Merlin/Motion 540-Cube Big Block Engine - Installation Process

Tuning the Tubes
The Kinsler Cross Ram injection system was first used in 1974 by road racer John Greenwood on his big-block Corvettes. Since the rules disallowed stacks poking through the hood, Kinsler laid them down and designed the Cross Ram configuration. The Cross Ram injection system has evolved from Lucas mechanical metered injection to the Merlin/Motion's sequential electronic fuel injection using Bosch 44-pound injectors, controlled by an Accel/DFI GEN VII computerized engine management system.

Because of the precision of its EFI system, the Kinsler Cross Ram injection manifold is the perfect induction system for the Camaro SuperCoupe. In fact, the intake's pattern is so complex, the foundry can only pour one manifold a day. Like the Merlin/Motion engine, each Kinsler intake is hand machined and hand built, so no two are exactly alike

The intake was modified to meet Motion's specifications. The throttles measure 2 3/8 inches and the Bosch 44 injectors are mounted low in the ports. The Kinsler intake is designed to have either upper or lower injector locations. Rosen and Keech preferred the lower position, so the upper boss was removed from the manifold. Kinsler coordinated with Mitchell to port the intake to match the Merlin III cylinder heads.

While the Merlin heads are beautifully machined, it's a good idea to make sure they're true. In this case, the deck was shaved 0.004 inch.
While the Merlin heads are beautifully machined, it's a good idea to make sure they're tru
The Merlin III combustion chamber measures out to 119 cc's and comes with a good three-angle valve job. The tolerances were checked and the valves were then lapped in.
The Merlin III combustion chamber measures out to 119 cc's and comes with a good three-ang
COMP Cam's roller valvetrain was installed with Hi Tech Stainless 1.70 rockers and 7/16 studs. The stainless steel valves measure 2.30 inches on the intake and 1.88 inches on the exhaust.
COMP Cam's roller valvetrain was installed with Hi Tech Stainless 1.70 rockers and 7/16 st

The concept of Cross Ram injection is simple. The tube length affects the torque and horsepower peaks are in the rpm band. Typically, a shorter tube produces more top end while a longer tube provides more bottom end. The tube's diameter is determined by hp and maximum rpm.

Predicated on camshaft selection, engine displacement, and flow characteristics, Motion and Kinsler ran computer simulations to determine the proper length and diameter for the ram tubes. In the case of the Merlin/Motion 540, the ram tubes are 6 inches long with an inside diameter of 2.50 inches.

The throttle size was reduced to give the engine good driveabilty, but still provides plenty of volume so it will flow enough to hit the hp curve's "sweet spot." The Merlin/Motion 540 with the Kinsler Cross Ram EFI injection and custom Motion grind roller camshaft produces an estimated 700-plus-hp at 6,500 rpm and 585 lb-ft of torque at an estimated 5,200 rpm.

Ten-degree retainers and keepers from COMP Cams were used for the big dual valve springs, which were set at 150 pounds at the seat.
Ten-degree retainers and keepers from COMP Cams were used for the big dual valve springs,
The height mic determined that the installed height of the valvespring was 1.88 inches in the Merlin/Motion head.
The height mic determined that the installed height of the valvespring was 1.88 inches in
Part of the Phase II process was to polish the second set of Mitchell Merlin III heads, add the roller rocker valvetrain, and install the new custom Motion grind camshaft. A Cloyes timing chain was then installed.
Part of the Phase II process was to polish the second set of Mitchell Merlin III heads, ad

The exhaust ports were blended and smoothed followed by a standard port and polish job. It wasn't necessary to raise them or do any welding.
The exhaust ports were blended and smoothed followed by a standard port and polish job. It
The Merlin III cylinder head boasts 350cc runners. The intakes were cleaned up and port matched to the intake manifold. That was good for 15-20 additional horses.
The Merlin III cylinder head boasts 350cc runners. The intakes were cleaned up and port ma
In keeping with tradition, the Motion team chose to install a set of original NOS Motion valve covers. They located the valve covers where everyone finds stuff these days-eBay. The pristine covers, which cost a cool grand, were sent out for polishing before installation.
In keeping with tradition, the Motion team chose to install a set of original NOS Motion v

The mind-blowing Kinsler Cross-Ram electronic fuel injection system was completely polished and prepped prior to installation on the Merlin/Motion 540 engine. The gorgeous ram tubes were tuned in length and diameter to provide optimum performance without sacrificing driveabilty.
The mind-blowing Kinsler Cross-Ram electronic fuel injection system was completely polishe
The machined billet Jackshaft linkage is not only a thing of beauty, it also replaces the traditional cross bar that connects the two sides of the manifold's butterflies. As the manifold expands and contracts during operation, the Jackshaft allows the two sides to move independently of each other. Any distortion is absorbed by the Jackshaft.
The machined billet Jackshaft linkage is not only a thing of beauty, it also replaces the
Larry Jaworske, Motion's CEO, is a key player in the development of the Motion Camaro SuperCoupe and its awesome Merlin/Motion 540 engine. Jaworske worked closely with Rosen and Mitchell on the Merlin/Motion 540's specifications.
Larry Jaworske, Motion's CEO, is a key player in the development of the Motion Camaro Supe