Performance ZZ502 Installation manual

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