Section 7

7.4 GSi and 8.2 GSi Engines

Table of Contents

Camshaft ........................................................................................... 7-15

Camshaft Lobe Lift, Measuring ....................................................... 7-19
Circulating Pump .............................................................................. 7-24
Connecting Rod Bearing Replacement .......................................... 7-21
Crankshaft ........................................................................................ 7-20
Cylinder Block .................................................................................. 7-23
Cylinder Head ..................................................................................... 7-9
Engine Coupler Replacement.......................................................... 7-27
Engine Specifications ...................................................................... 7-29
Exhaust Hose and Intermediate Pipe Replacement ...................... 7-27
Exhaust Manifold Replacement ........................................................ 7-5
Front Engine Mount Replacement .................................................. 7-24
GM Special Tools ................................................................................ 7-2
High-Rise Exhaust Elbow Replacement ......................................... 7-25
Intake Manifold ................................................................................... 7-3
Lubrication System .......................................................................... 7-16
Material Required ............................................................................... 7-2
Oil Pan ............................................................................................... 7-17
Oil Pump ........................................................................................... 7-17 7
Oil Seal Replacement, Rear Main Bearing ..................................... 7-19
Piston, Ring and Connecting Rod .................................................. 7-22
Remote Engine Oil Filter .................................................................. 7-16
Timing Chain, Cover and Seal ......................................................... 7-12
Torque Specifications ...................................................................... 7-32
Valve Lifter, Hydraulic ........................................................................ 7-6
Valve Spring and Seal Repair ............................................................ 7-8

Safety Warnings
Before working on any part of the engine, read the Safety section
at the end of this manual.
Unless instructed otherwise, always disconnect the battery cables
from the battery before working on electrical system (to prevent
possible sparks or arcing in the engine compartment).
Before starting engine after repair or maintenance procedures, al-
ways make sure engine compartment is free of fuel vapors to pre-
vent possible fire and explosion.
When working on an engine that is running or being cranked, use
extreme care to avoid getting hands, fingers or clothing caught in
the alternator, power steering and circulating pump belts, pulleys
and other moving parts.

Engine/eng 7-1
 GM Special Tools
Part
Item Number

Air Line Adaptor ....................................................................... J-23590

Camshaft Lobe Lift Indicator ..................................................... J-8520
Dial Indicator Set ........................................................................ J-5239
Crankshaft Seal/Sprocket Installer ......................................... J-22102
Crankshaft Sprocket Puller ........................................................ J-1619
Hydraulic Lifter Remover ..................................................... J-9290-01
Hydraulic Lifter Remover ....................................................... J-3049-A
Main Bearing Replacer .............................................................. J-8080
Ring Compressor ....................................................................... J-8037
Seal Installer ............................................................................ J-35468
Seal Installer ............................................................................ J-38841
Spring Compressor ................................................................ J-5892-C
Torsional Damper Puller ...................................................... J-23523-E
Valve Spring Compressor .......................................................... J-8062

Order Directly from:

Kent-Moore Tool Division
28635 Mound Road
Warren, MI 48092
(800) 345-2233
http://www.spxkentmoore.com

Price and ordering information is available from Kent-Moore Tool Divi-

sion.
Material Required
DuraPlus TM Synthetic Motor Oil
Volvo Penta Gasket Sealing Compound
Volvo Penta Thread Sealing Agent
3M Scotch Grip Rubber Adhesive 1300
GM Engine Oil Supplement, P/N 1052367
GM Sealer, P/N 1052289
GM Silicone Rubber Sealer, P/N 1052366
Loctite Primer
Molykote Lubricant
Plastigage (Green)

For additional service information not covered in this manual, obtain

the appropriate Chevrolet Engine Service Manual from:

Helm Inc.
P.O. Box 07130
Detroit, MI 48207
(800) 782-4356
http://www.helminc.com

7-2 Engine/eng
Intake Manifold
Removal

See On-Board Service section of GM EFI Diagnistics Manual for re-

moval of components from intake manifold.
1 2 1. Disconnect battery cables at battery, and drain
coolant from both sides of block and manifolds.
2. Remove alternator. If electrical leads are not disconnected, tie alter- 1
nator to oil hoses to prevent alternator weight damaging leads. 46200A

3. Remove thermostat housing.

4. Remove main electrical harness from clamps on port side of mani-
fold and at front of manifold. Disconnect other wire connections as nec-
essary.
3 5. Remove distributor cap Aand mark the position of the rotor on
the housing. Scribe a line on the distributor housing and intake mani-
fold for reassembly in the same position. Remove the distributor.
6. Unscrew attaching bolts, and remove intake manifold. NOTE: If nec-
essary to pry manifold away from cylinder heads, do not damage gas- 2
46199A
ket sealing surfaces.
7. Remove and discard intake manifold gaskets and seals.

Cleaning

Remove all gasket material and clean the sealing surfaces of the mani-
fold, block and thermostat housing. Remove excessive car- bon depos-
its from exhaust passages, scale and deposits from cooling passages.
Clean the manifold in a suitable solvent and dry it with compressed air.

Inspection
3
Inspect the manifold for cracks, damaged gasket surfaces, or other de- 31841

fects that would make it unfit for further service. Replace all studs that
are stripped or otherwise damaged. Remove all filings and foreign
matter that may have entered the manifold as a result of repairs.

Engine/eng Safety Related 7-3

Installation

1. Install new manifold seals on block, and new gaskets on cylinder

heads. Use only side gaskets having metal inserts covering the
center exhaust passage. Use sealer at water passages and where
seals butt to gaskets.
1 2. Install intake manifold. Tighten bolts in the sequence shown,
7.4 GSi: 30 ft. lb. (40 N m), 8.2 GSi: 35 ft. lb. (47 N m).
• •

Check torque of the intake manifold screws annually. The cen-

ter screws can become loose under normal usage.
3. Install distributor with rotor and align exactly as marked during re-
moval. Install clamp and tighten screw to 25 ft. lb. (34 N m). NOTE: If
•

engine was cranked while distributor was out, complete ignition timing
procedure must be followed.
4. Install distributor cap and high tension leads.
5. Place main wire harness under clamps on port side of manifold and
at front of manifold. Make other wire connections as necessary.
6. Apply Volvo Penta Gasket Sealing Compound to both sides of
a new thermostat housing gasket and place it on manifold. Place lift- 1
DRC6869
ing eye on long bolt, then install and tighten both screws to 12-16
ft. lb. (16-22 N m).
•

7. Install alternator and properly tension belt. Tighten mounting screws

securely.
8. Attach battery cables at battery. Start engine and check for
fuel and water leaks.

Safety Related 7-4 Engine/eng

Exhaust Manifold Replacement
Removal

Drain water from respective exhaust manifold before beginning

procedure.
1. Remove high-rise exhaust elbow following procedure under High-
Rise Exhaust Elbow Replacement.
2. Carefully pull wires off spark plugs.
3. Loosen hose clamp at front of manifold, and pull off water hose.
4. Remove manifold attaching screws, nuts and washers. Discard nuts. C
Remove manifold and discard manifold gasket.
A
Cleaning

Clean mating surfaces on manifold and cylinder head. Clean the threads B
on the exhaust manifold bolts.

Inspection

2 Inspect for cracks. To pressure check manifold, use a plate A 2

such as shown and a new elbow gasket B to seal water passage in DR2875

manifold. Be sure to apply sealer to gasket. Install rubber drain cap to

manifold and secure with clamp. Attach a gearcase pressure tester C
(such as Stevens Company S-34) to the water inlet hose. A bushing can
be made to secure pressure tester to hose. With the pressure tester
attached to the manifold, submerge manifold in water. Pressurize the
manifold to 10-15 PSI (22-25 kPa) and check for leaks.

Installation

1. Install a new exhaust manifold gasket.

3 4 2. Install manifold and secure with bolts, washers and new 3
18946
locknuts. Tighten nuts to 20-26 ft. lb. (27-35 N m). Tighten bolts to 24-
•

28 ft. lb. (33-38 N m).

•

3. Attach water hose to nipple at front of manifold and tighten clamp.

4. Attach spark plug wires to plugs. Make sure firing order is correct.
5. Install high-rise exhaust elbow following procedure under High-Rise
Exhaust Elbow Replacement.
6. Start engine and check for water and exhaust leaks.

4
18944

Engine/eng Safety Related 7-5

Hydraulic Valve Lifter
Checking Hydraulic Valve Lifter

When checking hydraulic valve lifters, rememberthat grit, sludge, var-

nish, or other foreign matter will seriously affect their operation. If any
foreign substance is found in the lifters or engine where it may be
circulated by the lubrication system, a thorough cleaning job must be
done to avoid a repetition of lifter trouble.
To help prevent lifter trouble, the engine oil and oil filter must be changed
as recommended in General Information Section. The engine oil must
be heavy-duty type (for Service SG) and must also conform to Gen-
eral Motors Standard 6094-M to avoid detrimental formation of sludge
and varnish. We recommend DuraPlusTM Synthetic Motor Oil. The boat
owner should be specifically advised of these requirements when the
unit is delivered. Faulty valve lifter operation usually appears under
one of the following conditions:
1. Rapping Noise Only When Engine is Started:
When the engine is stopped, any lifter on a camshaft lobe is under
pressure of the valve spring; therefore, leak down or escape of oil
from the lower chamber can occur. When the engine is started, a few
seconds may be required to fill the lifter, particularly in colder weather.
If noise occurs only occasionally, it may be considered normal, requir-
ing no correction. If noise occurs frequently, however, check for either
oil too heavy for prevailing temperatures, or excessive varnish in lifters.
2. Intermittent Rapping Noise:
An intermittent rapping noise that appears and disappears every few
seconds indicates leakage at check ball seat due to foreign particles,
varnish, or defective surface of check ball or seat.
3. Noise at Idle and Low Speed:
If one or more valve lifters are noisy at idle speed and up to approxi-
mately 1200 RPM, but quiet at higher speeds, it indicates excessive
leakdown rate orfaultycheckball seatorplunger.With engine idling, lifters
with excessive leak down rate may be spotted by pressing down on
each rocker arm above the push rod with equal pressure. Recondition
or replace noisy lifters.

7-6 Engine/eng
4. Generally Noisy at All Speeds:
Check for low or high oil level in crankcase. High oil levels will cause oil
foaming from the crankshaft and will force air bubbles into the lifters.
Low oil levels allow pump to pump air at high speed. With engine idling,
strike each rocker arm above the push rod several sharp blows with a
mallet; if noise disappears, it indicates that foreign material was keep-
ing check ball from seating. Stop engine and place lifters on camshaft
base circle. If there is lash clearance in any valve linkage, it indicates a
stuck lifter plunger, worn lifter roller, or worn camshaft lobe.
1
5. Loud Noise at Normal Operating Temperature Only: 11508

If a lifter develops a loud noise when the engine is at normal operating

temperature, but is quiet when engine is below normal temperature, it
indicates an excessively fast leak down rate of scored lifter plunger.
Recondition or replace lifter.

Removal

1. With air hose and cloths, clean dirt from cylinder heads and adjacent
parts to avoid getting dirt into engine. It is extremely important that no
dirt gets into the valve lifters.
2
2. Remove intake manifold. Remove exhaust manifolds. 11509

3. Remove rocker arm covers. Do not pry. If covers stick use rubber
mallet and strike cover end to jar loose. Loosen rocker arm nuts and
pivot the rocker arm free of the push rods.
1 2 4. Remove push rods. Remove the hydraulic lifter guides and
lifters that require service one at a time and place them in an organizer
rack. The lifters must be installed in the same bore from which they
were removed.
3 4 A stuck hydraulic lifter can be removed using Tool J-3049-A
(plier type) or Tool J-9290-01 (slide hammer type). 3
31350
5. If less than a complete set of lifters is being removed, immediately is
assemble one or two for presence of dirt or varnish. If lifters contain dirt
or varnish, it is advisable to remove all lifters for replacement. Other-
wise, it will be satisfactory to service only those lifters that are not oper- J 9290-1
ating properly.
5 6. Examine the cam roller (4) of the lifter. If this surface is exces-
sively worn, galled or otherwise damaged, discard the lifter assembly.
In this case, also examine the mating camshaft lobe for excessive wear
or damage.

Installation
4
GR970297

Before installing any new lifters, coat the bottom of the lifter
with Molykote or its equivalent.

5
178485

Engine/eng 7-7
1. Install valve lifters in cylinder block. If any new lifters or a new cam-
shaft has been installed, an additive containing EP lubricant such as
GM Engine Oil Supplement must be added to the crankcase oil for
break-in.
2. Install push rods onto lifters. Install intake manifold.
3. Pivot rocker arms in place and install rocker arm bolts. Tighten bolts
to 40 ft. lb. (54 N m).
•

4. Install rocker arm covers, using GM Sealer No. 1052289, and tighten
nuts to 115 in. lb. (13 N m).
•

5. Install exhaust manifold. Start engine and check for oil leaks at rocker
arm covers.

Valve Spring and Seal Repair

Removal

1 1. Remove rocker arm cover.

2. Remove spark plug, rocker arm, and push rod on the cylinder(s) to
be serviced.
2 3. Install Air Line Adaptertool J-23590 to spark plug port and ap-
ply compressed air to hold the valves in place.
2 4. LJsing tool J-5892-C, compress the valve spring and remove
the valve locks. Release and remove tool. Remove valve cap and shield,
and valve spring and damper.
5. Remove the valve stem oil seal.

Installation

1. Install seal over valve stem and seat against head.

2. Set the valve spring and damper, valve shield and valve cap in place. 1
DR3796
Compress the spring with tool J-5892-C and install oil seal in the lower
groove of the stem, making sure the seal is flat and not twisted. NOTE:
A light coat of oil on the seal will help prevent twisting.
3. Install the valve locks and release the compressor tool making sure
the locks seat properly in the upper groove of the valve stem. NOTE:
Grease may be used to hold the locks in place while releasing the
compressor tool.
4. Install spark plug and tighten to 22 ft. lb. (30 N m).
•

5. Install rocker arm cover. Tighten nuts to 115 in. lb. (13 N m).
2
•

DR3794

7-8 Engine/eng
Cylinder Head
Removal

1. Drain water from block and exhaust manifolds. Remove intake and
exhaust manifolds.
2. Remove valve covers and spark plugs.
3. Loosen rocker arm bolts and turn rocker arms aside. Remove push
rods. If lifters are to be serviced, remove them at this point. Otherwise
protect the lifters and the camshaft from the entrance of dirt by covering
the area with clean cloths.
4. Remove cylinder head bolts, cylinder heads and gasket. Place cylin-
der heads on bench, supporting them at each end on blocks of wood to
prevent damage to gasket faces of heads.

Disassembly

1. Remove rocker arm bolts, ball seats and rocker arms.

3 2. Using tool J-8062, compress the valve springs and remove the
valve keys. Release the compressor tool, and remove rotators, springs 3
and spring dampers, then remove oil seals. DR3125

3. Remove valve from bottom of cylinder heads and place them and
their respective valve springs in a rack in their proper sequence so they
can be assembled in their original positions.

Cleaning and Inspection

Refer to General Engine Mechanical section in this manual for cylin-

der head cleaning and inspection.

Repair

1. Valve Seats:
Reconditioning the valve seats is very important, because the seating
of the valve must be perfect for the engine to deliver the power and
performance built into it.
Another important factor is the cooling of the valve heads. Good con-
tact between each valve and its seat in the head is imperative to ensure
that the heat in the valve head will be properly carried away.

Engine/eng 7-9
Several different types of equipment are available for resealing valve
seats; the recommendations of the manufacturer of the equipment be-
ing used should be carefully followed to attain proper results.
Regardless of what type of equipment is used, however, it is essential
that valve guides be free from carbon or dirt to ensure proper center-
ing of pilot in the guide.
a. Install expanding pilot in the valve guide bore and expand
pilot by tightening nut on top of pilot.
b. Place roughing stone orforming stone over pilot and just clean
up the valve seat. Use a 46° stone for both the inlet and ex-
haust valve seats.
c. Remove roughing stone or forming stone from pilot, install
finishing stone on pilot and cut just enough metal from the
seat to provide a smooth finish.
d. Narrow down the valve seats to the proper width for the in-
take and exhaust. See Specifications at the end of this sec-
tion.
This operation is done by grinding the port side with a 30°
stone to lower seat and a 60° stone to raise seat.
e. Remove expanding pilot and clean cylinder head carefully to
remove all chips and grindings from above operations.
1 Valve seats should be concentric to within 0.002 in.
(0,0508 mm) total indicator reading.
J 8001
2. Valves:
Valves that are pitted can be refaced to the proper angle, ensuring
correct relation between the head and stern on a valve refacing ma-
chine. Valve stems which show excessive wear, or valves that are
warped excessively should be replaced. When a valve head which is
warped excessively is refaced, a knife edge will be ground on part or
all of the valve head due to the amount of metal that must be removed
to completely reface. Knife edges lead to breakage, burning or pre-
ignition due to heat localizing on this knife edge. If the edge of the
valve head is less than 1/32 in. (0.792 mm) thick after grinding, re-
place the valve. 1
10425

Safety Related 7-10 Engine/eng

 a. If necessary, dress the valve refacing machine grinding wheel
to make sure it is smooth and true. Set chuck at 45° mark for
grinding valves.
b. Clamp the valve stem in the chuck of the machine.
c. Start the grinder and move the valve head out in line with the
grinder wheel by moving the lever to the left.
d. Turn the feed screw until the valve head just contacts wheel.
Move valve back and forth across the wheel and regulate the
feed screw to provide light valve contact.
e. Continue grinding until the valve face is true and smooth all
around valve. If this makes the valve thin, the valve must be
replaced as the valve will overheat and burn.
f. Remove valve from chuck and place stem in “V” block. Feed
valve squarely against grinding wheel to grind any pit from
rocker arm end of stem. NOTE: Only the extreme end of the
valve stem is hardened to resist wear. Do not grind end of
stern excessively.
g. After cleaning valve face and cylinder head valve seat of grind-
ing particles, make pencil marks about 1/4 in. (6,35 mm) apart
across the valve face, place the valve in cylinder head and
give the valve one-half turn in each direction while exerting
firm pressure on face of valve.
h. Remove valve and check face carefully. If all pencil marks have
not been removed at the point of contact with the valve seat, it
will be necessary to repeat the refacing operation and recheck
for proper seating.
i. Grind and check remaining valves in the same manner.

Assembly

When replacing valve springs, refer to the latest parts catalog

for ordering information.
2 Starting with number 1 cylinder, place the valves in the designated
ports and assemble all but the seal and locks. Then, using tool J-5892-
C, compress the spring A and install the seal B and locks C . See that
the seal is flat and not twisted in the valve stem groove, and that the
locks seat properly in the valve stern groove.

2
DR3795

Engine/eng 7-11
 Place valve spring in position with the closed coil end toward
the cylinder head.

Installation

1. Wipe off engine block gasket surface and be certain no foreign ma-
terial has fallen into the cylinder bores, bolt holes, or the valve lifter
area. It is good practice to clean out bolt holes with an air hose.
This engine has special marine head gaskets. Do not substi-
tute automotive head gaskets.
2. Install new head gasket on cylinder block. Dowels in the block will
holdthe gasket in position. Always handle gaskets carefully to avoid
kinking or damage to the surface treatment of the gaskets. DO NOT
use any type of sealing material on head gaskets. The gaskets are
coated with a special lacquer to provide a good seal, once the parts
have warmed up.
3. Carefully set in place on the engine block dowel pins.
4. Clean and lubricate the head bolts with Volvo Penta Gasket Sealing
Compound . Install bolts.
1 5. Tighten the head bolts with a torque wrench, in three progres-
sive steps, following the sequence shown.
Step 1 - 35 ft. lb. (47 N m)
•

Step 2 - 65 ft. lb. (88 N m)

•

Step 3 - 85 ft. lb. (115 N m)•

Damage to the cylinder block threads can result if bolts are

not lubricated with Volvo Penta Gasket Sealing Compound prior to
installation or if the bolts are tightened excessively. Use an accurate
torque wrench when installing head bolts and do not overtightens Un-
even tightening of the cylinder head bolts can distort the cylinder bores, 1
DR2905
causing compression loss and excessive oil consumption.

Timing Chain, Cover and Seal

Harmonic Balancer Removal

1. Remove alternator and power steering belts, and crankshaft pulley.

2 2. Attach tool J-23523-E to balancer, and turn puller screw to
remove balancer from crankshaft.

The timing chain cover is made of composit material with an 2

integral seal. The seal and gasket is not serviceable. Onece the cover DR3573

is removed it must be replaced by a new timing chain cover.

7-12 Engine/eng
Timing Chain Cover Removal

1. Remove circulating pump pulley, alternator brace, and power steer-

ing pump.
2. Drain cooling system and remove hose at circulating pump. Discon-
nect temperature sender wire, then remove circulating pump and dis-
card gaskets.
3. Remove oil pan. See Oil Pan in this section.
4. Remove the front cover-to-block attaching screws. Remove front cover 3
DR3579
and gasket.

Timing Chain and Sprocket Replacement

3 1. Crank engine until “0” marks on camshaft and crankshaft sprock-
ets are in alignment. In this position, engine is timed to fire No. 6
cylinder.
2. Remove camshaft sprocket bolts. Remove sprocket and timing chain
together. Sprocket is a slight press-fit for approximately 1/8 inch. If
sprocket does not come off easily, a light blow with a plastic-faced ham-
mer on the lower edge of the camshaft sprocket should dislodge it. 4
DR3574
4 3. If crank sprocket requires replacement, use a two or three jaw
puller such as J-1619 that pilots on end of crankshaft to pull off sprocket.
5 4. Install crank sprocket using tool J-22102 to drive it into place
over keyway.
3 5. Install timing chain on camshaft sprocket. Hold the sprocket
vertical with the chain hanging below. Align the cam and crank sprocket
timing marks, and attach the chain to the crank sprocket.

5
DR3577

Engine/eng 7-13
6. Align dowel in camshaft with dowel hole in sprocket and install
sprocket on camshaft.
Do not hammer sprocket onto camshaft. This may loosen rear
camshaft welsh plug.
7. Draw sprocket onto camshaft using the mounting bolts. Lubricate
the timing chain with engine oil.

Timing Chain Cover Installation

1. Clean gasket surface on block and crankcase front cover.

2. Install new oil pan gasket and oil pan. See Oil Pan in this section.
3. Coat the gasket with sealer and place in position on cover. Apply a
1/8 in. (3.175 mm) bead of GM Silicone Rubber Sealer, P/N 1052366
(or equivalent), to the joint formed at the oil pan and cylinder block.
4. Position crankcase front cover over crankshaft. Press cover down-
ward against oil pan until cover is aligned and installed over dowel
pins on block.
5. Install the front cover-to-block attaching screws.
6. Tighten front cover to block bolts. See Torque Specifications at
the end of this section for the torque figure.

Harmonic Balancer Installation

1. Coat machined outer surface of balancer hub with engine oil. Align
keyway and start balancer onto crankshaft.
1 2. Using appropriate end of tool J-23523-E threaded into crank-
shaft, or a large washer and a 7/16-20 x 4 in. bolt and nut threaded
into center hole in crankshaft, tighten nut to seat harmonic balancer
on crankshaft.
2 3. Remove installing tool. Install crankshaft pulley and tighten 1
DR3576
screws securely. Thread 7/16-20 x 2 in. bolt and thick washer into crank-
shaft and tighten. See Torque Specifications at the end of this sec-
tion for the torque figure.
4. Install circulating pump and pulley, and tighten screws securely. At-
tach water hose to pump.
5. Install alternator and power steering pump brackets. Install alterna-
tor and power steering belts and adjust tension to specifications.

2
24965

7-14 Engine/eng
Camshaft
Removal

3 1. Remove distributor A . Remove intake manifold and circulating

pump.
2. Remove rocker arm covers, loosen rocker arms, then remove push
rods and valve lifters.
3. Remove crankshaft pulley, harmonic balancer, timing chain cover,
3
timing chain, and camshaft sprocket. 28257

4 4. Install two or three 5/16-18 x 4 in. bolts in camshaft sprocket

bolt holes and carefully pull out camshaft. Use care not to damage cam-
shaft bearings.
Measure:
Camshaft Journals. Refer to General Engine Mechanical section in
this manual. Do not attempt to repair the camshaft. Replace the cam-
shaft if damaged. Whenever the camshaft needs to be replaced, a new
set of valve lifters must also be installed.

Bearings
4
DR3790

Refer to General Engine Mechanical section in this manual for cam-

shaft bearing disassembly, cleaning, inspection, and assembly.

Installation

1. Lubricate camshaft journals with engine oil.

Whenever a new camshaft is installed, lubricate the cam- shaft
lobes with Molykote Lubricant or its equivalent. Also add one can of GM
Engine Oil Supplement to crankcase oil.
2. Install three 5/16-18 x 4 in. bolts in camshaft bolt holes. Install cam-
shaft, being careful not to damage bearings.
3. Install cam sprocket (making sure timing marks face outward), timing
chain, and timing chain cover.
4. Install harmonic balancer and crankshaft pulley. Install circulating
pump and connect coolant hose.
5. Install valve lifters, push rods, rocker arms, and intake manifold. In-
stall rocker arm covers.
6. Install distributor and set initial timing.

Engine/eng 7-15
Lubrication System
Description and Operation

The oil pump consists of two gears and a pressure relief valve en-
closed in a two-piece housing, and is driven by the distributor driveshaft
which in turn is driven by a helix gear on the camshaft.
The pump is flange mounted to the cylinder block with two bolts. The
pump cover is equipped with a pressure regulator valve that regulates
oil pressure at approximately 40-60 PSI (275.8-413.7 kPa) at 2000
RPM. The pump intake is of the fixed screen type. A mesh screen
filters out small particles of dirt and sludge which may be present.
A baffle incorporated in the intake screen has been designed
to eliminate pressure loss due to sudden surging stops. In the event
that a screen becomes plugged, a steel grommet opens and bypasses
oil to the pump. Oil passes through an opening in the mounting flange
to the cylinder block, then into an oil filter adapter.
The main oil galleries run the full length of the crankcase and cut into
the valve lifter guide holes to supply oil at full pressure to the lifters.
The rocker arms and valves are lubricated by an oil channel in each
push rod. Excess oil drains off and returns to the oil pan through pas-
sages in the cylinder head and block.
Connecting passages drilled in the crankcase permit delivery of oil at
full pressure to all crankshaft and camshaft bearings, distributor drive
gear, and shaft, and the timing chain.
Holes drilled in the crankshaft carry oil from the crankshaft bearings to
the connecting rod bearings. Pistons and cylinder walls are lubricated
by oil forced through a small notch in the bearing parting surface on
the connecting rod, which registers with the hole in the crankpin once
every revolution. Piston pins are lubricated by splash. 1
28256
Remote Engine Oil Filter
1 2 A full flow oil filter A
is mounted to a bracket attached to the
port exhaust elbow. Two hoses connect it to an oil cooler and an en-
gine block adaptor B .
1 2 Oil exits the block through the outboard opening C of the
adaptor, and travels through a hose to the rear oil cooler fitting. It leaves
the front cooler fitting, and travels through a hose that connects to the
filter bracket inner (starboard) opening D . Return oil leaves the filter
bracket at the outer (port) opening E travels through a hose and re- 2
enters the engine at the forward opening F of the adaptor. 19046A

If hoses are improperly attached at adaptor or filter bracket, oil

flow will be reversed. Oil pressure will drop and engine damage may
result.

7-16 Engine/eng
 3 Normally, all engine oil passes from the block through an OEM
filter adapter G . If the remote oil filter or lines become restricted, a
spring loaded bypass valve H opens in the adaptor and circulates oil
back into the block.
3 Inspect bypass valve spring and valve disc H for proper operation
or damage. If replacement of bypass valve is necessary, remove bolts
and adaptor. Clean valve chamber in block and replace adaptor.

Oil Pan 3
DR2906
Removal

1. Remove timing chain cover. See Timing Chain, Cover and Seal in
this section.
2. Remove oil dipstick and withdraw oil using a suction pump.
3. Remove oil dipstick tube. Remove screws, oil pan and gasket.
4. Remove oil dipstick tube fitting from oil pan.

Installation

1. Thoroughly clean all gasket sealing surfaces.

4
DR3788

4 2. Apply GM Silicone Rubber Sealer, P/N 1052366 to the front and

rear corners of the block.
4 3. Attach gasket to block. Install rear portion of oil pan seal in groove
in rear main bearing cap.
4 4. Install front portion of oil pan seal by pressing the corners into
sealer applied to block.
5. Install oil pan and tighten screws. See Torque Specifications at the
end of this section for the torque figure.
5 6. Install dipstick tube fitting to pan; leave screw loose. Orient fit- 5
31576
ting and attach dipstick tube. Then tighten fitting screw and flare nut.
See Torque Specifications at the end of this section for the torque
figure.
7. Fill crankcase with specified engine oil. See Crankcase Oil in the
General Information Section.

Oil Pump
Removal and Disassembly

1. Remove oil pan. 6

DR3580
6 2. Remove pump to rear main bearing cap bolt, and remove pump,
extension shaft, and collar. NOTE: Baffle nuts have to be loosened.

Engine/eng 7-17
3. Disconnect pump shaft from extension. Remove four cover attach-
ing screws, cover, gasket, idler gear and drive gear, and shaft.
4. Remove pressure regulator valve and valve parts.
5. If the pickup screen or pipe need replacing, replace the entire pump
and pickup screen assembly.
6. Wash all parts in cleaning solvent and dry using compressed air.

Inspection

Should any of the following conditions be found during inspection op-

erations, the pump and pickup screen assembly should be replaced.
1. Inspect pump body for cracks or excessive wear. Inspect oil pump
gears for excessive wear or damage.
2. Check shaft for looseness in the housing. Check inside of cover for
wear that would permit oil to leak past the ends of gears.
3. Check the oil pickup screen for damage to screen or relief grommet.
Check for oil in the air chamber.
4. Check pressure regulator valve plunger for fit in cover.

Assembly and Installation

1. Place drive gear and shaft in pump body. Install idler gear so that
smooth side of gear will be toward the cover.
2. Install a new pump to cover gasket to ensure correct end clearance
of the gears.
3. Install cover and attaching screws. Tighten screws to 80 in. lb. (9
N m), and check to see that shaft turns freely.
•

4. Install regulator valve plunger, spring, retainer, and pin.

5. Assemble collar end of extension shaft assembly over pump
driveshaft, aligning tang of extension shaft with slot in end of pump
driveshaft.
6. Assemble pump and extension shaft to rear main bearing cap, align-
ing slot on top end of extension shaft with drive tang on lower end of
distributor shaft. NOTE: Oil pump should slide easily into place. If not,
remove and relocate slot or locate other problem. Install mounting
screws and tighten. See Torque Specifications at the end of this sec-
tion for the torque figure.
7. Tighten baffle nuts.
8. Install oil pan using new gasket. Connect oil drain tube.

7-18 Engine/eng
Measuring Camshaft Lobe Lift
1 1. Remove rocker arm covers. Loosen rocker arms and pivot away
from push rods. Position indicator with ball socket adapter (Tool J-8520)
on push rod. Make sure push rod is in the lifter socket.
2. Rotate the crankshaft slowly in the direction of rotation until the lifter
is on the heel of the cam lobe. At this point, the push rod will be in its
lowest position.
3. Set dial indicator on zero, then rotate the crankshaft slowly, or attach 1
an auxiliary starter switch and “bump” the engine over, until the push DR3791

rod is fully raised position.

Whenever the engine is cranked:
2 Remove gray and black connectors from ignition coil to prevent
accidental starting of engine.
4. Compare the total lift recorded from the dial indicator with specifica-
tions. If camshaft readings for all lobes are within specifications, re-
move dial indicator assembly.
5. Install valve mechanism as outlined. Install rocker arm covers.
2
DR5655
Rear Main Bearing Oil Seal Replacement
Removal

Pry out rear crankcase oil seal. NOTE: Care should be taken when
removing the rear crankcase oil seal so as not to nick the crankcase
seal surface.

Cleaning and Inspection

Clean sealing surface on crankshaft with a non-abrasive cleaner. In-

spect chamfer on crankshaft for grit, loose rust, and burrs. Correct as 3
necessary. DR1979

Installation

1. Lubricate the inner and outer diameter of the seal with engine oil.
3 2. Position the seal onto tool J-38841 A so seal lip will face the
block.
4 3. Position tool J-38841 against the crankshaft. Thread the attach-
ing screws into the tapped holes in the crankshaft and tighten securely.
This will ensure that the seal B is installed squarely overthe crank-
shaft. Turn the handle until it bottomsthen remove the tool. 4
DR3789

Engine/eng Safety Related 7-19

Crankshaft
Description

Main bearings are of the precision insert type and do not utilize shims
for adjustment. If clearances are found to be excessive, a new bear-
ing, both upper and lower halves, will be required. Bearings are avail-
able in standard size and 0.001 in. (0.0254 mm), 0.002 in. (0.0508
mm), 0.010 in. (0.245 mm) and 0.020 in. (0.508 mm) undersize.
Selective fitting of both rod and main bearing inserts is necessary in
production in order to obtain close tolerances. For this reason you
may find one-half of a standard insert with one-half of a 0.001 in. (0.0254
mm) undersize insert which will decrease the clearance 0.0005 in.
(0.0127 mm) from using a full standard bearing.
When a production crankshaft cannot be precision fitted by this method,
it is then ground 0.009 in. (0.2286 mm) undersize on only those main
journals that cannot be properly fitted. All journals will not necessarily
be ground undersize. A 0.009 in. (0.2286 mm) undersize bearing and
0.010 in. (0.245 mm) undersize bearing may be used for precision
fitting in the same manner as previously described.
If, for any reason, main bearing caps are replaced, shimming
may be necessary. Laminated shims for each cap are available for
service. Shim requirement will be determined by bearing clearance.

Cleaning, Inspection and Repair

Refer to General Engine Mechanical section in this manual

for cleaning, inspection, and measurements.
In general, (except No. 1 bearing) the lower half of the bearing shows
a greater wear and the most distress from fatigue. If upon inspection
the lower half is suitable for use, it can be assumed that the upper half
is also satisfactory. If the lower half shows evidence of wear or dam-
age, both upper and lower halves should be replaced. Never replace
one half without replacing the other half.
These dimensions should be checked with a micrometer for out-of-
round, taper or undersize. If the journals exceed 0.001 in. (0.0254 mm)
out-of-round, or taper, the crankshaft should be replaced or recondi-
tioned to an undersize figure that will enable the installation of under-
size precision type bearings.
The crankshaft should also be checked for runout. To perform this op-
eration, support the crankshaft at the front and rear main bearing jour-
nals in “V” blocks, and indicate the runout of both the rear intermedi-
ate and front intermediate journals, using a dial indicator. The runout
limit of each of these journals is 0.002 in. (0.0508 mm). If the runout
exceeds 0.002 in. (0.0508 mm), the crankshaft must be repaired or
replaced.

7-20 Engine/eng
Main Bearing Replacement

1 1. Install a main bearing removing and installing tool J-8080 A

in
oil hole in crankshaft journal. NOTE: If such a tool is not available, a
cotter pin may be bent as required to do the job.
2. Rotate the crankshaft clockwise as viewed from the front of engine.
This will roll upper bearing out of block.
3. Oil new selected size upper bearing and insert plain (unnotched) end
between crankshaft and indented or notched side of block. Rotate the
bearing into place, and remove tool from oil hole in crankshaft journal.
1
DR2916

4. Oil new lower bearing and install in bearing cap. Install main bearing
cap with arrows pointing toward front of engine. Torque main bearing
cap bolts to specifications.
Measure:
Refer to General Engine Mechanical section in this manual for crank-
shaft bearing clearance procedures.

Connecting Rod Bearing Replacement

Connecting rod bearings are of the precision insert type and do not
utilize shims for adjustment. DO NOT FILE RODS OR ROD CAPS. If
clearances are found to be excessive a new bearing will be required.
Bearings are available in standard size and 0.001 in. undersize for use
with standard size crankshafts.
1. With oil pan and oil pump removed, remove the connecting rod cap
and bearing.
2. Wipe the bearings and crankpin clean of oil. Inspect the bearing for
evidence of wear or damage.
3. Measure the crankpin for out-of-round or taper with a micrometer. If
not within specifications, replace or recondition the crankshaft. If within
specifications and a new bearing is to be installed, measure the maxi-
mum diameter of the crankpin to determine new bearing size required.
4. If within specifications, measure new or used bearing clearances with
Plastigage or its equivalent.
If a bearing is being fitted to an out-of-round crankpin, be sure
to fit to the maximum diameter of the crankpin. If the bearing is fitted to
the minimum diameter and the crankpin is out-of-round 0.001 in., inter-
ference between the bearing and crankpin will result in rapid bearing
failure.
a. Place a piece of gauging plastic the full width of the crankpin
parallel to the crankshaft. (Note: Surfaces must be free from
oil.)

Engine/eng 7-21
 b. Install the bearing in the connecting rod and cap.
c. Install the bearing cap and evenly tighten nuts to specifica-
tions.
Do not turn the crankshaft with the gauging plastic in-
stalled.
d. Remove the bearing cap and using the scale on the gauging
plastic envelope, measure the gauging plastic width at the
widest point.
5. If the clearance exceeds specifications select a new, correct size
bearing and remeasure the clearance.
6. Coat the bearing surface with oil, install the rod cap and tighten nuts
to specifications.
7. When all connecting rod bearings have been installed tap each rod
lightly (parallel to the crankpin) to make sure they have clearance.
1 8. Measure all connecting rod side clearances (see Specifica-
tions at end of this section), between connecting rod caps.

Piston, Ring and Connecting Rod 1

47427

Piston and Rod Removal

1. Remove oil pan, oil pump, and cylinder head. Turn crankshaft until
piston is at bottom of stroke. Place a cloth on top of piston to collect
cuttings.
2. Before attempting to remove piston, remove cylinder bore ridge as
necessary.
Refer to General Engine Mechanical section in this manual
for cylinder bore ridge reamer procedures.
3. Inspect connecting rods and connecting rod caps for cylinder iden-
2
DR3792
tification. If necessary mark them.
2 4. Remove connecting rod cap and install tool J-5239 on studs.
Push connecting rod and piston assembly out of top of cylinder block.
It will be necessary to turn the crankshaft slightly to discon-
nect some of the connecting rod and piston assemblies and push them
out of the cylinder.

Disassembly

Refer to General Engine Mechanical section in this manual for piston

and connecting rod disassembly.

7-22 Engine/eng
Assembly

Refer to General Engine Mechanical section in this manual for piston

and connecting rod assembly.

Piston and Rod Installation

1. Lightly coat pistons, rings and cylinder walls with light engine oil.
2. With bearing caps removed, install tool J-5239 on bearing cap bolts.
Check position of ring end gaps. They must be aligned with 3
each other as described previously. See General Engine Mechanical. 47437

3. Install each piston in its respective bore, using tool J-5239 on each
assembly. For valve clearance, the teardrop in the piston faces up and
the oil hole on the connecting rod should be to the center of the cylinder
block. Guide the connecting rod into place on the crankshaft journals
with the long detail of tool J-5239.
3 4. Use tool J-8037 A to compress the piston rings.
5. Install bearing caps and check the bearing clearance. Refer to Gen-
eral Engine Mechanical section in this manual for connecting rod side
clearance procedure.

Cylinder Block
Cylinder Bore

Inspect:
Cylinder bores for scoring or other damage. Refer to General
Engine Mechanical section in this manual.
Measure:
Cylinder bore taper and out-of-round. Refer to General Engine
Mechanical section in this manual.

Cylinder Bore Reconditioning

Measure:
Refer to General Engine Mechanical section in this manual.

Piston Selection

1. Check USED piston to cylinder bore clearance as follows:

a. Measure the “Cylinder Bore Diameter” with a telescope gauge
2 1/2 in. (64 mm) from top of cylinder bore.
b. Measure the “Piston Diameter” (at skirt across centerline of
piston pin).

Engine/eng 7-23
 c. Subtract piston diameter from cylinder bore diameter to de-
termine “Piston to Bore Clearance.”
d. Calculate piston to bore clearance and determine if piston to
bore clearance is in the acceptable range.
2. If used piston is not acceptable, check if a new piston can be se-
lected to fit cylinder bore within the acceptable range.
3. If cylinder bore must be reconditioned, measure new piston diam-
eter (across centerline of piston pin), then hone cylinder bore to cor-
rect clearance (preferable range). Mark the piston to identify the cylin-
der for which it was fitted.
Handle the pistons with care, and do not attempt to force them
through the cylinder until the cylinder has been bored to correct size
as this type piston can be distorted through careless handling.

Circulating Pump
The circulating pump is manufactured specially for marine use.
It is serviced only as an assembly. Do not replace with an automotive
circulating pump.

Inspection

Remove alternator and power steering belts. Grasp circulating pump

pulley and check end and side play. Turn pulley to check for drag.
Look for water leaking from indicator hole beneath pump shaft behind
pulley. Replace pump if play, drag, or leakage are evident.

Removal and Installation

1. Drain water from block and disconnect water hose from circulating
pump. Remove pulley. Remove circulating pump bolts, pump and gas-
kets.
2. Use new pump to block gaskets and sealer. Install new pump as-
sembly on cylinder block and tighten bolts as specified. Install pulley.
Install alternator and power steering belts, then adjust tension. Con-
nect hose to circulating pump. Lake or tank test unit and check for
leaks.

Front Engine Mount Replacement

Removal

1 1. Remove two lag screws A and washers from mounts.

2
1
2. Lift engine with 1500 lb. (680 kg) minimum capacity 11982
hoist to allow removal of front mount and bracket. Remove three
mount screws and lock washers B .

2
11981
Safety Related 7-24 Engine/eng
 3 Prior to disassembly of front mount assembly, measure
distance between large washer and flat on upper mount bracket.

Disassembly

4 1. Remove three nuts C, one lock washer, and engine mount

bracket D from mount bolt E while holding bolt secure with socket.
5 2. Remove one large washer F , one small washer G and engine
mount bolt E from mount.

Reassembly
3
11980

6 1. Place small washer G on mount bolt and insert bolt up through

mount. Install large washer F and secure with nut C . Tighten to 60-75
ft. lb. (81-102 N m).•

4 2. Install upper inner nut and place engine mount bracket on D

engine mount bolt. NOTE: Measure distance between large washer and
flat on upper mount bracket. Distance must be the same as that prior to
disassembly.
3. Install lock washer and lower nut. Tighten nut to 50-70 ft. lb. (68-95
N m).
•
4
11979
Installation

1. Spray the engine mount screws threads with Loctite Primer and al-
low to air dry. Apply Volvo Penta Thread Sealing Agent to the screws.
Attach engine mount assembly to engine with three screws and wash-
ers. Tighten to 32-40 ft. lb. (43-54 N m). •

2. Install lag screws and tighten securely.

Height Adjustment
7 1. To change engine height, tighten or loosen nuts H and I as 5
required. 11978

2. Lift engine with 1500 lb.(680 kg) minimum capacity hoist.

Position engine at desired height.
7 3. After setting mount position, turn nut I
up against underside of
engine bracket and hold nut with a wrench. Tighten upper nut H to 100-
120 ft. lb. (136-163 N m). •

High-Rise Exhaust Elbow Replacement

Removal
6
Drain water from respective exhaust manifold. 11983

1. Loosen two clamps securing upper hose to elbow.

7
2953

Engine/eng Safety Related 7-25

2. Port Elbow - Remove four thru-bolts, lock washers, and washers.
Move remote oil filter aside.

• Move crankcase oil filter bracket aside.

1 3. Starboard Elbow - Remove two thru-bolts A , lock washers,
and washers attaching circuit breaker bracket. Set bracket assembly
aside.
2 4. Lubricate inside of exhaust hose with a soapy water solution,
then remove remaining elbow bolt. Tap elbow with a soft hammer to
free it, then twist it out of the hose. Remove and discard the manifold 1
DR6451
gasket.

Installation
3 2. Apply Volvo Penta Gasket Sealing Compound to both sides of
a new gasket B , and place it on the manifold. Lubricate inside of ex-
haust hose with a soapy water solution to ease elbow installation.
3. Twist elbow into hose and position it on the gasket. Install the outer
rear thru-bolt, washer, and lock washer, and turn it in finger tight.
4. Port Elbow - Position remote oil filter at front of elbow.
2
28265
• Mount oil filter bracket on elbow.
Install four thru-bolts, washers, and lock washers finger tight. Tighten
small screw securely.
1 5. Starboard Elbow - Position circuit breaker assembly at front
of elbow. Install two thru-bolts A , washers, and lock washers finger
tight.
6. Tighten all elbow thru-bolts to 12-18 ft. lb. (16-24 N m).
•

7. Properly position the two exhaust hose clamps and tighten

them securely.
3
28266

Safety Related 7-26 Engine/eng

Exhaust Hose and Intermediate Pipe
Replacement
Removal

1. Loosen eight clamps that attach the upper and lower exhaust hoses,
and slide clamps down onto exhaust Y-pipe.
4 2. Lubricate inside of lower hose with a soapy water solution, and
push lower hose down onto exhaust Y-pipe.
4
5 3. Twist intermediate pipe out of upper hose. Lubricate inside of 19377A

upper hose with a soapy water solution for ease of removal.

4. Slide upper hose off high-rise elbow. Slide lower hose off exhaust Y-
pipe.

Installation

1. Lubricate inside diameter of 3.5 in. (8,89 cm) I.D. lower hose with a
soapy water solution. Slide it all the way onto the exhaust Y-pipe.
6 2. On the inside of the 4 in. (10,16 cm) I.D. upper hose, there is a
circular rib 1.5 in. (3,81 cm) from one end. The ribbed end of the hose 5
must face the intermediate pipe (rearward) when it’s installed. Slide 28264

hose onto high-rise elbow until it seats. NOTE: If hose is not properly
positioned, it will not completely engage the high-rise elbow or allow
secure attachment.
5 3. With a twisting motion, insert intermediate pipe all the way into
the upper hose. Slide the lower hose up until it’s halfway onto the inter-
mediate pipe.
4. Slide four No. 68 clamps up onto the upper hose. Slide four No.
64 clamps up onto lower hose. Position clamps in their proper chan-
nels and tighten them securely.
6
16041
Engine Coupler Replacement
Removal

1. Remove engine from boat.

2. Disconnect all wires, lines and connectors from bellhousing.
7 8 3. Remove seven screws securing bellhousing cover and slide
cover off.

7
20034

8
19996

Engine/eng Safety Related 7-27

 1 4. Pull drain hose out of bellhotising if equipped.
5. Remove bolts and nuts retaining bellhousing. Disconnect ground
wires and oil cooler bracket. Note oil cooler orientation.
6. Remove bell housing.
2 7. Use an offset box end wrench to remove the six nuts securing
the coupler, and slide coupler off studs.
8. Remove old gasket from bellhousing cover. Clean gasket surface
thoroughly. 1
19842
Installation

3 1. Install coupler and attach six locknuts. Use a suitable adaptor

and tighten nuts to 40-45 ft. lb. (54-61 N m).
•

2. Install bellhousing. Attach oil cooler with same orientation as noted

in a previous step. Tighten nuts and bolts to 32-40 ft. lb. (43-54 N m).•

Attach ground wires and tighten nuts to 15-20 ft. lb. (20-27 N m).
•

3. Push drain hose into bellhousing if equipped.

4. Apply Volvo Penta Gasket Sealing Compound to both sides of a
new bellhousing gasket and position it on cover.
2
6712

4 5. Clean seven self-tapping screws with a wire brush. Install

bellhousing cover and screws and tighten to 60-84 in. lb. (7-9 N m).•

6. Connect all wires, lines and connectors to bellhousing. Install en-

gine in boat.

3
6714

4
19083

7-28 Engine/eng
Engine Specifications
7.4 GSi and 8.2 GSi Models
General Information:
Type - No. of Cylinder .................................................................................................................................. 90° - V-8
Valve Arrangement ......................................................................................................................................... In head
Bore and Stroke
7.4 GSi ................................................................................................... 4.250 x 4.000 in. (107.95 x 101.6 mm)
8.2 GSi .................................................................................................. 4.468 x 4.000 in. (1 13.48 x 101.6 mm)
Piston Displacement
7.4 GSi ........................................................................................................................ 7.4 liter/454 Cubic Inches
8.2 GSi ..................................................................................................................... 8.2 Liters/502 Cubic Inches
Cylinder Numbers - Front to Rear
Starboard Bank ........................................................................................................................................ 2-4-6-8
Port Bank .................................................................................................................................................. 1-3-5-7
Firing Order ........................................................................................................................................ 1-8-4-3-6-5-7-2
Compression Ratio
7.4 GSi .......................................................................................................................................................... 8.6:1
8.2 GSi .......................................................................................................................................................... 8.8:1
Water Temperature Control .................................................................................................................... Thermostat
Thermostat Opens at .......................................................................................................................... 140° F (60° C)
Alternator Belt Adjustment ................................................................................... 1/4-1/2 in. give w/finger pressure
Full Throttle Operation Range
7.4 GSi ..................................................................................................................................... 4800 - 5200 RPM
8.2 GSi ..................................................................................................................................... 4600 - 5000 RPM
Pistons:
Production Clearance
7.4 GSi .................................................................................................. 0.003 - 0.004 in. (0.0762 - 0.1016 mm)
8.2 GSi .................................................................................................. 0.004 - 0.005 in. (0.1016 - 0.1270 mm)
Service Limit ................................................................................................................... 0.005 in. (0.127 mm) Max.
Piston Rings. Compression:
Production Groove Clearance
Top .................................................................................................... 0.0012 - 0.0029 in. (0.0304 - 0.0736 mm)
2nd .................................................................................................... 0.0012 - 0.0029 in. (0.0304 - 0.0736 mm)
Service Groove Clearance (both) ................................................................................... + 0.001 in. (+0.0254 mm)
Gap
Top ........................................................................................................... 0.010 - 0.018 in. (0.254 - 0.475 mm)
2nd ............................................................................................................ 0.016 - 0.024 in. (0.406 - 0.609 mm)
Service (both) ..................................................................................................................... + 0.010 in. (+0.254 mm)
Piston Rings. Oil:
Groove Clearance
Production ............................................................................................ 0.005 - 0.0065 in. (0.127 - 0.1651 mm)
Service ........................................................................................................................ + 0.001 in. (+0.0254 mm)
Gap
Production ................................................................................................ 0.010 - 0.030 in. (0.254 - 0.762 mm)
Service .......................................................................................................................... + 0.010 in. (+0.254 mm)

Engine/eng 7-29
Engine Specifications
Piston Pins:
Diameter .................................................................................................. 0.9895 - 0.9897 in. (25.133 - 25.138 mm)
Clearance in Piston
Production ........................................................................................ 0.0002 - 0.0007 in. (0.0050 - 0.0177 mm)
Service Limit .................................................................................................................... 0.001 in. (0.0254 mm)
Rod Fit ................................................................................ 0.0031 - 0.0021 in. (0.0787 - 0.0533 mm) lnterference
Connecting Rods:
Bearing Clearance
Production ...................................................................................... 0.0011 - 0.0029 in. (0.0279 - 0.07366 mm)
Service Limit .................................................................................................................... 0.003 in. (0.0762 mm)
Side Clearance ......................................................................................... 0.0013 - 0.023 in. (0.0330 - 0.5842 mm)
Crankshaft:
End Play ........................................................................................................ 0.006 - 0.010 in. (0.1524 - 0.254 mm)
Main Journal Diameter
No. 1, 2, 3, 4, 5 ............................................................................ 2.7482 - 2.7489 in. (69.8042 - 69.8220 mm)
Taper
Production ............................................................................................................ 0.0002 in. (0.0051 mm) Max.
Service Limit .......................................................................................................... 0.001 in. (0.0254 mm) Max.
Out-of-Round
Production ........................................................................................................... 0.0002 in. (0.0051 mm) Max.
Service Limit .......................................................................................................... 0.001 in. (0.0254 mm) Max.
Main Bearing Clearance. Production
No. 1, 2, 3, 4 .................................................................................... 0.0017 - 0.0030 in. (0.0432 - 0.0762 rnm)
No. 5 ................................................................................................. 0.0025 - 0.0040 in. (0.0635 - 0.0965 mm)
Main Bearing Clearance. Service
No. 1, 2, 3, 4 ..................................................................................... 0.0010 - 0.0030 in. (0.0254 - 0.0762 mm)
No. 5 ................................................................................................. 0.0025 - 0.0040 in. (0.0635 - 0.0965 mm)
Crankpin Diameter
7.4 GSi .............................................................................................. 2.199 - 2.1996 in. (55.854 - 55.8698 mm)
8.2 GSi .................................................................................................................................. 2.20 in. (55.88 mm)
Taper
Production ................................................................................................ 0.0005 in. (0.0127 mm) Max.
Service Limit .............................................................................................. 0.001 in. (0.0254 mm) Max.
Out-of-Round
Production ................................................................................................ 0.0005 in. (0.0127 mm) Max.
Service Limit .............................................................................................. 0.001 in. (0.0254 mm) Max.
Camshaft:
Camshaft Bearing Journal Diameter ..................................................... 1.9482 - 1.9492 in. (49.484 - 49.509 mm)
Lobe Lift - 0.002 in. (0.0508 mm)
7.4 GSi
Intake ....................................................................................................................... 0.2343 in. (5.9512 mm)
Exhaust ................................................................................................................... 0.2530 in. (6.4262 mm)
8.2 GSi
Intake ......................................................................................................................... 0.510 in. (12.954 mm)
Exhaust ..................................................................................................................... 0.510 in. (12.954 mm)

7-30 Engine/eng
Engine Specifications
Valve Systems:
Lifter Type .................................................................................................................................................... Hydraulic
Rocker Arm Ratio
7.4 GSi ...................................................................................................................................................... 1.7 to 1
8.2 GSi ...................................................................................................................................................... 1.7 to 1
Valve Lash - Intake and Exhaust ............................................................................................. zero lash + one turn
Valve Face Angle (I & E) ....................................................................................................................................... 45°
Valve Seat Angle (I & E) ..................................................................................................................................... 46°
Valve Seat Runout (I & E) ............................................................................................ 0.002 in. (0.0508 mm) Max.
Stem to Guide Clearance
Intake, Production ............................................................................ 0.0010 - 0.0027 in. (0.0254 - 0.0270 mm)
Exhaust, Production ......................................................................... 0.0012 - 0.0029 in. (0.0304 - 0.0736 mm)
Intake, Service ............................................................................. Hi Limit Production + 0.001 in. (0.0254 mm)
Exhaust, Service .......................................................................... Hi Limit Production + 0.002 in. (0.0508 mm)
Recommended Valve Seat Width
Intake .......................................................................................................... 1/32 to 1/16 in. (0.794 - 1.587 mm)
Exhaust ....................................................................................................... 1/16 to 3/32 in. (1.587 - 2.381 mm)
Valve Spring Free Length .......................................................................................................... 2.15 in. (54.41 mm)
Valve Spring Installed Height ............................................................................................. 1 51/64 in. (45.641 mm)
Valve Spring Pressure
Lb. @ In. (kg @ mm) Closed .................................................................. 74-86 @ 1.80 in. (33.5 - 39 @ 45.72)
Lb. @ In. (kg @ mm) Open ............................................................ 195-215 @ 1.40 in. (88.4 - 97.5 @ 35.56)
Installed Height ± 1/32 in. (0.794 mm)
Valve Spring Fit In Damper ................................................................................ 0.042 - 0.094 in. (1.06 - 2.38 mm)
Engine Lubrication:
Type Oil Pump .................................................................................................................................................... Gear
Normal Pressure. Warm Engine ............................................................................. 10 PSI (70.3 kPa) @ 500 RPM
40-60 PSI (281 - 422 kPa) @ 2000 RPM
Crankcase Capacity
7.4 GSi .......................................................................... Approx. 8 qt. (7.57 liters); 9 qt. (8.51 liters) with Filter
8.2 GSi .......................................................................... Approx. 8 qt. (7.57 liters); 9 qt. (8.51 liters) with Filter
Oil Grade Recommended
32° F (0° C) and Above ............................................................................................................................ SAE 30
0° F to 32° F (-18° C to 0° C) ......................................................................................................... SAE 20W-20
Below 0° F (-18° C) .............................................................................................................................. SAE 10W
We recommend DuraPlusTM Synthetic Motor Oil, which is specially for-
mulated for heavy duty marine use, and ideal for stern drive engines. It
provides better antiwear qualities, especially during long high speed
operation. In addition, it neutralizes acids caused in all internal com-
bustion engines, offers superior corrosion protection, and is formulated
to offer better resistance to oxidation and high temperature sludge for-
mation.
Fuel Recommendation ................. See General Information Section

Engine/eng 7-31
Torque Specifications
Use a reliable torque wrench to tighten the parts listed to prevent straining or distorting the parts or possibly damag-
ing the threads. These specifications are for clean threads only. Dirty threads produce friction which prevents accu-
rate measurement of tightness. It is important that these torque specifications be strictly observed. Overtightening to
any extent may damage threads, thus preventing proper torque from being obtained, requiring replacement or repair
of the damaged part.

ITEM FT. LB. IN. LB. Nm•

Screw
Camshaft Sprocket
7.4 GSi 20 - 27
8.2 GSi 25 - 34
Circulating Pump 30 - 40
Distributor Clamp 25 - 34
Dipstick Tube Fitting 15-18 - 20-24
Flywheel Bellhousing 32-40 - 43-54
Flywheel Cover - 60-84 7-9
Front Mount Bracket to Block 32-40 - 43-54
Oil Pan to Block - 200 22
Oil Pan to Front Cover 70 7,9
Oil Pump Cover - 80 9
Power Steering Pump Bracket 26-30 - 35-41
Starter Motor 30-36 - 41-49
Thermostat Housing 12-16 - 16-22
Timing Chain Cover
7.4 GSi - 106 12
8.2 GSi - 120 13,6
Water Pump
7.4 GSi 30 - 40
8.2 GSi 35 - 47

7-32 Engine/eng
Torque Specifications (cont.)

ITEM FT. LB. IN. LB. Nm

•

Nut
Connecting Rod Cap
7.4 GSi 48 - 65
8.2 GSi 73 - 99
Exhaust Manifold 20-26 - 27-35
Flame Arrestor - 25-35 2,8-4,0
Flare-Dipstick Tube 15-18 - 20-24
Flywheel Bellhousing 32-40 - 43-54
Flywheel and Coupler 40-45 - 54-61
Front Mount (upper) 100-120 - 136-163
Rocker Arm Cover - 115 13

Bolt
Cylinder Head
Step 1 35 - 47
Step 2 65 - 88
Step 3 85 - 115
Exhaust Manifold 24-28 - 33-38
Flywheel to Crankshaft 70 - 95
Front Mount 65-75 - 81-102
Harmonic Balancer
7.4 GSi 85 - 115
8.2 GSi 90 - 122
High-Rise Elbow 12-18 - 16-24
Intake Manifold
7.4 GSi 30 - 40
8.2 GSi 35 - 47
Main Bearing Cap (All)
7.4 GSi 100 - 135
8.2 GSi 110 - 149
Oil Pump
7.4 GSi 65 - 90
8.2 GSi 70 - 95
Remote Oil Filter Adaptor (to block) 20-25 - 27-34
Rocker Arm 40 - 54
Vibration Damper 24 - 33

Stud
Power Steering Pump 13-15 - 18-20
Rocker Arm Cover - 60-90 7-10

Miscellaneous
Oil Filter one turn after contact
Spark Plugs
(cylinder head - new) 22 - 30
(cylinder head - all subsequent installations) 15 - 20

Engine/eng 7-33