benda

I have a 1992 Chapparral 2200 with a Merc 454 300hp with a Bravo 1 drive (thru hub exhaust). My son overheated last summer and now it is locked up. I would like to replace the engine with a Mercrusier 502 MPI or a 496 HO. The engine compartment space is tight. It appears I can get a crate motor for $8500 to $9000 respectively. I was wondering what hidden cost I might run into with regards to the exhaust, fuel lines, outdrive, etc. I've been told the 502 is a drop in while the 496 is a major effort. Is this true? Thanks. Dave

puder

you can pickup a crate 502 for less than 8500!!!!

check 800runsnew.com

all yoru accessories from the 330 should bolt up to the 502.

there was alsoa complete 502 volvoa (GM base) setup for sale in eth classifieds for damn good rpice

muffman

496 HO is the way to go . similar situation happen to me I got a great deal on a volvo one same as the 496Ho. All you have to do is switch the bell housing, coupler and engine mounts. I bought mine from the same person that has some for sale in the parts section right now.

Quaid24

When you say a crate motor, is it only a long block or a complete motor? I bought a 502MPI crate motor (long block) last year for $4400.00. They have gone up some, but only some where in the $5000.00's. From what I understand, the 496 is a completely different motor. My buddy owns a Marine and says the brackets and accessory mounting holes are all different. The 496 is a better motor, but the 502 is still fine.

benda

Thanks for the advice. I was looking to purchase a complete MPI motor not just the long block. Muffman - where did you get the bellhousing, coupler, and mounts to convert to a 496? How much extra did this cost? Since I'm going from a carb to MPI, do I need to modify the lines from the fuel tank (for 496 HO)?
Puder - The website you suggested was not found ( 800runsnew.com ). Is there a different spelling?
Regarding exhaust, I currently have thru hub. Can I run a 502 or 496 thru hub and a thru transom with captains call or something similar? Finally, I have 275 hours on the Bravo. What type of maintenance should I perform on it while I have it out?
Thanks.

wallynt

Hey Dave.

The web site Puder suggested is www.1800runsnew.com.

good luck with the swap.

Pat McPherson

Dave,
If you go with the new 496, Buy the complete Volvo Penta set up Sean (ido1320). I bought an engine from him and it worked great; you won't find a better deal.
If you go 502 carb, wallynt is right... JK at 1800runsnew,
$5200 for a new 435HP/502 marine base engine.

muffman

Benda, Patrick is right Sean is his name. I had a 1993 454 330hp and the bell housing, coupler and engine mounts off of it work perfectly. There are holes in the 496h0 flywheel to accept the coupler but don't try to use the old coupler bolts because the 496ho is metric I found this out the hard way other wise everything is pretty simple. You have to fab a bracket for your throttle and make a new connection for your trim and tilt senders on the back of the motor. Piece of cake. I gained almost 10mph in a 26' Corsa .

ursus

the bellhousing,engine mounts , exhaust are drop in for the 502 no problems however; all the accessories from a MK IV 330 will not bolt onto a Gen 6 502

1. you will need the larger oil cooler and seperate P/S cooler and all new hoses since they take a different route rather than the small combined oil p/s cooler on the 330. The small oil cooler from the 330 is not large enough, don't try it unless you boat at Frobisher bay .

2. The raw water pump is different ,the Gen 6 is shorter and so the bracket will need to be shimmed about 3/16" or you will need to get a gen 6 pump.

3. the alternator brackets etc use 7/16 vs 3/8 bolts in dif locations and will need to be re-drilled

4. the Gen 6 block does not have provision for the 3rd foward mounting screw on the the starter motor altho one can be fabricated from a brass plug.

5. the flywheel and harmonic balancer are different if the crate engine does not come with them.