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454 MAGNUM
MerCruiser 454 MAGNUM User Manual
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90-823224--2 796
454 CID (7.4L) / 502 CID (8.2L) - 3A-–3
ENGINE
454 CID (7.4L) / 502 CID (8.2L)
2
Table of Contents
Table of Contents
2
Torque Specifications
5
Special Tools
7
Lubricants/Sealers/Adhesives
7
Gen V and Gen VI (Except 7.4L Gen VI) Engine Specifications
8
7.4L Gen VI Engine Specifications
14
General
19
Engine Identification
19
Cylinder Head Identification
19
Engine Rotation
20
Crankshaft
20
Piston and Connecting Rods
20
Camshaft and Drive
20
Cylinder Head
20
Valve Train
20
Intake Manifold
21
Lubrication System
21
Bearing Failures
22
Piston Failures
23
Pre-Ignition
23
Detonation
23
Engine Mounts
24
Rocker Arm Cover
26
Removal
26
Installation
26
Intake Manifold
26
Cleaning and Inspection
26
Installation
27
Rocker Arm / Push Rod
28
Removal
28
Cleaning and Inspection
28
Installation
28
Valve Adjustment
28
Hydraulic Valve Lifters (Flat and Roller Lifter)
28
Locating Noisy Lifters
29
Removal
29
Installation
30
Valve Stem Oil Seal/Valve Spring
30
Removal - Head Installed
30
Valve Assembly (Exploded View)
31
Installation - Head Installed
32
Cylinder Head
33
Removal
33
Cleaning and Inspection
33
Installation
33
Cylinder Head and Valve Conditioning
34
Disassembly
34
Cleaning
34
Inspection
35
Valve Guide Bore Repair
35
Valve Springs - Checking Tension
36
Valve Seat Repair
36
Valve Grinding
37
Reassembly
37
Dipstick Specifications
40
All Engines
40
Oil Pan
41
Removal
41
Installation
41
Oil Pump 3A-38
42
Removal
42
Disassembly
42
Cleaning and Inspection
43
Reassembly
43
Installation
43
Torsional Damper
43
Removal
43
Installation
44
Crankcase Front Cover/Oil Seal
45
Oil Seal Replacement (Without Removing Front Cover)
45
Crankcase
45
Removal
45
Cleaning and Inspection
45
Installation
46
Flywheel
46
Removal
46
Inspection
47
Installation
47
Rear Main Oil Seal
48
Removal
48
Cleaning and Inspection
48
Installation
49
Main Bearings
49
Inspection
49
Checking Clearances
49
Replacement
50
Connecting Rod Bearings
51
Inspection and Replacement
51
Connecting Rod/Piston Assembly
53
Removal
53
Disassembly
54
Cleaning and Inspection
54
Reassembly
55
Installation
57
Crankshaft
58
Removal
58
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MerCruiser 454 MAGNUM Specifications
General
Engine Type
V8
Compression Ratio
8.0:1
Displacement
454 cubic inches (7.4 liters)
Bore x Stroke
4.25 x 4.00 inches
Cooling System
Raw water or Closed cooling
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