Performance ZZ502 Installationshandbuch

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.

Observe all safety precautions and warnings in the service manuals when installing a ZZ502 Big Block Chevrolet (BBC)

deluxe assembly in any vehicle. Wear eye protection and appropriate protective clothing. Support the vehicle securely

with jackstands when working under or around it. Use only the proper tools. Exercise extreme caution when working with

ammable, corrosive, and hazardous liquids and materials. Some procedures require special equipment and skills. If you do

not have the appropriate training, expertise, and tools to perform any part of this conversion safely, this work should be done

by a professional.

The information contained in this publication is presented without any warranty. All the risk for its use is entirely assumed

by the user. Specic component design, mechanical procedures, and the qualications of individual readers are beyond the

control of the publisher, and therefore the publisher disclaims all liability incurred in connection with the use of the information

provided in this publication.

Legal and Emissions Information

This publication is intended to provide information about the ZZ502 engine and related components. This manual

also describes procedures and modications that may be useful during the installation of a ZZ502 engine. It is

not intended to replace the comprehensive service manuals and parts catalogs which cover Chevrolet engines

and components. Rather, it is designed to provide supplemental information in areas of interest to “do-it-yourself”

enthusiasts and mechanics.

This publication pertains to engines and vehicles which are used off the public highways except where specically

noted otherwise. Federal law restricts the removal of any part of a federally required emission control system on

motor vehicles. Further, many states have enacted laws which prohibit tampering with or modifying any required

emission or noise control system. Vehicles which are not operated on public highways are generally exempt from

most regulations, as are some special interest and pre-emission vehicles. The reader is strongly urged to check all

applicable local and state laws.

Many of the parts described or listed in this manual are merchandised for off-highway application only, and are

tagged with the “Special Parts Notice” reproduced here:

Special Parts Notice

This part has been specically designed for Off-Highway application only. Since the installation of this part may

either impair your vehicle’s emission control performance or be uncertied under current Motor Vehicle Safety

Standards, it should not be installed in a vehicle used on any street or highway. Additionally, any such application

could adversely affect the warranty coverage of such an on-street or highway vehicle.

Chevrolet, Chevy, the Chevrolet Bow Tie Emblem, General Motors, and GM are all registered trademarks of the General

Motors Company.

Package contents:

Item Description Quantity GM Part Number

1 Deluxe Engine Assembly (ZZ502) 1 19201332

2 Short Block Instructions 1 19171883

3 Long Block Instructions 1 12487523

4 Deluxe Engine Instructions 1 19171884

5 Starter Motor Package 1 19302919

6 Carburetor Package 1 19170094

NOTE: A packing check sheet is included that indicates each individual loose part included with this engine

assembly.

ZZ502 Engine Torque Specications:

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

Note: These torque values are in addition to those documented within the short and long block instructions.

FRONT

Information may vary with application. All specications listed are based on the latest production information available at

the time of printing.

Caution

This engine assembly needs to be lled with oil and primed. You should add the specied oil (see startup

instructions) to your new engine. Check the engine oil level on the dipstick and add accordingly.

Start-up and Break-in Procedures

1. After installing the engine, ensure the crankcase has been lled with 5W30 motor oil (non-synthetic) to the recommended

oil ll level on the dipstick. Also check and ll as required any other necessary uids such as coolant, power steering uid,

etc.

2. The engine should be primed with oil prior to starting. Follow the instructions enclosed with the tool. To prime the engine,

first remove the distributor to allow access to the oil pump drive shaft. Note the position of the distributor before removal.

Install the oil priming tool, part number 141-955 from our licensed partner. Using a 1/2" dill motor, rotate the engine oil

priming tool clockwise for three minutes. While you are priming the engine, have someone else rotate the crankshaft

clockwise to supply oil throughout the engine and to all the bearing surfaces before the engine is initially started. This is the

sure way to get oil to the bearings before you start the engine for the first time. Also, prime the engine if it sits for extended

periods of time. Reinstall the distributor in the same orientation as it was removed.

3. Safety rst. If the vehicle is on the ground, be sure the emergency brake is set, the wheels are chocked and the car

cannot fall into gear. Verify everything is installed properly and nothing was missed.

4. Start the engine and adjust the initial timing. Set the ignition timing to 10º before top dead center (BTDC) at 650

rpm with the vacuum advance line to the distributor disconnected and plugged. This setting will produce 32º of total

advance at wide-open throttle (WOT). The HEI vacuum advance canister should remain disconnected. This engine is

designed to operate using only the internal centrifugal advance to achieve the correct timing curve. Rotate the distributor

counterclockwise to advance the timing. Rotate the distributor clockwise to retard the timing.

5. When possible, you should always allow the engine to warm up prior to driving. It is a good practice to allow the oil sump

and water temperature to reach 180°F before towing heavy loads or performing hard acceleration runs.

6. Once the engine is warm, Double check the total advance timing is 32° at 4000 RPM if using the deluxe engine

conguration.

7. The engine should be driven at varying loads and conditions for the rst 30 miles or one hour without wide open throttle

(WOT) or sustained high RPM accelerations.

8. Run ve or six medium throttle (50%) accelerations to about 4000 RPM and back to idle (0% throttle) in gear.

9. Run two or three hard throttle (WOT 100%) accelerations to about 4000 RPM and back to idle (0% throttle) in gear.

10. Change the oil and lter. Replace with 5W30 motor oil (not synthetic) and a PF454 AC Delco oil lter. Inspect the oil and

the oil lter for any foreign particles to ensure that the engine is functioning properly.

11. Drive the next 500 miles under normal conditions or 12 to 15 engine hours. Do not run the engine at its maximum rated

engine speed. Also, do not expose the engine to extended periods of high load.

12. Change the oil and lter. Again, inspect the oil and oil lter for any foreign particles to ensure that the engine is functioning

properly.

13. Do not use synthetic oil for break-in. It would be suitable to use synthetic motor oil after the second recommended oil

change and mileage accumulation. In colder regions, a lower viscosity oil may be required for better ow characteristics.

ZZ502 Component Information

Ignition System

The HEI distributor (Part Number 93440806) included with the ZZ502 deluxe engine is a self-contained ignition system that

includes a magnetic pickup, a module, a coil, a rotor, and a cap. The HEI’s large diameter cap minimizes arcing and cross

ring between adjacent spark plug terminals. The cap’s male terminals provide a reliable, positive connection for the spark

plug leads. However, the HEI’s large diameter cap may interfere with other underhood components in vehicles not originally

equipped with HEI ignition systems. Check for adequate clearance before installation. The HEI distributor supplied with the

ZZ502 deluxe engine has a hardened drive gear that is compatible with a steel camshaft. Use of a non-hardened distributor

gear will result in excessive wear.

The HEI system requires a 12-volt power supply for proper operation. The HEI ignition system should be connected directly

to the battery with 10 or 12 gauge wire through a high quality ignition switch. If you are installing an HEI ignition in an early-

model vehicle originally equipped with a point-type ignition, be sure to remove or bypass the resistor in the wiring harness to

ensure the HEI receives 12 volts continuously. Use distributor connector package Part Number 12167658, which includes

connectors and wires for the HEI’s tachometer and 12 volt terminals.

Water Pump

The ZZ502 deluxe engine comes with an aluminum, short style water pump, Part Number 12494151. The pump included

with this kit has a standard rotation impeller that is used with conventional accessory drives. Some serpentine belt systems

require a water pump with a reverse-rotation impeller. In these instances, install a water pump specied for the original

application.

Timing Information

Set initial spark timing at 10º before top dead center (BTDC) at 650 rpm with the vacuum advance line to the distributor

disconnected and plugged. This setting will produce 32º of total advance at wide-open throttle (WOT). The HEI vacuum

advance canister should remain disconnected. This engine is designed to operate using only the internal centrifugal

advance to achieve the correct timing curve. The HEI distributor supplied with the ZZ502 deluxe engine has mechanical

centrifugal spark advance with the following curves:

Mechanical Advance:

RPM Advance

1100 0.0º

1600 12.0º

2400 16.0º

4600 22.0º

Carburetor

The carburetor included with the ZZ502 deluxe engine is a Holley 4-barrel Model 4160 dual feed fuel inlet, vacuum

secondary carburetor. This carburetor features center hung oat bowls, electric choke, power valve blow-out protection, and

a secondary power valve. It has the correct calibration for ZZ502 crate engines. For more information and carburetor set up

instructions, see the specic carburetor instruction sheet or visit www.holley.com.

Air Cleaner

The ZZ502 deluxe engine does not include an air cleaner assembly. Chevrolet Performance Parts has two chromed, 14-inch

diameter, open element air cleaner assemblies for single four-barrel carburetors. Part number 141-306 available from our

licensed partner www.factoryperformanceparts.com, has a plain top and part number 141-302 available from our licensed

partner www. factoryperformanceparts.com, has a Chevrolet logo. Both of these assemblies are supplied with a 3-inch tall

lter element, part number 6421746 (AC# A212cw). A taller 4-inch element is available, part number 8997189 (AC# A698c).

ZZ502Service Parts List:

Part # Quantity Name

19302919 1 Motor Asm, Start

19170094 1 Carburetor Pkg, 870 Cfm 4 Bbl

12366985 1 Gasket Pkg, Int Manif

12494151 1 Pump Kit, Wat

19307141 8 Sparkplug

12368384 1 Wire Pkg, Splg*Perf Parts Logo*

93440806 1 Distributor Asm

12167658 1 Connector Pkg, Distr Hei Pwr

12363407 1 Manifold Pkg, Int*Holley Base

10202456 1 Thermostat Asm-Eng Cool

10108470 1 Outlet-Wat

10105135 1 Gasket-Wtr Otlt

19303069 1 Valve, Pcv

12363390 2 Head Asm, Cyl (Oval Port) W/Val

12366987 4 Intake Valve

12366988 4 Exhaust Valve

12366993 1 Valve Stem Seals

12462970 1 Inner/Outer Valve Spring

3947880 16 Valve Locks

3875916 8 Valve Spring Shim

3921912 8 Rocker Arm Stud

3860038 4 Guideplate

12363411 2 Gasket, Cyl Hd

12495488 1 Cover Pkg, Rkr Arm

14085759 2 Gasket Asm-Vlv Rkr Cvr

12366994 2 Decal, Eng Displ*502 Performanc

12557083 1 Indicator Asm-Oil Lvl

12550533 1 Tube Asm-Oil Lvl Ind

274244 1 Seal-O Ring

12368081 1 Rod Asm Pkg, Vlv Push(Qty 16)

10227762 8 Rod Asm-Vlv Push

10227763 8 Rod,Exh Vlv Push

12368085 1 Arm Kit, Vlv Rkr

12368082 16 Arm Kit, Vlv Rkr(Qty 1)

19170540 1 Block Asm, Eng

6264902 1 Seal, Rr Brg Cap (O Ring

Part # Quantity Name

10181306 1 Bearing, Cr/Shf Upr/Lwr (Std)

12529885 3 Bearing, Cr/Shf Upr/Lwr (Std)

10181307 1 Bearing, Cr/Shf Thr Upr/Lwr Thrust

10183723 1 Crankshaft Asm

10101164 1 Seal Asm, Cr/Shf Rr Oil

14097040 1 Deector, Cr/Shf Oil

10216339 1 Balancer Asm, Cr/Shf

10114166 1 Key, Torsional Dpnr

10126796 1 Bolt/Screw, Cr/Shf Balr

3864814 1 Washer, Cr/Shf Balr

10185034 1 Flywheel Asm

3727207 6 Bolt/Screw, Flywhl

19170198 8 Rod, Conn

19180155 2 Bolt/Screw, Conn Rod

3942410 2 Nut, Conn Rod

12533507 8 Piston Asm, (W/ Pin And Rings)

12524293 8 Ring Kit

10181277 16 Bearing, Conn Rod

10240721 1 Pan Asm, Oil

11562588 1 Plug Asm, Oil Pan Drn

3536966 1 Seal, Oil Pan Drn Plug

19213986 1 Gasket, Oil Pan

19210599 1 Pump Asm, Oil (W/ Scrn)

3998289 1 Shaft, O/Pmp Drv

3764554 1 Retainer, O/Pmp Drv Shf

10230954 1 Cover Asm, Eng Frt (W/ T

10191640 1 Seal Asm, Cr/Shf Frt Oil

10198910 1 Gasket, Eng Frt Cvr

12366543 1 Camshaft Asm

12560176 1 Sprocket, Cm/Shf

9424877 3 Bolt/Screw, Cm/Shf Spkt

12560177 1 Sprocket, Cr/Shf

10114177 1 Chain Asm, Tmg

17120061 16 Lifter Asm, Vlv

12551397 8 Guide, Vlv Lftr

Inhaltsverzeichnis

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