SERVICE MANUAL NUMBER 23
454 CID (7.4L) / 502 CID (8.2L)
4.
Check cylinder head gasket surfaces for warpage with a machinist’s straight-edge and
a feeler gauge, as shown. Take measurements diagonally across surfaces (both ways)
and straight down center. If surfaces are warped more than .003 in. (0.07 mm) in a 6 in.
area or .007 in. (0.17 mm) overall, block must be resurfaced by an automotive machine
shop.
a
b
72566
a - Machinist’s Straight Edge
b - Feeler Gauge
CYLINDER CONDITIONING
1.
2.
Performance of the following operation depends upon engine condition at time of repair.
If cylinder block inspection indicates that block is suitable for continued use (except for
out-of-round or tapered cylinders), they can be conditioned by honing or boring.
3.
4.
If cylinders have less than .005 in. (0.127 mm) taper or wear, they can be conditioned
with a hone and fitted with high limit standard size piston. A cylinder bore of more than
.005
in. wear or taper may not clean up entirely when fitted to a high limit piston. To
entirely clean up the bore, it will be necessary to bore for an oversize piston. If more than
in. taper or wear, bore and hone to smallest oversize that will permit complete
.005
resurfacing of all cylinders.
When pistons are being fitted and honing is not necessary, cylinder bores may be
cleaned with a hot water and detergent wash. After cleaning, swab cylinder bores
several times with light engine oil and a clean cloth, then wipe with a clean dry cloth.
CYLINDER BORING
1.
Before using any type boring bar, file off top of cylinder block to remove dirt or burrs. This
is very important to prevent boring bar tilt, with result that bored cylinder wall is not at
right angles to crankshaft.
2.
Measure piston to be fitted with a micrometer, measuring at center of piston skirt and
at right angles to piston pin. Bore cylinder to same diameter as piston and hone to give
specified clearance.
NOTE: Hone cylinders as outlined under “Cylinder Honing” and “Piston Selection,” follow-
ing.
3.
Carefully observe instructions furnished by manufacturer of equipment being used.
CYLINDER HONING
1.
Followhonemanufacturer’s recommendationsforuseofhoneandcleaningandlubrica-
tion during honing.
2.
Occasionally, during the honing operation, thoroughly clean cylinder bore and check
piston for correct fit in cylinder.
Index
90-861326--1 MARCH 1999
Page 3A-83
| Categories | Mercury MerCruiser Manuals |
|---|---|
| Tags | Mercury MerCruiser 454 CID, Mercury MerCruiser 502 CID |
| Model Year | 1998, 1999, 2000, 2001 |
| Download File |
|
| Document File Type | |
| Copyright | Attribution Non-commercial |
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