ZZ502 Engine (19201332 Deluxe) Specifications - Chevrolet

ZZ502 Engine (19201332 Deluxe) Specifications

Specifications 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 final (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. Visit our website at for the Chevrolet Performance Parts Authorized Center nearest you.

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 specifications, 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 significant differences in the water pump, torsional damper, etc., between a ZZ502 deluxe engine and an older big block V8 engine. These differences may require modifications 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 specific 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 specifications 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.

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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 flammable, 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. Specific component design, mechanical procedures, and the qualifications 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 modifications 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 specifically 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 specifically designed for Off-Highway application only. Since the installation of this part may either impair your vehicle's emission control performance or be uncertified 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

1 Deluxe Engine Assembly (ZZ502)

1

2 Short Block Instructions 1

3 Long Block Instructions 1

4 Deluxe Engine Instructions 1

5 Starter Motor Package 1

6 Carburetor Package 1

GM Part Number 19201332 19171883 12487523 19171884 19302919 19170094

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

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ZZ502 Engine Torque Specifications: 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 specifications listed are based on the latest production information available at the time of printing. Caution This engine assembly needs to be filled with oil and primed. You should add the specified oil (see startup instructions) to your new engine. Check the engine oil level on the dipstick and add accordingly.

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Start-up and Break-in Procedures

1. After installing the engine, ensure the crankcase has been filled with 5W30 motor oil (non-synthetic) to the recommended oil fill level on the dipstick. Also check and fill as required any other necessary fluids such as coolant, power steering fluid, 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 first. 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 10? before top dead center (BTDC) at 650 rpm with the vacuum advance line to the distributor disconnected and plugged. This setting will produce 32? 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 configuration.

7. The engine should be driven at varying loads and conditions for the first 30 miles or one hour without wide open throttle (WOT) or sustained high RPM accelerations.

8. Run five 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 filter. Replace with 5W30 motor oil (not synthetic) and a PF454 AC Delco oil filter. Inspect the oil and the oil filter 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 filter. Again, inspect the oil and oil filter 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 flow characteristics.

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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 firing 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 earlymodel 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 specified for the original application.

Timing Information Set initial spark timing at 10? before top dead center (BTDC) at 650 rpm with the vacuum advance line to the distributor disconnected and plugged. This setting will produce 32? 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 1100 1600 2400 4600

Advance 0.0? 12.0? 16.0? 22.0?

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 float 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 specific carburetor instruction sheet or visit .

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 , has a plain top and part number 141-302 available from our licensed partner , has a Chevrolet logo. Both of these assemblies are supplied with a 3-inch tall filter element, part number 6421746 (AC# A212cw). A taller 4-inch element is available, part number 8997189 (AC# A698c).

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ZZ502Service Parts List:

Part # 19302919 19170094 12366985 12494151 19307141 12368384 93440806 12167658 12363407 10202456 10108470 10105135 19303069 12363390 12366987 12366988 12366993 12462970 3947880 3875916 3921912 3860038 12363411 12495488 14085759 12366994 12557083 12550533 274244 12368081 10227762 10227763 12368085 12368082 19170540 6264902

Quantity Name

1

Motor Asm, Start

1

Carburetor Pkg, 870 Cfm 4 Bbl

1

Gasket Pkg, Int Manif

1

Pump Kit, Wat

8

Sparkplug

1

Wire Pkg, Splg*Perf Parts Logo*

1

Distributor Asm

1

Connector Pkg, Distr Hei Pwr

1

Manifold Pkg, Int*Holley Base

1

Thermostat Asm-Eng Cool

1

Outlet-Wat

1

Gasket-Wtr Otlt

1

Valve, Pcv

2

Head Asm, Cyl (Oval Port) W/Val

4

Intake Valve

4

Exhaust Valve

1

Valve Stem Seals

1

Inner/Outer Valve Spring

16 Valve Locks

8

Valve Spring Shim

8

Rocker Arm Stud

4

Guideplate

2

Gasket, Cyl Hd

1

Cover Pkg, Rkr Arm

2

Gasket Asm-Vlv Rkr Cvr

2

Decal, Eng Displ*502 Performanc

1

Indicator Asm-Oil Lvl

1

Tube Asm-Oil Lvl Ind

1

Seal-O Ring

1

Rod Asm Pkg, Vlv Push(Qty 16)

8

Rod Asm-Vlv Push

8

Rod,Exh Vlv Push

1

Arm Kit, Vlv Rkr

16 Arm Kit, Vlv Rkr(Qty 1)

1

Block Asm, Eng

1

Seal, Rr Brg Cap (O Ring

Part # 10181306 12529885 10181307 10183723 10101164 14097040 10216339 10114166 10126796 3864814 10185034 3727207 19170198 19180155 3942410 12533507 12524293 10181277 10240721 11562588 3536966 19213986 19210599 3998289 3764554 10230954 10191640 10198910 12366543 12560176 9424877 12560177 10114177 17120061 12551397

Quantity 1 3 1 1 1 1 1 1 1 1 1 6 8 2 2 8 8 16 1 1 1 1 1 1 1 1 1 1 1 1 3 1 1 16 8

Name Bearing, Cr/Shf Upr/Lwr (Std) Bearing, Cr/Shf Upr/Lwr (Std) Bearing, Cr/Shf Thr Upr/Lwr Thrust Crankshaft Asm Seal Asm, Cr/Shf Rr Oil Deflector, Cr/Shf Oil Balancer Asm, Cr/Shf Key, Torsional Dpnr Bolt/Screw, Cr/Shf Balr Washer, Cr/Shf Balr Flywheel Asm Bolt/Screw, Flywhl Rod, Conn Bolt/Screw, Conn Rod Nut, Conn Rod Piston Asm, (W/ Pin And Rings) Ring Kit Bearing, Conn Rod Pan Asm, Oil Plug Asm, Oil Pan Drn Seal, Oil Pan Drn Plug Gasket, Oil Pan Pump Asm, Oil (W/ Scrn) Shaft, O/Pmp Drv Retainer, O/Pmp Drv Shf Cover Asm, Eng Frt (W/ T Seal Asm, Cr/Shf Frt Oil Gasket, Eng Frt Cvr Camshaft Asm Sprocket, Cm/Shf Bolt/Screw, Cm/Shf Spkt Sprocket, Cr/Shf Chain Asm, Tmg Lifter Asm, Vlv Guide, Vlv Lftr

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Caract?ristiques techniques du moteur ZZ502 (19201332 de luxe)

Num?ro de pi?ce des caract?ristiques techniques 19171884

Ce document sur le moteur en caisse de luxe ZZ502 doit ?tre utilis? conjointement avec le moteur embiell? ZZ502, num?ro de pi?ce 19171883, et le bloc long ZZ502, num?ro de pi?ce 12487523. Les documents compris dans cet ensemble de renseignements s'appuient sur les renseignements du moteur embiell? ZZ502 et ? bloc long ZZ502. Veuillez trouver les renseignements sur le moteur embiell? ZZ502 et ? bloc long ZZ502, puis commencer ? cet endroit. Ceci est la section finale (troisi?me) des instructions de montage du moteur ZZ502 de luxe.

Nous vous remercions d'avoir choisi Chevrolet Performance Parts comme source de haute performance. Chevrolet Performance Parts s'est engag?e ? offrir une technologie de rendement ?prouv?e et novatrice qui est r?ellement... beaucoup plus que de la puissance. Les pi?ces de Chevrolet Performance ont ?t? con?ues, ?labor?es et mises ? l'essai ? l'usine de mani?re ? d?passer vos attentes de r?glage pr?cis et de fonction. Visitez notre site Web ? l'adresse pour conna?tre le centre Chevrolet Performance Parts autoris? de votre r?gion.

La pr?sente publication offre de l'information d'ordre g?n?ral sur les composants et les proc?dures pouvant s'av?rer utile lors de la pose ou de l'entretien du moteur de luxe ZZ502. Veuillez lire en entier la pr?sente publication avant de commencer ? travailler. Veuillez ?galement v?rifier que tous les composants ?num?r?s dans la section Contenu de l'ensemble ci-dessous ont ?t? envoy?s avec la trousse.

Les renseignements ci-dessous sont divis?s dans les sections suivantes : contenu de l'ensemble, renseignements sur le couple, caract?ristiques techniques de l'ensemble moteur de luxe ZZ502, proc?dures de d?marrage et de rodage du moteur, renseignements sur les composants et liste de pi?ces de rechange.

L'ensemble moteur de luxe ZZ502 comprend plus de composants que l'ensemble ? bloc long, qui composent le moteur de luxe. Les composants importants suppl?mentaires comprennent la tubulure d'admission, un carburateur, un distributeur et la pompe ? eau. Le moteur de luxe ZZ502 est un moteur compl?tement mont?. Ce moteur est mont? au moyen de composants neufs de premi?re qualit?. Le moteur de luxe ZZ502 est fabriqu? sur l'outillage de production actuel ; par cons?quent, il est possible de rencontrer des dissemblances entre le moteur de luxe ZZ502 et les pr?c?dentes versions du gros bloc V8. En g?n?ral, les ?l?ments tels que les fixations du moteur, les entra?nements accessoires, les tubulures d'?chappement, etc. peuvent ?tre transf?r?s sur un moteur de luxe ZZ502 lorsqu'il est mont? sur un v?hicule ?quip? ? l'origine d'un moteur V8 ? gros bloc. Toutefois, comme il est indiqu? dans les sections suivantes, il pourrait y avoir des diff?rences importantes entre la pompe ? eau, l'amortisseur de vibrations, etc., entre le moteur de luxe ZZ502 et un moteur V8 ? gros bloc plus ancien. Ces diff?rences peuvent n?cessiter des modifications ou des composants suppl?mentaires non compris dans le moteur de luxe ZZ502. Lors du montage d'un moteur de luxe ZZ502 sur un v?hicule non ?quip? ? l'origine d'un V8 ? gros bloc, il peut ?tre n?cessaire d'adapter ou de fabriquer divers composants pour les syst?mes de refroidissement, d'alimentation en carburant, ?lectriques et d'?chappement. En raison du grand nombre de v?hicules sur lesquels le moteur de luxe ZZ502 peut ?tre mont?, certaines proc?dures et recommandations peuvent ne pas s'appliquer aux applications particuli?res.

Chevrolet recommande l'utilisation d'un carburant ? indice d'octane minimale de 92 (R+M/2) dans le moteur ZZ502 (taux de compression 9.6:1) pour ?viter le pr?allumage. Ces caract?ristiques techniques ne sont pas destin?es ? remplacer les pratiques d'entretien compl?tes et d?taill?es expliqu?es dans les manuels de r?paration d'usine.

Pour obtenir de l'information sur l'?tendue de la garantie, pri?re de communiquer avec le concessionnaire Chevrolet Performance Parts local.

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Observer toutes les pr?cautions et tous les avertissements en mati?re de s?curit? pr?sent?s dans le Manuel d'entretien au moment de monter un ensemble moteur de luxe Chevrolet (BBC) ? gros bloc ZZ502 dans n'importe quel v?hicule. Porter un protecteur pour la vue et des v?tements de protection appropri?s. Soutenir fermement le v?hicule avec des chandelles au moment de travailler sous le v?hicule ou autour de celui-ci. Utiliser seulement les outils appropri?s. Faire preuve d'extr?me prudence lors de travaux avec des liquides ou des mat?riaux inflammables, corrosifs ou dangereux. Certaines proc?dures n?cessitent l'utilisation d'un ?quipement sp?cial et des habilet?s particuli?res. Si vous ne poss?dez pas la formation, l'expertise et les outils n?cessaires pour effectuer toute partie de cette conversion en toute s?curit?, ce travail devrait ?tre r?alis? par un professionnel.

Les renseignements contenus dans cette publication sont pr?sent?s sans aucune garantie. Tout risque encouru pendant l'utilisation de cette publication est enti?rement assum? par l'utilisateur. La conception de composant sp?cial, les proc?dures m?caniques et les qualifications de chaque lecteur sont hors du contr?le de l'?diteur et c'est pourquoi il d?cline toute responsabilit? aff?rente en lien avec l'utilisation des renseignements fournis dans cette publication.

Renseignements l?gaux et renseignements sur les ?missions

Le pr?sent document a pour objet de fournir des renseignements sur le moteur ZZ502 et les composants connexes. Le pr?sent manuel d?crit ?galement les proc?dures et les modifications pouvant ?tre utiles pendant la pose d'un moteur ZZ502. Ces renseignements ne sont pas destin?s ? remplacer les manuels de r?paration complets et les catalogues de pi?ces en mati?re de moteurs et de composants de Chevrolet. Plut?t, ce guide a ?t? con?u pour offrir des renseignements suppl?mentaires sur les mati?res pouvant int?resser les ? bricoleurs ? et les m?caniciens.

Cette publication s'applique aux moteurs et aux v?hicules qui sont utilis?s hors des voies publiques, sauf indication contraire expresse. Les r?glements f?d?raux restreignent la d?pose des v?hicules automobiles de toute partie d'un syst?me antipollution exig? par la loi f?d?rale. En outre, de nombreux ?tats ont ?tabli des lois qui interdisent le trafiquage ou la modification de tout syst?me antipollution ou antibruit exig? par la loi. En r?gle g?n?rale, les v?hicules qui ne roulent pas sur les voies publiques, tout comme certains v?hicules d'int?r?t sp?cial et pr?-?missions, sont exempts de la plupart de la r?glementation. On sugg?re fortement au lecteur de consulter tous les r?glements municipaux et provinciaux applicables.

Plusieurs des pi?ces qui sont d?crites ou ?num?r?es dans le pr?sent ouvrage sont commercialis?es ? des fins hors autoroute seulement et elles portent l'?tiquette ? Special Parts Notice ? (avis sur les pi?ces sp?ciales) qui est reproduite ici.

Avis sur les pi?ces sp?ciales

Cette pi?ce a ?t? con?ue sp?cifiquement pour une application hors route seulement. Puisque la pose de cette pi?ce pourrait nuire au rendement antipollution du v?hicule ou donner lieu ? son manque d'homologation en vertu des normes de s?curit? actuelles des v?hicules automobiles, celle-ci ne doit pas ?tre pos?e dans un v?hicule qui sera utilis? sur une voie publique ou une autoroute. En outre, une telle application pourrait donner lieu ? l'annulation de la garantie d'un tel v?hicule sur route ou autoroute.

Chevrolet, Chevy, l'embl?me Chevrolet, General Motors et GM sont des marques d?pos?es de General Motors.

Contenu de l'ensemble :

Item Description

Quantit?

N? de pi?ce GM

1

Ensemble moteur de luxe (ZZ502) 1

19201332

2

Instructions du bloc-moteur embiell? 1

19171883

3

Instructions pour bloc long 1

12487523

4

Instructions relatives au moteur de luxe 1

19171884

5

Ensemble d?marreur 1

19302919

6

Ensemble carburateur 1

19170094

REMARQUE : Une fiche de v?rification de contenu est incluse et indique chaque pi?ce individuelle incluse dans l'ensemble moteur.

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