ENGINES

3
A

72872

MECHANICAL INFORMATION

Index
Table of Contents
Page
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

3A-0 - MECHANICAL INFORMATION Index 90-806535970 1296

Engine Identification V-8
MCM (Stern Drive) Code Rotation
4 Cylinder 5.7L Bravo
5.7L Alpha
MJ
5.7L Alpha EFI
5.7L Bravo EFI
5.7LX, Alpha
5.7LX Bravo MD LH
350 Magnum Alpha
350 Magnum EFI
a Alpha Gen +
5.7L Bravo EFI Gen+ MH

73584
350 Magnum MPI Gen +
Bravo and Blackhawk
a - Location of G.M. Engine Code
MIE (Inboard) Code Rotation
MCM (Stern Drive) Code Rotation
5.7L MM
3.0LX RK LH
5.7L Competition Ski MJ
350 Magnum Tournament Ski LH
V-6 350 Magnum MPI Tournament MH
Ski (Black Scorpion)

MCM (Stern Drive) Code Rotation

7.4L XW
7.4L Bravo Three (Note) XX
7.4LX EFI Bravo UJ
7.4LX MPI Bravo UD LH
a
454 Magnum XA
72312
454 Magnum MPI UA
a - Location of GM Engine Code
502 Magnum MPI HJ

MCM MIE (Inboard) Code Rotation

Code Rotation
(Stern Drive)
7.4L XY
4.3LX Gen + Alpha and Bravo LJ
7.4L EFI UK
4.3LXH Gen +
LH 7.4L MPI UD LH
Alpha and Bravo LK
262 Magnum EFI Gen + 8.2L HH
454 EFI Ski UA

90-806535970 1296 Index MECHANICAL INFORMATION - 3A-1

 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

DESCRIPTION PART NUMBER
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
Stud Bore Reamer (.013 in. oversize) J6036
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

3A-2 - MECHANICAL INFORMATION Index 90-806535970 1296

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⋅m
Camshaft 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 or
15 1.7
Crankcase
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.

90-806535970 1296 Index MECHANICAL INFORMATION - 3A-3

181 CID / 3.0L Engine Specifications

UNIT OF MEASUREMENT
in. (mm)

CYLINDER BORE

Diameter 3.9995-4.0025(101.588-101.790)
Production .0005(0.012) Max
Out of Round
Service .002(0.05) Max
Thrust Side .0005(0.012) Max
Production
T
Taper 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

Top
Groove Production .0012-.0029(0.030-0.073)
0012- 0029(0 030-0 073)
2nd
Clearance
Service .003(0.09) Max
Top
Production .010-.020(0.254-0.762)
010- 020(0 254-0 762)
G
Gap 2nd
Service .035(0.88) Max

PISTON RING: OIL

Production .001-.006(0.026-0.152)
Groove Clearance
Service Limit .007(0.17) Max
Production .010-.030(0.254-0.762) Max
Gap
Service Limit .040(1.01) Max

PISTON PIN

Diameter .9270-.9271(23.546-23.550)
Production .0003-.0006(0.008-0.016)
Clearance
Service Limit .001(0.02) Max
Fit in Rod .0008-.0019(0.020-0.050) Interference

3A-4 - MECHANICAL INFORMATION Index 90-806535970 1296

181 CID / 3.0L Engine Specifications

CRANKSHAFT

Diameter 2.2979-2.294(58.367-58.404)
Production .0002(0.005) Max
Taper
M i JJournall
Main Service .001(0.02) Max
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
M i Bearing
B i g Service No.5 .0016-.0035(0.041-0.088)
C
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)
Production .0003(0.007) Max
Taper
C k i
Crankpin Service .001(0.02) Max
Production .0002(0.51) Max
Out of Round
Service .001(0.02) Max
Rod Bearing Production .0017-.0027(0.044-0.0686)
Clearance Service N/A
Rod Size Clearance .006-.017(0.153-0.4318) Max

CAMSHAFT

Intake .2529(6.425)
Lobe Lift (Max
(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

.003-.008 in any 6 in.(152)

Gasket Surface Flatness
or .007(0.15) Overall Maximum

90-806535970 1296 Index MECHANICAL INFORMATION - 3A-5

181 CID / 3.0L Engine Specifications

VALVE SYSTEM

Lifter Hydraulic
Rocker Arm Ratio 1.75 to 1
Collapsed Tappet Gap 3/4 Turn Down from Zero Lash
Intake 45°
Face Angle
Exhaust 45°
Seat Angle (Intake & Exhaust) 46°
Seat Runout (Intake & Exhaust) .002(0.05) Max
Intake 1/16 [.0625] in. (1.16 mm)
Seat Width
Exhaust 1/16-5/64 [.0625-.07812] in. (1.6-2.0 mm)
Intake .0010-.0027(0.025-0.069)
Production
S
Stem Exhaust .0007-.0027(0.018-0.069)
Clearance
C Intake .003(0.09) Max
Service
Exhaust .004(0.11) Max
Free Length 2-1/16(52)
Valve Closed 100-110 lb. (136-149 N) at 1-19/32 in. (41 mm)
Pressure
Sp i g
Spring Valve Open 208-220 lb. (282-300 N) at 1-7/32 in. (31 mm)
Installed Intake
Height± 1/32[1 6562] (42)
1/32[1.6562]
.031(8) Exhaust
Internal Damper None

3A-6 - MECHANICAL INFORMATION Index 90-806535970 1296

 262 CID / 4.3L Gen+

Special Tools
MERCURY MARINE SPECIAL TOOLS
DESCRIPTION PART NUMBER
Piston Ring Expander 91-24697
Engine Coupler Wrench 91-35547

SNAP-ON SPECIAL TOOLS

DESCRIPTION PART NUMBER
Torque Angle Gauge (Degree Wheel Torquing) TA360

KENT-MOORE SPECIAL TOOLS

DESCRIPTION PART NUMBER
Valve Spring Compressor (Head On) J5982
Valve Spring Compressor (Head Off) J8062
Valve Spring Tester J8056
Valve Guide Cleaner J8101
Valve Guide Reamer J5830-2
Valve Guide Reamer J7049
Carbon Remover Brush J8089
Piston Pin Remover Kit J24086-B
Piston Ring Groove Cleaner J3936-03
Piston Ring Compressor J8037
Connecting Rod Bolt Guide Set (3/8-24) J5239
Oil Pump Suction Pipe Installer J21882
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

90-806535970 1296 Index MECHANICAL INFORMATION - 3A-7

Lubricants/Sealers/Adhesives
DESCRIPTION PART NUMBER
Quicksilver Loctite 8831 92-823089-1
Quicksilver Perfect Seal 92-34227-1
Quicksilver RTV Sealer 92-91601-1
General Motors Cam and Lifter Prelude Obtain Locally

262 CID / 4.3L Torque Specifications

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 22 30

Angle Torque Second Sequence Short Bolt 55 Degrees
Medium Bolt 65 Degrees
Long Bolt 75 Degrees
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 25

3A-8 - MECHANICAL INFORMATION Index 90-806535970 1296

262 CID / 4.3L Torque Specifications
DESCRIPTION Lb. In. Lb. Ft. N⋅m
Fuel 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 Bolts
15 20
Oil Pan Drain Plug
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
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)
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

90-806535970 1296 Index MECHANICAL INFORMATION - 3A-9

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

LH ROTATION
FRONT

Firing Order
1-6-5-4-3-2

72976

3A-10 - MECHANICAL INFORMATION Index 90-806535970 1296

262 CID / 4.3L Gen + Engine Specifications

Unit of Measurement
in. (mm)

CYLINDER BORE

Diameter 4.0007-4.0017(101.618-101.643)
Production .001 (0.025) Maximum
Out of Round
Service .002 (0.051) Maximum
Thrust Side .0005 (0.012) Maximum
Production
T
Taper 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)

Top .02-.06 (0.51-1.52)

Production
G
Groove Clearance
Cl 2nd .04-.08 (1.02-2.03)
Service .0042 (0.107) Maximum
Top .010-.016 (0.25-0.40)
Production
G
Gap 2nd .018-.026 (.046-.066) Maximum
Service 0.06-0.035 (1.524-0.88) Maximum

PISTON RING: OIL

Production .002-.007 (0.51-0.20)

Groove Clearance
Service 0.02-0.08 (0.51-2.032)
Production .015-.050 (0.38-1.27)
Gap
Service Limit 0.009-0.065 (0.23-1.65)

PISTON PIN

Diameter .9267-.9271 (23.545-23.548)

Production .0002-.0007 (0.005-0.0178)
Clearance
Service Limit .001 (0.025) Maximum
Fit in Rod .0008-.0016 (0.021-0.040) Interference

90-806535970 1296 Index MECHANICAL INFORMATION - 3A-11

262 CID / 4.3L Engine Gen + Specifications

Unit of Measurement
in. (mm)

CRANKSHAFT

No.1 2.4488-2.4495 (62.199-62.217)

Di
Diameter No. 2, 3 2.4485-2.4494 (62.191-62.215)
No.4 2.4479-2.4489 (62.179-62.203)
M i
Main
Production .0003 (0.007) Maximum
Journal Taper
Service .001 (0.025) Maximum
Production .0002 (0.005) Maximum
Out of Round
Service .001 (0.025) Maximum
No.1 .0008-.0020 (0.020-0.051)
g
Main Bearing Production
No.2, 3, 4 .0010-.025 (0.025-0.635)
C
Clearance
Service No 1 2,
No.1, 2 3,
3 4 .0010
0010 .0020
0020 (0.03
.0010-.0020 (0 03 0.051)
0 051)
(0.03-0.051)
Crankshaft End Play .002-.008 (0.05-0.20)
Diameter 2.2487-2.2497 (57.117-57.142)
Production .0003 (0.007) Maximum
C
Connecting
i R Rod
d Taper
Service .001 (0.025) Maximum
Journal
Production .0002 (0.0051) Maximum
Out of Round
Service .001 (0.025) Maximum
Production .0013-.0035 (0.033-0.088)
Rod Bearing Clearance
Service .0010-.0030 (0.025-0.076)
Rod Side Clearance .006-.017 (0.15-0.43)
Crankshaft Runout .001 (0.025) Maximum

3A-12 - MECHANICAL INFORMATION Index 90-806535970 1296

262 CID / 4.3L Gen + Engine Specifications

Unit of Measurement
in. (mm)

VALVE SYSTEM

Lifter Hydraulic Roller

Rocker Arm Ratio 1.50 to 1
Intake .414 (10.52)
Valve Lift
Exhaust .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
Intake .035-.060 (0.89-1.52)
Seat Width
Exhaust .062-.093 (1.58-2.38)
Intake
Production .0010-.0027
0010- 0027 (0.025-0.069)
(0 025-0 069)
Stem
S Exhaust
C
Clearance Intake .001 (0.025) Maximum
Service
Exhaust .002 (0.51) Maximum
Intake
Stem Diameter .3400-.3407
3400- 3407 (8.636-8.653)
(8 636-8 653)
Exhaust
Valve Margin Intake and Exhaust .031 (0.79)

VALVE SPRING

Free Length 2.03 (51.6)

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

90-806535970 1296 Index MECHANICAL INFORMATION - 3A-13

262 CID / 4.3L Gen + Engine Specifications

Unit of Measurement
in. (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)

3A-14 - MECHANICAL INFORMATION Index 90-806535970 1296

 350 CID / 5.7L

Special Tools
MERCURY MARINE SPECIAL TOOLS
DESCRIPTION PART NUMBER
Piston Ring Expander 91-24697
Engine Coupler Wrench 91-35547
Rocker Stopper 91-66273

KENT-MOORE SPECIAL TOOLS

DESCRIPTION PART NUMBER
Valve Spring Compressor (Head on) J5892
Valve Spring Compressor (Head off) J8062
Valve Spring Tester J8056
Valve Guide Cleaner J8101
Valve Guide Reamer (Standard) J7049
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
Stud Bore Reamer (.013 in. oversize) J6036
Carbon Remover Brush J8089
Piston Pin Tool J24086-B
Piston Ring Groove Cleaner J3936-03
Piston Ring Compressor J8037
Connecting Rod Guide Tool (3/8 -24) J5239
Oil Pump Suction Pipe Installer J21882
Camshaft Bearing Installer/Remover Tool J6098-01
Ball Socket Adapter J8520-1
Torsional Damper Remover and Installer J23523-E
Crankcase Front Cover Seal Installer J35468
Crankshaft Gear and Sprocket Puller J5825-A
Crankshaft Gear and Sprocket Installer J5590
Air Adapter J23590
Main Bearing Remover and Installer J8080
Rear Main Seal Installer J26817-A

90-806535970 1296 Index MECHANICAL INFORMATION - 3A-15

Lubricants/Sealers/Adhesives
DESCRIPTION PART NUMBER
Quicksilver Loctite 8831 92-823089-1
Quicksilver Perfect Seal 92-34227-1
Quicksilver Needle Bearing Assembly Lubricant 92-825265A1
Quicksilver RTV Sealer 92-91601-1
General Motors Cam and Lifter Prelube or Equiva- Obtain Locally
lent

350 CID / 5.7L Torque Specifications

NOTE: Any Differences in Gen + Engines Will Be Noted With ”Gen +”.

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
Camshaft Sprocket Gear 216 24
Carburetor 132 15
Connecting Rod Cap Nuts 45 61
Connecting Rod Cap Nuts
20 27
Gen +(Plus An Additional 55 Degrees)
Coupler/Flywheel(MCM)
35 48
Crankshaft Pulley
Cylinder Head Bolt 65 88
Cylinder Head Bolt Gen + First Sequence 22 30
A l Torque
Angle T S
Second dS
Sequence ShShortt B lt
Bolt 55 Degrees
g
Medium Bolt 65 Degrees
g
Long Bolt 75 D
Degrees
Distributor Hold Down 25 34
Exhaust Manifold
20 27
Filter Adapter (5/16-18)
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

3A-16 - MECHANICAL INFORMATION Index 90-806535970 1296

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

DESCRIPTION Lb. In. Lb. Ft. N⋅m

Intake Manifold Bolts Gen+
27 3
(Torque Three Steps) First Step
Second Step 106 12
Third Step 133 15
Main Bearing Cap 80 109
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 Block
30 41
Power Steering Pump Bracket
Rear Crankshaft Oil Seal Retainer Screws and
133 15
Nuts
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
Spark Plugs 15 20
Starter Motor 50 50
Thermostat Housing 30 41
Timing Chain or Gear Cover 106 12
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 144 16
Seawater Pump Brace
30 41
Seawater Pump Bracket

90-806535970 1296 Index MECHANICAL INFORMATION - 3A-17

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

Unit Of Measurement
In. (mm)

MCM MCM MCM 350

Engine
5.7L 5.7L Magnum
Model
Alpha Bravo Alpha
Displacement 350 CID (5.7 Litre)
Bore 4.00(101.6)
Stroke 3.48(88.4)
Compression Ratio 9.3:1
Heads Cast Iron
Intake
Cast Iron (Magnums-High Rise-See Note 2)
Manifold
Block Cast Iron (2 Bolt Main Bearing Caps)
Rods Forged Steel
Crankshaft Cast Iron
Pistons Cast Aluminum
Steel
Camshaft Cast Iron
(See Note 1)
Fuel Pump Cast Iron
Steel
Push Rod (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

3A-18 - MECHANICAL INFORMATION Index 90-806535970 1296

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

Unit Of Measurement
In. (mm)

Engine MCM MCM

Model 5.7L EFI Alpha 5.7L EFI Bravo
Displacement 350 CID (5.7 Litre)
Bore 4.00(101.6)
Stroke 3.48(88.4)
Compression Ratio 9.3:1
Heads Cast Iron
Intake Manifold Cast Iron
Block Cast Iron (2 Bolt Main Bearing Caps)
Rods Forged Steel
Crankshaft Cast Iron
Pistons Cast Aluminum
Camshaft Steel (See Note 1)
Fuel Pump
Cast Iron (See Note 1)
Push Rod

Note 1: Engine with roller lifters and steel camshaft

90-806535970 1296 Index MECHANICAL INFORMATION - 3A-19

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

Unit Of Measurement
In. (mm)

MIE MIE
Engine MIE 5.7L 350 Magnum
Model 5.7L Competition Tournament
Ski Ski
Displacement 350 CID (5.7 Litre)
Bore 4.00(101.6)
Stroke 3.48(88.4)
Compression Ratio 9.3:1
Heads Cast Iron
Intake Manifold Cast Iron (Magnum-High Rise-See Note 2)
Block Cast Iron (2 Bolt Main Bearing Caps)
Rods Forged Steel
Crankshaft Cast Iron
Pistons Cast Aluminum
Camshaft Cast Iron Steel (Note 1)
Fuel Pump
Steel Cast Iron (Note 1)
Push Rod

Note1: Engine with roller lifters and steel camshaft

Note 2: Includes- 350 Magnum Tournament Ski and 350 EFI Magnum Tournament Ski. Gen + engines with
an aluminum manifold.
A
LH ROTATION
FRONT

Firing Order
1-8-4-3-6-5-7-2

72008

3A-20 - MECHANICAL INFORMATION Index 90-806535970 1296

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

Unit Of Measurement
In. (mm)

CYLINDER BORE

3.9995-4.0025
Diameter
(101.5873-101.6635)
Production .001(0.025) Max
Out of Round
Service .002(0.05) Max
Thrust Side .0005(0.012) Max
Production
T
Taper 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

Top
Production .0012-.0032(0.030-0.081)
0012- 0032(0 030-0 081)
G
Groove Clearance
Cl 2nd
Service High Limit Production + .001(0.025)
Top ( )
.010-.020(0.254-0.508)
Production
Gap
G 2nd .010-.025(.0254-.0635)
( )
Service High Limit Production + .010(0.25)

PISTON RING: OIL

Production .002-.007(0.051-0.177)
Groove Clearance
Service High Limit Production + .001(0.025)
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)
Production .0002–.0007(0.005-0.017)
Clearance
Service Limit .001(0.02) Max
Fit in Rod .0008-.0016(0.020-0.406) Interference

90-806535970 1296 Index MECHANICAL INFORMATION - 3A-21

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

Unit Of Measurement
In. (mm)

CRANKSHAFT

No.1 2.4484-2.4493 (62.198-62.212)

Di
Diameter No. 2, 3 2.4481-2.4490 (62.181-62.204)
No.4 2.4479-2.4488 (62.176-62.199)
M i
Main
Production .0002 (0.005) Max
Journal Taper
Service .001 (0.02) Max
Production .0002 (0.005) Max
Out of Round
Service .001 (0.005) Max
No.1 .0008-.0020 (0.020-0.050)
Production
P d i No. 2, 3 .0011-.0023 (0.027-0.058)
Main
M i Bearing
B i g No.4 .0017-.0032 (0.043-0.081)
Cl
Clearance No.1 .0010-.0015 (0.025-0.038)
S i
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)
Production .0005 (0.021) Max
C
Connecting
i R Rod
d Taper
Service .001 (0.02) Max
Journal
Production .0005 (0.021) Max
Out of Round
Service .001 (0.02) Max
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

3A-22 - MECHANICAL INFORMATION Index 90-806535970 1296

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

Unit Of Measurement
In. (mm)

VALVE SYSTEM

Flat Hydraulic
Lifter Type (NOTE 1)
Roller Hydraulic
Rocker Arm Ratio 1.50 to 1
Intake .394(10.00)
Valve Lift
Exhaust .404(10.26)
Valve Lash (Intake and Exhaust) 1 Turn Down from Zero Lash
Intake 45°
Face Angle
Exhaust 45°
Seat Angle (Intake & Exhaust) 46°
Seat Runout (Intake & Exhaust) .002(0.05) Max
Intake .03215-.0625 (0.79-1.58)
Seat Width
Exhaust .0625-.09375 (1.58-2.38)
Intake .0010-.0027(0.025-0.069)
Production
S
Stem Exhaust .0010-.0027(0.025-0.069)
Clearance
Cl Intake .0037(0.09) Max
Service
Exhaust .0047(0.11) Max
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 Valve
Pressure 76-84 Lb. Ft.(103-113 N⋅m) at1.785(43.16)
24-48347
24 48347 Closed
(NOTE 2)
Lavender 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)
Free Length 1.86[1-55/64](47)
Damper
Approximate 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

90-806535970 1296 Index MECHANICAL INFORMATION - 3A-23

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

Unit Of Measurement
In. (mm)

CAMSHAFT AND DRIVE

Exhaust .263(6.680)
Lobe Lift ± .002(0.051)
002(0 051)
Intake .287(7.29) (See Note)
Duration at .050 In.(1.27mm)
( ) Exhaust .269(6.833)
C
Cam Lift
f 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
.375(9.5) from taut position [total .75(19)]
[LH Rotation]

FLYWHEEL

Runout .008(0.203) Max

CYLINDER HEAD

Gasket Surface Flatness .004(0.1016) Overall Maximum

3A-24 - MECHANICAL INFORMATION Index 90-806535970 1296

350 CID / 5.7L Gen+ Engine Specifications

Unit Of Measurement
In. (mm)

Engine
350 CID / 5.7L
Model
Displacement 350 CID (5.7 Litre)
Bore 4.00(101.6)
Stroke 3.48(88.4)
Compression Ratio 9.4:1
Heads Cast Iron
Intake Manifold Cast Aluminum
Block Cast Iron (2 Bolt Main Bearing Caps)
Rods Powdered Metal
Crankshaft Cast Iron
Pistons Cast Aluminum
Camshaft Steel

90-806535970 1296 Index MECHANICAL INFORMATION - 3A-25

350 CID Gen + Engine Specifications

Unit Of Measurement
In. (mm)

NOTE: These specifications cover only Gen + engines.

CYLINDER BORE

4.0007-4.0017
Diameter
(101.618-101.643)
Production .0005(0.12) Max
Out of Round
Service .002(0.05) Max
Thrust Side .0005(0.012) Max
Production
T
Taper Relief Side .001(0.025) Max
Service .001(0.025) Over Production

PISTON CLEARANCE

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

Service .0027(0.068) Max
PISTON RING: COMPRESSION
Top
Production .0012-.0032(0.030-0.081)
0012- 0032(0 030-0 081)
G
Groove Clearance
Cl 2nd
Service High Limit Production + .001(0.025)
Top .010-.020(0.25-0.51)
Production
G
Gap 2nd .018-.026(0.46-0.66)
Service High Limit Production ± .010(0.25)

PISTON RING: OIL

Production .002-.007(0.051-0.17)
Groove Clearance
Service High Limit Production ± .001(0.025)
Production .010-.030(0.25-0.76)
Gap
Service Limit High Limit Production ± .001(0.25)

PISTON PIN

Diameter .9270-.9271(23.545-23.548)
Production .0004-.0008(0.0120-0.0210)
Clearance
Service Limit .0010(0.025) Max
Fit in Rod .0008-.0016(0.021-0.40) Interference

3A-26 - MECHANICAL INFORMATION Index 90-806535970 1296

350 CID Gen + Engine Specifications

Unit Of Measurement
In. (mm)

CRANKSHAFT

Main
Diameter No.1 2.4484-2.4493(62.189-62.212)
Journal
No. 2, 3, 4 2.4481-2.4490(62.182-62.205)
Diameter
No.5 2.4479-2.4488(62.177-62.199)
Main
M i Production .0002(0.005) Max
Taper
Journal Service .001(0.025) Max
Production .0002(0.005) Max
Out of Round
Service .001(0.005) Max
No.1 .0007-.0021(0.018-0.053)
P d i
Production No.2, 3, 4 .0022-.00610(0.0009-0.0024)
Main
M i B
Bearing
i g No.5 .00250-.00690(0.0010-0.0027)
C
Clearance No.1 .0010-.0.0020(0.250-0.510)
S i
Service No.2, 3, 4 .0010-.0025(0.0250-0.0640)
No.5 .0025-.0035(0.0760-0.0380)
Crankshaft End Play .002-.008(0.0500-0.2000)
Diameter 2.0978-2.0998(53.2840-53.3340)
Production .0003(0.007) Max
C
Connecting
i R Rod
d Taper
Service .001(0.025) Max
Journal
Production .0003(0.007) Max
Out of Round
Service .001(0.025) Max
Production .0006-.0014(0.16-0.35)
Rod Bearing Clearance
Service 0.0010-0.0030(0.025-0.076)
Rod Side Clearance .006-.014(0.15-0.35)

90-806535970 1296 Index MECHANICAL INFORMATION - 3A-27

350 CID Gen + Engine Specifications

Unit Of Measurement
In. (mm)

VALVE SYSTEM

Lifter Type Roller Hydraulic

Rocker Arm Ratio 1.50 to 1
Intake .431(10.947)
Valve Lift
Exhaust .450(11.43)
Valve Lash (Intake & Exhaust) 1 Turn Down from Zero Lash
Face Angle (Intake & Exhaust) 45°
Seat Angle (Intake & Exhaust) 46°
Seat Runout (Intake & Exhaust) .002(0.05) Max
Intake .040-.0625(1.02-1.65)
Seat Width
Exhaust .065-.098(1.65-2.49)
Intake .0010-.0027(0.025-0.069)
Production
Stem
S Exhaust .0010-.0027(0.025-0.069)
Cl
Clearance Intake High Limit Production + .001(0.025)
Service
Exhaust High Limit Production + .0002(0.050)

VALVE SPRING

Free Length 2.02(51.3)

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

3A-28 - MECHANICAL INFORMATION Index 90-806535970 1296

350 Gen + Engine Specifications

Unit Of Measurement
In. (mm)

CAMSHAFT

Exhaust .300(7.62)
Lobe Lift ± .002(0.051)
002(0 051)
Intake .287(7.289)
Duration at .050 In.(1.27mm)
( ) Exhaust .294(7.467)
C
Cam Lift
f Intake .307(7.797)
Journal Diameter 1.8682-1.8692(47.440-47.490)
End Play .011-0.030(0.004-0.0012)
Timing Chain Deflection
.375(9.5) from taut position [total .75(19)]
[LH Rotation]

FLYWHEEL

Runout .008(0.203) Max

CYLINDER HEAD

Gasket Surface Flatness .004(0.10) Overall Maximum

90-806535970 1296 Index MECHANICAL INFORMATION - 3A-29

 454 CID / 7.4L / 502 CID / 8.2L

Special Tools
MERCURY MARINE SPECIAL TOOLS
DESCRIPTION PART NUMBER
Piston Ring Expander 91-24697
Engine Coupler Wrench 91-35547

KENT-MOORE SPECIAL TOOLS

DESCRIPTION PART NUMBER
Valve Spring Compressor (Head on) J5892
Valve Spring Compressor (Head off) J8062
Valve Spring Tester J8056
Valve Guide Cleaner J8101
Carbon Remover Brush J8089
Piston Pin Tool J24086-B
Piston Ring Groove Cleaner J3936-03
Piston Ring Compressor J8037
Connecting Rod Guide Tool (3/8 -24) J5239
Connecting Rod Guide Tool (7/16-20) J35228
Oil Pump Suction Pipe Installer J21882
Lift Indicator Tool J8520
Torsional Damper Remover and Installer J23523-E
Crankcase Front Cover Seal Installer J22102
Crankshaft Gear and Sprocket Puller J24420-B
Crankshaft Gear and Sprocket Installer J20158-20
Air Adapter (Cylinder Inflator) J23590
Main Bearing Remover and Installer J8080
Rear Main Seal Installer J38841

Lubricants/Sealers/Adhesives
DESCRIPTION PART NUMBER
Quicksilver Loctite 8831 92-32609-1
Quicksilver Perfect Seal 92-34227-1
Quicksilver RTV Sealer 92-91601-1
General Motors Cam and Lifter Prelube
Obtain Locally
or Equivalent

3A-30 - MECHANICAL INFORMATION Index 90-806535970 1296

454 CID / 7.4L / 502 CID / 8.2L Torque Specifications
DESCRIPTION Lb. In. Lb. Ft. N⋅m
Alternator Brace to Alternator 192 9
Alternator Brace to Engine 30 41
Alternator to Mounting Bracket 35 48
Alternator Mounting Bracket 30 41
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
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
Rocker Arm Cover 90 10
Rocker Arm Bolts 7.4L/454 40 54
454 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).

90-806535970 1296 Index MECHANICAL INFORMATION - 3A-31

454 CID / 7.4L / 502 CID / 8.2L Torque Specifications
DESCRIPTION Lb. Ft. N⋅m
Remote 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
Thermostat Housing 30 41
Torsional Damper 40 54
Transmission To Housing 50 68
Water Circulating Pump 35 48
Water Temperature Sender 20 27

3A-32 - MECHANICAL INFORMATION Index 90-806535970 1296

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 Cast Iron
(Oval Port) (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: 7.4L / 454 and 502 Magnum MPI are equipped with a cast aluminum intake manifold with brass inserts.

CYLINDER BORE
502 MAGNUM/
ENGINE 7.4L 454 MAGNUM
8.2L
4.2500-4.2507 4.2451-4.2525 4.4655-4.4662
Diameter
(107.950-107.967) (107.826-108.013) (113.423-113.441)
Production .001(0.025) Max
Out of Round
Service .002(0.05) Max
Thrust Side .0005(0.0127) Max
Production
T
Taper Relief Side .001(0.0254) Max
Service .001(0.02) Over Production
PISTON
.0018-.0030 .0025-.0037 .0040-.0057
Production
(0.0457-0.0762) (0.0635-0.0939) (0.1016-0.1447)
Clearance
.0018(0.0457)
Service .0075(0.15) Max .0065(0.16) Max
Max

90-806535970 1296 Index MECHANICAL INFORMATION - 3A-33

454 CID / 7.4L / 502 CID / 8.2L Engine Specifications
Unit of Measurement
In. (mm)
PISTON RING
502 MAGNUM
ENGINE 7.4L 454 MAGNUM
8.2L
.0012-.0029 .0017-.0032 .0017-.0032
Top
(0.0305-0.0737) (0.044-0.081) (0.044-0.081)
C Groove Production
o Side .0012-.0029 .0017-.0032 .0017-.0032
2nd
m Clearance (0.0305-0.0737) (0.044-0.081) (0.044-0.081)
p
r Service High Production Limit +.010(0.02) Max
e .010-.018 .011-.021
s Top
(0.25-0.46) (0.28-0.53)
s Production
i G
Gap .016-.024 .016-.026
o 2nd
(0.41-0.61) (0.41-0.66)
n
Service High Limit Production + .010(0.25) Max
Production .0050-.0065(0.127-0.165)
Groove
Side High Limit
Clearance Service High Limit Production + .001(0.25) Production
.005(0.12) Max
Oil .010-.030 .020-.035 .010-.030
Production
(0.254-0.762) (0.508-0.889) (0.254-0.76)
G
Gap High Limit
Service High Limit Production + .001(0.25) Production
.005(0.12) Max

PISTON PIN

502 MAGNUM
ENGINE 7.4L 454 MAGNUM
8.2L
.9895-.9897 .9895-.9898
Diameter
(25.132-25.1371) (25.134-24.140)
Produc- .0002-.0007 .00025-.00035
Clearance In Pin tion (0.0050-0.0177) (0.0064-0.0088)
Service .001(0.025) Max
.0021-.0031
.0008-.0016(0.021-0.040)
Fit In Rod (0.0533-0.0787)
Interference
Interference

3A-34 - MECHANICAL INFORMATION Index 90-806535970 1296

454 CID / 7.4L / 502 CID / 8.2L Engine Specifications
Unit of Measurement
In. (mm)

CRANKSHAFT

502 MAGNUM / 8.2L

ENGINE 7.4L
454 MAGNUM
Diameter No.1,2,3,4,5 2.7482-2.7489(69.8042-69.8220)
Production .0004(0.010) Max .0002(0.005) Max
M i
Main Taper
Service .001(0.02) Max
Journal
Production .0002(0.005) Max
Out of Round
Service .001(0.005) Max
.0017-.0030 .0017-.0030
No.1,2,3,4
Production (0.043-0.076) (0.043-0.076)
No.5 .0025-.0038(0.063-0.096)
Main
M i BBearing
i .001-.003 .0010-.0015
No.1
Clearance (0.03-0.07) (0.0254-0.0381)
S i
Service .001-.003 .0010-.0025
No.2,3,4
(0.03-0.07) (0.0254-0.0635)
No.5 .0025-.0040(.0635-.1016)
.005-.0011 .006-.0010
Crankshaft End Play
(0.127-0.279) (0.15-0.2)
Diameter 2.1990-2.1996(55.8546–55.8698)
Production .0005(0.0127) Max
C
Connecting
i Taper
Service .001(0.0254) Max
Rod Journal
Production .0005(0.0127) Max
Out of Round
Service .001(0.0254) Max
Production .0011-.0029(0.028-0.074)
Rod Bearing Clearance
Service .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

90-806535970 1296 Index MECHANICAL INFORMATION - 3A-35

454 CID / 7.4L / 502 CID / 8.2L Engine Specifications
Unit of Measurement
In. (mm)

VALVE SYSTEM

502 MAGNUM
ENGINE MODEL 7.4L 454 MAGNUM
8.2L
Lifter Hydraulic
Rocker Arm Ratio 1.70 to 1
Face Angle (Intake & Exhaust) 45°
Seat Angle (Intake & Exhaust) 46°
Seat Runout (Intake & Exhaust) .002(0.05) Max
.0300 .0600 in.
.03125 .0625 in.
Intake (0.7620-1.5240
(0.79-1.58 mm)
mm)
Seat Width
.0600-.0950 in.
.0625-.09375 in.
Exhaust (1.5240-2.4130
(1.58-2.38 mm)
mm)
.0010-.0029 .0010-.0027
Intake
(0.0254-0.737) (0.025-0.069)
Production
Stem
S .0012-.0031
Exhaust .0012-.0029(0.0304-0.0736)
Clearance (0.0300-0.0787)
Intake .001(0.02) .003(0.07) .0037(0.09)
Service
Exhaust .002(0.05) .004(0.10) .0049(0.12)
Intake .372(9.45)
Stem Diameter
Exhaust .372(9.45)
Valve Margin Intake and Exhaust .0312(0.79)
Valve Lash (Intake and Exhaust) Fixed Lash

3A-36 - MECHANICAL INFORMATION Index 90-806535970 1296

454 CID / 7.4L / 502 CID / 8.2L Engine Specifications
Unit of Measurement
In. (mm)

VALVE SPRING

454 MAGNUM
ENGINE MODEL 7.4L 502 MAGNUM
8.2L
Free Length 2.12(53.9) 2.15(54.6)
Closed at Does Not 110Lbs.
1.88 in. (47.8 mm) Apply (489 N)
Closed at 71-79 Lbs. Does Not
Valve
V l Spring
S i 1.838 in. (46.7 mm) (316-351 N) Apply
(Note 1) P
Pressure
(Note 2) Open at Does Not 316 Lbs.
1.34 in. (35.1 mm) Apply (1406 N)
Open at 238-262 Lbs. Does Not
1.347 in. (34.120 mm) (1059-1165 N) Apply
Installed Height 1.838(46.7) 1.88(47.7)
Damper
p or Damper
p Free Length Does Not 1.86(47.2)
S
Shield Approximate Number Of Coils Apply 4
Damper or Damper .42-.094(1.07-2.38) Does Not
Valve Spring Fit in Damper Shield
Shield Interference 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.

90-806535970 1296 Index MECHANICAL INFORMATION - 3A-37

454 CID / 7.4L / 502 CID / 8.2L Engine Specifications
Unit of Measurement
In. (mm)

ROLLER TAPPET CAMSHAFT

454 MAGNUM
ENGINE MODEL 7.4L 502 MAGNUM
8.2L
Exhaust .284 (7.214) .342 (8.687)
Lobe Lift ± .020
020 (0
(0.051)
051)
Intake .282 (7.163) .342 (8.687)
Duration at .050 In.(1.27mm)
( ) Exhaust 209° 227°
C
Cam Lift
f Intake 209° 211°
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 .375(9.5) from taut position [total .75(19)]

FLYWHEEL

Runout .008(0.203) Max

CYLINDER HEAD

.004(0.1016) .007(0.178)
Overall Maximum Overall Maximum
Gasket Surface Flatness
.003(0.076)within a .003(0.076)within a
6 in.(152 mm) Span 6 in.(152 mm) Span

3A-38 - MECHANICAL INFORMATION Index 90-806535970 1296

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

3.0LX

20 lb. ft. (27 N⋅m)

1 6 2 3 7
0

50 lb. ft. (68 N⋅m)

5 1 4
9 8
90 lb. ft. (120 N⋅m)

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

90-806535970 1296 Index MECHANICAL INFORMATION - 3A-39

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

3A-40 - MECHANICAL INFORMATION Index 90-806535970 1296

Intake Manifold Torque Sequence

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

5.7L / 350

35 lb. ft. (48 N⋅m) FRONT

72878

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

8 4 1 5

Torque Three Steps

First Step - 27 lb. in. (3 N·m) FRONT
Second Step - 106 lb. in. (12 N·m)
Third Step - 133 lb. in. (15 N⋅m)
6 2 3 7

72878

454 CID / 7.4L / 502 CID / 8.2L

Carburetor and Throttle Body Injection

35 lb. ft. (48 N⋅m) 9 8 10 2 3 11 12 13

Multi-Port Injection FRONT

25-30 lb. ft. (34-41 N⋅m)

7 6 5 1 4 16 14 16

90-806535970 1296 Index MECHANICAL INFORMATION - 3A-41

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3A-42 - MECHANICAL INFORMATION Index 90-806535970 1296

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ALLOW FOR CORRECTIONS OR ADDITIONS
AT A LATER DATE

90-806535970 1296 Index MECHANICAL INFORMATION - 3A-43