Performance ZZ502 - User Manual

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ZZ502 Engine (19201332 Deluxe) Specifications

Specications Part Number 19171884

This ZZ502 Deluxe Crate Engine documentation should be used in conjunction with the ZZ502 short block, part number

19171883, and ZZ502 long block, part number 12487523. The documentation included within this information packet builds

on the ZZ502 short block and ZZ502 long block information. Please locate the ZZ502 short block and ZZ502 long block

information and begin there. This is the nal (third) section of the instruction for the ZZ502 deluxe engine assembly.

Thank you for choosing Chevrolet Performance Parts as your high performance source. Chevrolet Performance Parts

is committed to providing proven, innovative performance technology that is truly…. more than just power. Chevrolet

Performance Parts are engineered, developed and tested by the factory to exceed your expectations for fit and function.

This publication provides general information on components and procedures that may be useful when installing or

servicing a ZZ502 deluxe assembly. Please read this entire publication before starting work. Also, please verify that all of

the components listed in the Package Contents section below were shipped in the kit.

The information below is divided into the following sections: package contents, torque information, ZZ502 deluxe engine

assembly specications, engine start-up and break-in procedures, component information, and a service parts list.

The ZZ502 deluxe engine assembly includes additional components to the long block assembly which make up the deluxe

engine. Additional key items include the intake manifold, carburetor, distributor, and the water pump. The ZZ502 deluxe

engine is a fully assembled engine. This engine is assembled using brand new, premium quality components. The ZZ502

deluxe engine is manufactured on current production tooling; consequently you may encounter dissimilarities between

the ZZ502 deluxe engine assembly and previous versions of the big block V8. In general, items such as motor mounts,

accessory drives, exhaust manifolds, etc. can be transferred to a ZZ502 deluxe engine when installed in a vehicle originally

equipped with a big block V8 engine. However, as noted in the following sections, there may be signicant differences

in the water pump, torsional damper, etc., between a ZZ502 deluxe engine and an older big block V8 engine. These

differences may require modications or additional components not included with the ZZ502 deluxe engine. When installing

the ZZ502 deluxe engine in a vehicle not originally equipped with a big block V8, it may be necessary to adapt or fabricate

various components for the cooling, fuel, electrical, and exhaust systems. Due to the wide variety of vehicles in which a

ZZ502 deluxe engine can be installed, some procedures and recommendations may not apply to specic applications.

Chevrolet recommends that you use a minimum octane rating of 92 (R+M/2) fuel in the ZZ502 (9.6:1 compression ratio) to

prevent preignition. It is not the intent of these specications to replace the comprehensive and detailed service practices

explained in the factory service manuals.

For information about warranty coverage, please contact your local Chevrolet Performance Parts dealer.

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Overview

Function Description
Important Technical Specifications
Torque Specifications (in addition to short and long block instructions)
Mechanical Advance Curve (HEI Distributor)
Usage Features
Maintenance Features

The ZZ502 Deluxe Crate Engine is a high-performance, fully assembled engine manufactured by Chevrolet Performance Parts. This documentation, part number 19171884, serves as the final (third) section of the instruction for the ZZ502 deluxe engine assembly and should be used in conjunction with the ZZ502 short block (part number 19171883) and ZZ502 long block (part number 12487523) information. The engine is built with brand new, premium quality components and is designed to exceed expectations for fit and function.

Function Description:

The ZZ502 Deluxe Crate Engine is designed for off-highway applications, providing a powerful and reliable solution for enthusiasts and mechanics. It is a complete engine assembly, including key components such as the intake manifold, carburetor, distributor, and water pump, in addition to the long block assembly. The engine is intended for installation in vehicles, particularly those originally equipped with a big block V8 engine, though adaptations may be necessary for other vehicle types. Its primary function is to deliver high performance, with a focus on durability and advanced engineering.

Important Technical Specifications:

Engine Type: Big Block Chevrolet (BBC) V8
Compression Ratio: 9.6:1
Recommended Fuel: Minimum 92 (R+M/2) octane fuel to prevent preignition.
Initial Spark Timing: 10° before top dead center (BTDC) at 650 rpm (vacuum advance line disconnected and plugged).
Total Advance Timing: 32° at wide-open throttle (WOT) at 4000 RPM (using internal centrifugal advance only).
Distributor: HEI (High Energy Ignition) system, self-contained, Part Number 93440806. Requires a 12-volt power supply. Features a hardened drive gear compatible with a steel camshaft.
Water Pump: Aluminum, short style, standard rotation impeller, Part Number 12494151.
Carburetor: Holley 4-barrel Model 4160 dual feed fuel inlet, vacuum secondary carburetor. Features center hung float bowls, electric choke, power valve blow-out protection, and a secondary power valve. Calibrated specifically for ZZ502 crate engines.
Oil Type for Break-in: 5W30 non-synthetic motor oil.
Oil Filter for Break-in: PF454 AC Delco oil filter.
Air Cleaner: Not included. Chevrolet Performance Parts offers two chromed, 14-inch diameter, open element air cleaner assemblies (Part Numbers 141-306 and 141-302) with a 3-inch tall filter element (Part Number 6421746). A taller 4-inch element (Part Number 8997189) is also available.

Torque Specifications (in addition to short and long block instructions):

Distributor bolt/screw: 18 ft.-lbs. / 25 N-m
Flywheel bolt/screw: 65 ft.-lbs. / 90 N·m
Intake manifold bolt/screw:
- First pass: 10 ft.-lbs. / 14 N-m
- Second pass: 25 ft.-lbs. / 34 N-m
Oil level indicator tube bolt/screw: 106 in.-lbs. / 12 N-m
Oil pan drain plug: 15 ft.-lbs. / 20 N·m
Spark plug: 22 ft.-lbs. / 30 N·m
Starter motor bolt/screw: 35 ft.-lbs. / 48 N-m
Water pump bolt/screw: 30 ft.-lbs. / 40 N·m

Mechanical Advance Curve (HEI Distributor):

1100 RPM: 0.0° Advance
1600 RPM: 12.0° Advance
2400 RPM: 16.0° Advance
4600 RPM: 22.0° Advance

Usage Features:

Pre-installation: Users must ensure adequate clearance for the HEI's large diameter cap, which may interfere with other underhood components in vehicles not originally equipped with HEI ignition systems. For early-model vehicles with point-type ignition, the resistor in the wiring harness must be removed or bypassed to ensure the HEI receives 12 volts continuously.
Fluid Filling: The crankcase must be filled with 5W30 non-synthetic motor oil to the recommended level on the dipstick. Other necessary fluids like coolant and power steering fluid should also be checked and filled.
Engine Priming: Prior to starting, the engine should be primed with oil. This involves removing the distributor, installing an oil priming tool (part number 141-955), and rotating it clockwise with a 1/2" drill motor for three minutes. Simultaneously, the crankshaft should be rotated clockwise to distribute oil throughout the engine and to all bearing surfaces. The engine should also be primed if it sits for extended periods.
Safety Precautions: Before starting, ensure the emergency brake is set, wheels are chocked, and the car cannot fall into gear. All installations must verify proper component installation.
Initial Start-up and Timing Adjustment: Start the engine and adjust initial timing to 10° BTDC at 650 rpm with the vacuum advance line disconnected and plugged. The HEI vacuum advance canister should remain disconnected. The engine is designed to use only internal centrifugal advance for timing. Rotate the distributor counterclockwise to advance timing and clockwise to retard it.
Warm-up: It is recommended to allow the engine to warm up, reaching 180°F oil sump and water temperature, before driving, especially when towing heavy loads or performing hard acceleration runs.
Driving Conditions: The engine should be driven at varying loads and conditions for the first 30 miles or one hour without wide-open throttle (WOT) or sustained high RPM accelerations.
Acceleration Runs: Perform five or six medium throttle (50%) accelerations to about 4000 RPM and back to idle, followed by two or three hard throttle (WOT 100%) accelerations to about 4000 RPM and back to idle.
Adaptability: While components like motor mounts and exhaust manifolds can often be transferred from an older big block V8, differences in the water pump or torsional damper may necessitate modifications or additional components not included with the ZZ502 deluxe engine. For vehicles not originally equipped with a big block V8, adaptation or fabrication of cooling, fuel, electrical, and exhaust systems may be required.

Maintenance Features:

Oil and Filter Changes:
- First Change: After the initial acceleration runs (approximately 30 miles/1 hour), change the oil and filter. Replace with 5W30 non-synthetic motor oil and a PF454 AC Delco oil filter. Inspect for foreign particles.
- Second Change: After driving the next 500 miles under normal conditions or 12 to 15 engine hours (avoiding maximum rated engine speed and extended periods of high load), change the oil and filter again. Inspect for foreign particles.
Synthetic Oil Usage: Synthetic oil should not be used for break-in. It is suitable for use after the second recommended oil change and mileage accumulation. A lower viscosity oil may be required in colder regions for better flow characteristics.
Service Parts List: The manual includes a comprehensive service parts list with GM Part Numbers and quantities for various engine components, facilitating easy identification and ordering of replacement parts.
Warranty Information: For details regarding warranty coverage, users should contact their local Chevrolet Performance Parts dealer.
Documentation: The publication provides general information and is not intended to replace comprehensive service manuals. Users are urged to consult factory service manuals for detailed service practices.
Emissions and Legal Compliance: This engine is primarily for off-highway applications. Federal and state laws restrict tampering with emission and noise control systems on public highway vehicles. Users are strongly urged to check all applicable local and state laws. Parts described as "Special Parts Notice" are specifically designed for Off-Highway application only and should not be installed in vehicles used on any street or highway, as this could affect emission control performance, motor vehicle safety standards, and warranty coverage.

Performance ZZ502 Specifications

General

Brand	Performance
Model	ZZ502
Category	Engine
Language	English