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MerCruiser 502 MAGNUM User Manual

MerCruiser 502 MAGNUM
71 pages
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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)

Table of Contents

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MerCruiser 502 MAGNUM Specifications

General IconGeneral
Engine TypeV8
Displacement502 cu in (8.2 L)
Fuel SystemElectronic Fuel Injection (EFI)
Ignition SystemElectronic
Cooling SystemRaw water or closed cooling
Alternator65 amp
Bore x Stroke4.47 in x 4.00 in
Horsepower415 HP
Recommended Fuel87 Octane
Torque500 lb-ft (678 Nm)

Summary

Torque Specifications

Gen V And Gen VI Engine Specifications

Bearing Failures

Piston Failures

Pre-Ignition

Explains abnormal fuel ignition, causes, and potential engine damage.

Detonation

Describes abnormal combustion, causes like low octane fuel, and potential damage.

Cylinder Head Service

Cylinder Head and Valve Conditioning

Cylinder Head Inspection and Repair

Valve Guide Bore Repair

Procedure for reaming valve guide bores for oversized valves.

Valve Seat and Spring Service

Valve Seat Repair

Importance of valve seat reconditioning for performance and heat dispersion.

Valve Grinding and Reassembly

Oil Pan Service

Oil Pump Service

Oil Pump Cleaning, Reassembly, and Installation

Torsional Damper Service

Crankcase Front Cover and Oil Seal Service

Oil Seal Replacement (Without Removing Front Cover)

Procedure for replacing the front oil seal without removing the cover.

Crankcase Front Cover Installation and Flywheel Removal

Flywheel

Procedures for removing the flywheel, coupler, and drive plate.

Main Bearings Service

Checking Clearances

Procedure for measuring main bearing and journal clearances using Plastigage.

Main Bearing and Connecting Rod Bearing Service

Main Bearings

Procedures for installing main bearings with or without crankshaft removed.

Connecting Rod Bearings

Details on connecting rod bearings, their types, and adjustment limitations.

Inspection and Replacement

Steps for inspecting and replacing connecting rod bearings, including marking.

Connecting Rod/Piston Assembly Service

Connecting Rod/Piston Assembly

Procedures for removing piston and rod assemblies, including ridge reaming.

Connecting Rod and Piston Service

Crankshaft Service

Crankshaft Installation and Timing Chain Procedures

Timing Chain and Sprocket

Procedures for removing timing chains and sprockets.

Timing Chain and Sprocket Service

Camshaft Service

Camshaft

General information about the camshaft.

Measuring Lobe Lift

Procedure for measuring camshaft lobe lift using a dial indicator.

Camshaft Removal and Camshaft Bearings Service

Camshaft Bearings Installation

Camshaft Bearings

Detailed instructions for installing camshaft bearings.

Cylinder Block Service

Cylinder Block Conditioning and Honing

CYLINDER CONDITIONING

Evaluating cylinder block condition and suitability for honing or boring.

CYLINDER BORING

Procedures for boring cylinder bores to specified clearances.

CYLINDER HONING

Instructions for honing cylinder bores to achieve proper piston fit.

Piston Selection

Oil Filter By-Pass Valve and Adaptor Service

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