MerCruiser 502 MAGNUM Boat Engine Manuals

Manuals and User Guides for MerCruiser 502 MAGNUM Boat Engine. We have 1 MerCruiser 502 MAGNUM Boat Engine manual available for free PDF download: Manual

MerCruiser 502 MAGNUM Manual

MerCruiser 502 MAGNUM Manual (71 pages)

7.4L/8.2L

Brand: MerCruiser | Category: Engine | Size: 1 MB

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
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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