Mercruiser/GM 454, 502 c.i. Marine Engine Service Manual (Gen V & VI)


SKU: 908232242 Category:

Covers: Mercruiser/GM 7.4L, 8.2L V8 Gen. V and VI Marine Engines

  • See full model compatibility list at the bottom of this page

Pages: 930
File size: 16mb
Compatibility: Windows/Mac/Tablet
Notes: Bookmarked, searchable, printable. Instant digital download only.

This PDF service manual contains all the necessary instructions for any repair your MerCruiser 7.4L (454 CID) and 8.2L (502 CID) V8 Gen 5 and 6 marine engine may require from top to bottom. This is the same professional-grade manual technicians use to diagnose and repair your marine engine in downloadable format. Whether it’s routine maintenance, such as tune-ups and fuel system service, or more extensive repairs involving engine and transmission disassembly, this 900+ page manual provides the most accurate information to perform the job.


General Information

  • Maintenance
  • Fluids and Capacities
  • Troubleshooting

Removal and Installation

  • MCM Models – Bravo and Blackhawk Drives
  • MCM Models – Bravo and Blackhawk Drives with Driveshaft Extension
  • MIE Models – Velvet Drive Transmission
  • MIE Models – Hurth Transmission

454 cid (7.4L) / 502 cid (8.2L) Engine

  • Engine Specifications
  • Torque Specifications
  • Overview
  • Engine Mounts
  • Rocker Arm
  • Pushrod
  • Valve Adjustment
  • Hydraulic Lifters
  • Valve Stem Seal and Spring
  • Cylinder Head and Valve Conditioning
  • Dipstick
  • Oil Pump and Pan
  • Damper
  • Front Cover
  • Oil Seals
  • Flywheel
  • Main Bearings
  • Connecting Rods and Pistons
  • Crankshaft
  • Timing Chain and Sprocket
  • Camshaft and Bearings
  • Cylinder Block
  • Compression Test
  • Oil Filter Bypass Valve and Adaptor

Electrical System

  • Starting System
  • Ignition System
  • Charging System
  • Instrumentation
  • Electrical Kits
  • Wiring Diagram

Fuel System

  • Fuel Delivery Systems and Fuel Pumps
  • Weber 4 Barrel Carburetor
  • Electronic Fuel Injection (Throttle Body and Multi-Port Injection)

Cooling System

  • Seawater Cooled Models
  • Closed Cooled Models

Exhaust System

  • General
  • Manifolds and Elbows
  • Risers
  • Collectors


  • Velvet Drive In-Line Transmission
  • Velvet Drive V-Drive Transmission
  • Hurth Down Angle Transmission
  • Drive Shaft / Propeller Shaft Models

Power Steering

Full model compatibility list:



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