(316-351 N)

Does Not Apply

(Note 1)(Note 2)

PressureOpen at

1.34 in. (35.1 mm)Does Not

Apply316 Lbs.(1406 N)

Open at1.347 in. (34.120 mm)

238-262 Lbs.(1059-1165 N)

Does Not Apply

Installed Height 1.838(46.7) 1.88(47.7)

Damper or DamperS

Free Length Does Not 1.86(47.2)p pShield Approximate Number Of Coils Apply 4

Damper or DamperShield

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.




ROLLER TAPPET CAMSHAFT

ENGINE MODEL 7.4L454 MAGNUM502 MAGNUM

8.2L

Lobe Lift ± 020 (0 051)Exhaust .284 (7.214) .342 (8.687)

Lobe Lift ± .020 (0.051)Intake .282 (7.163) .342 (8.687)


Exhaust 209° 227°( )Cam Lift Intake 209° 211°


Journal Out Of Round .001(0.025) Max

Camshaft Runout .002(0.051) Max

Timing Chain Deflection .375(9.5) from taut position [total .75(19)]

FLYWHEEL


CYLINDER HEAD

Gasket Surface Flatness

.004(0.1016)Overall Maximum

.003(0.076)within a6 in.(152 mm) Span

.007(0.178)Overall Maximum

.003(0.076)within a6 in.(152 mm) Span


Cylinder Head Torque Sequences

IMPORTANT: Torque to specifications listed in sequence until maximum torque is reached.

3.0LX

20 lb. ft. (27 N⋅m)26 31

07

50 lb. ft. (68 N⋅m)

15 4

0

90 lb. ft. (120 N⋅m)15 4

9 8

4.3LX / 4.3LXH / 262 Magnum Gen+

22 lb. ft. (30 N⋅m) First Sequence

Angle Torque Second Sequence

Short Bolts 55 Degrees

Medium Bolts 65 Degrees

Long Bolts 75 Degrees 72883

5.7L / 350 CID

20 lb. ft. (27 N⋅m)

40 lb. ft. (54 N⋅m)

65 lb. ft. (88 N⋅m)72332


Cylinder Head Torque Sequences (Continued)

350 Gen +

22 lb. ft. (30 N⋅m) First Sequence

Angle Torque Second Sequence

Short Bolts 55 Degrees

Medium Bolts 65 Degrees

Long Bolts 75 Degrees 72332

7.4L / 454 CID / 8.2L / 502 CID

20 lb. ft. (27 N⋅m)

50 lb. ft. (68 N⋅m)

85 lb. ft. (115 N⋅m)72944


Intake Manifold Torque Sequence

IMPORTANT: Install and hand tighten all manifold bolts, then torque to specification in sequence asshown.

5.7L / 350

35 lb. ft. (48 N⋅m) FRONT

72878

4.3LX / 4.3 LXH / 5.7L / 350 CID Gen +

14 58

Torque Three StepsFirst Step - 27 lb. in. (3 N·m)Second Step - 106 lb. in. (12 N·m)Third Step - 133 lb. in. (15 N⋅m)

FRONT

1

2 3

4 5

6 7

8

72878

454 CID / 7.4L / 502 CID / 8.2L

Carburetor and Throttle Body Injection35 lb. ft. (48 N⋅m) 9 8 10 2 3 11 12 13

Multi-Port Injection 25-30 lb. ft. (34-41 N⋅m)

FRONT

7 6 5 1 4 16 14 167 6 5 1 4 16 14 16

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AT A LATER DATE


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