Home

3.0L Service Manual Revision

1. 79363006 3 10 Engine Electrical el am 95 M 33d SMISSNOMIDO Se8 9813 j TN UNE Xm ONIAVSO JTvIS IN 00 Br Wh Wa 0 LAES UIDHS Eu Ie JLLYNIHIS DENTATA oo O CB 21084 38 70088 aa iw m ei ave Gore 3 WISIN QUA IN Gwe 15 NO OMS al AMGLLYS JOAZ1 DL enis ti TE 90014 xu OB OB OZA pis 5 Ey Bam 80224 2 OTTER WOOT D en Tides 20009 2 ST e Ug 8 a a E gt d x WE wl 22 jg M s 4 un E Xu ALIAVE O O O B g 2 P AY Ha lm T Mine LLENO NO OnLS au N gl MOLMBTALSIO E NI 8 008 COTA 20028 B 5 XDLIINNDJ 3 LINI ONTONAS Fi 83H H E i E INVICOZ E a ADLIENNEI cano m m ee SSSNGYH h E J CES ZOE Malays ANIONS zm 5 Rm 2 083 200 0 8 3 RES la B B 8111230 311 IIM NNS 3 a m 2 E 8001 T 3anssaed 110 a a a 5 a Ns ALIA T e T ce OE k s Bn URGE Uh E i i SRM N S z anna E m E z E O N
2. 1 64 Engine Front Cover and Seal Installation 1 65 Oil Pump Installation 2 2 2 1 66 Oil Pan Installation 1 66 Crankshaft Pulley Installation 1 67 Cylinder Head Installation 1 67 Valve Lifter Installation 1 68 Valve Rocker Arm and Pushrod Installation 1 68 Pushrod Cover Installation 1 70 Valve Rocker Arm Cover Installation 1 71 Oil Level Indicator and Tube Installation 1 71 Water Pump Installation 1 71 1 2 Engine Mechanical Industrial 3 0L Intake Exhaust Manifold Installation 1 72 Spark Plug Installation 1 72 Lift Bracket Installation 1 72 Ignition Coil Installation 1 73 Distributor Installation 1 73 Engine Flywheel Installation 1 74 Engine Block Coolant Plug Oil Filter Installation 1 74 Description and Operation 1 76 Engine Component Description 1 76 Engine 44 1 76 Cylinder
3. 1 40 Distributor Lower Bushing and Thrust Washer ae an 1 41 Piston and Connecting Rod Disassemble 1 41 Piston and Connecting Rod Clean and Inspect 1 42 Piston Selection 240 1 44 Piston and Connecting Rod Assemble 1 45 Camshaft and Bearings Clean and Inspect 1 46 Camshaft Sprocket and Retainer Removal and Installation 1 48 Camshaft Bearing Installation 1 49 Oil Pump Disassemble 1 50 Oil Pump Clean and 1 51 Oil Pump Assemble 1 52 Cylinder Head Disassemble 1 53 Cylinder Head Clean and Inspect 1 54 Valve Guide Reaming Valve and Seat Grinding 1 57 Rocker Arm Stud Removal and Installation 1 58 Cylinder Head Assemble 1 59 Service Prior to Assembly 1 60 Crankshaft Bearings and Bearing Cap Installation 1 60 Crankshaft Rear Oil Seal and Housing Installation 1 61 Piston Connecting Rod and Bearing Installation 1 62 Timing Gear Oil Nozzle Installation 1 64 Crankshaft Sprocket Installation 1 64 Camshaft Installation
4. 3 38 Specifications 3 3 Ignition Coil not Operating Properly 3 41 Fastener Tightening Specifications 3 3 Spark Plug Wires Not Operating Properly 3 41 Battery Usage coii cec ite ner reme rer er 3 3 Spark Plug Wire Resistance Test 3 41 Starter Motor 3 4 Spark Plug Wire Routing 3 41 Starter 3 4 Testing Pick up Coil 3 43 Starter Motors and Solenoid Switches 3 4 Repair Instructions 3 44 Generator USAge cte iter nr Rp e pa 3 4 Battery Cable 3 44 Spark Plug 3 4 Battery 22 3 45 Schematic and Routing Diagrams 3 5 Charging Procedure seucena aeneen 3 45 Lincoln Electric Gasoline Only 3 5 Charging Time Required 3 46 Tennant Gasoline Only Model 550 3 6 Battery Charge Low or Completely Discharged 3 47 Tennant LPG Only Mod
5. 2 17 Radiator Replacement 2 17 Description and Operation 2 18 Cooling System Description 2 18 Radiator Assembly Description 2 18 Pressure Cap Description 2 19 Water Pump Description 2 20 Thermostat Description 2 20 Special Tools and Equipment 2 20 2 2 Engine Cooling Industrial 3 0L Fastener Notice NOTICE Always use the correct fastener in the proper location When you replace a fastener use ONLY the exact part number of that application UNLESS OTHERWISE SPECIFIED Do Not use supplemental coatings paints greases or other corrosion inhibitors on threaded fasteners or fastener joint interfaces Generally such coating adversely affect the fastener torque and the joint clamping force and may damage the fastener When you install fasteners use the correct tightening sequence and specifications Following these instructions can help you avoid damage to parts and systems Industrial 3 0L Engine Cooling 2 3 Engine Cooling 3 0L Specifications Fastener Tightening Specifications Application Nm bh Coolant Temperature Sensor 9 8 Coolant Inlet Housing Bots 2530 Coolant Thermostat
6. 1 24 Oil Pan 1 24 Oil Pump 2 0420 4000 1 24 Oil Level Indicator and Tube Removal 1 25 Engine Front Cover Removal nen 1 25 Measuring Crankshaft and Camshaft Sprocket ee 1 26 Measuring Timing Sprocket Teeth Backlash 1 26 Crankshaft Sprocket Removal 1 26 Camshaft 1 27 Crankshaft and Camshaft Sprocket Inspect 1 27 Timing Gear Oil Nozzle Removal 1 28 Piston Connecting Rod and Bearing Removal 1 28 Crankshaft and Bearings Clean and Inspect Connecting Rod Bearing Clearance 1 29 Crankshaft Rear Oil Seal and Housing Removal 1 31 Crankshaft Bearings and Bearing Cap Removal 1 32 Crankshaft and Bearings Clean and 1 33 Crankshaft and Bearings Clean and Inspect Main Bearing Clearance 1 35 Camshaft Bearing 1 37 Distributor Lower Bushing and Thrust Washer Removal assan eiae edere d px ie 1 38 Oil Filter Bypass Valve Removal and Installation 1 38 Cylinder Block Clean and Inspect 1 39 Cylinder Bore Measurements 1 39 Cylinder Boring and Honing
7. 4044504 3 36 3 2 Engine Electrical Industrial 3 0L Fastener Notice NOTICE Always use the correct fastener in the proper location When you replace a fastener use ONLY the exact part number of that application UNLESS OTHERWISE SPECIFIED Do Not use supplemental coatings paints greases or other corrosion inhibitors on threaded fasteners or fastener joint interfaces Generally such coating adversely affect the fastener torque and the joint clamping force and may damage the fastener When you install fasteners use the correct tightening sequence and specifications Following these instructions can help you avoid damage to parts and systems Industrial 3 0L Engine Electrical 3 3 Engine Electrical 3 0L Specifications Fastener Tightening Specifications Application were Distributor Hold Down Bolt 80 Ib in 37 Ib ft Battery Usage Cold Cranking Amperes Rating Reserve Capacity Load Test Amperes LU orm mc 340 3 4 Engine Electrical Industrial 3 0L Starter Motor Usage Starter Specifications Engine Part Number Series Load Test 440 Volts Application p AMPS p Le Maximum 3 0L 900885 PG 260L 65 9 2825 3275 900895 Starter Motors and Solenoid Switches No Load Test 1 5 Volts Includes Solenoid Current Part Number Amer RPM Starter 900885 Minimum Maximum Minimum Maximum or 900895 3 8 Use GM P N 1960954 Grease Lubricant or the equivalent Poth
8. 0 19 Approximate Fluid 0 19 Filter Chart 3 0L Engine 0 20 0 2 General Information Industrial 3 0L Fastener Notice NOTICE Always use the correct fastener in the proper location When you replace a fastener use ONLY the exact part number of that application UNLESS OTHERWISE SPECIFIED Do Not use supplemental coatings paints greases or other corrosion inhibitors on threaded fasteners or fastener joint interfaces Generally such coating adversely affect the fastener torque and the joint clamping force and may damage the fastener When you install fasteners use the correct tightening sequence and specifications Following these instructions can help you avoid damage to parts and systems Industrial 3 0L General Information 0 3 General Information 3 0L Conversion English Metric Conversion English Metric cont d English Multiply Metric Divide by Multiply Metric Divide by 1 6093 a ae CB _ eeXT80 992 5 232 215 mpg Lfh00km Equivalents Decimal and Metric sq yd ga 93784 1 5 04536 kg kg tonne t newtons N newtons N b 4448 ft s m s m s Torque Nem Nem Po Power kW kPa kPa J J one Ws J J one Ws J J one Ws 0 4 General Information Industrial 3 0L Equivalents Decimal a
9. 1 76 Granksh ft 2 82 22 1 76 Camshaft 2 isn 1 76 Pistons and Connecting Rods 1 76 Valve Train 1 76 Lubrication u ehe 1 77 Thread Repair 1 77 Cleanliness and Care 1 78 Replacing Engine Gaskets 1 78 Use of RTV and Anaerobic Sealer 1 78 Separating Parts 1 79 Tools and Equipment 1 79 Special Tools and Equipment 1 80 Industrial 3 0L Engine Mechanical 1 3 Fastener Notice NOTICE Always use the correct fastener in the proper location When you replace a fastener use ONLY the exact part number of that application UNLESS OTHERWISE SPECIFIED Do Not use supplemental coatings paints greases or other corrosion inhibitors on threaded fasteners or fastener joint interfaces Generally such coating adversely affect the fastener torque and the joint clamping force and may damage the fastener When you install fasteners use the correct tightening sequence and specifications Following these instructions can help you avoid damage to parts and systems 1 4 Engine Mechanical Industrial 3 0L Engine Mechanical 3 0L Specifications Fastener Tightening Specifications Applic
10. WVYDVIC TAN ONIMVAC SIE NO NOLLVIASOANI TIY OL SIHON TVENKILNOJ Wd SNOTSNIAXT ODLETINOTO ol SNOISNSHAYU 00 NIC TOYU E 70E0 WIC TOV TAT 3SIAMSHLO JAAS 88971471 dady LTTE SWIVTO ONT SNOLLTTOS MIA Od yg Eid IOL I via ONT SNOLLNTOS 4 yu NOLLASI DNILOO I AYIM 4 45 MS 100 OL E Tid 1100 01 Lure 3HGHO DNDIIJ ANIONG 40 HGIS WOU MID SINOLLVLO HNIDNA INOW AOLNATULSIC dash LON 1 HOVL AVUD SIOLLNOD 3ONWJAOD NYWH TOD HHEUIVH SIVNIWAHL OL AGO ATLLOYHL NVYATIOI A INO dads HI TISN AZ T YOLVNYHLTV 14908 TAS 79363007 Industrial 3 0L 3 12 Engine Electrical 45 Wadd GOOM TAL H LEINSIZ POSTS PLA ANSY Bd SNOINARIG OTRETAOTO mn al SNOISNGINIQ TIONV 8084 5 IDEWVIOVI DNDHA RIDES 090 5 ENT AVAD ONIAVISIHLNONOLVAMORNITIV OL SIHON IVIINAGHNOO uam FSM RAHLO CHUTE an 7 anqa es Tinh 9 1 2 ANVIOU SAIVTO O
11. 3 16 Ignition Coil 3 54 Charging System 3 16 Distributor Module Replacement 3 55 Starting System 3 16 Pick up Coil Replacement 3 56 Battery Common Causes of Failure 3 17 Setting Ignition Timing eessss 3 58 Battery 3 17 PSI Fuel Injected and Dual Fuel Engines 3 58 Important Battery Diagnosis Information 3 17 Zenith Z E E M S Throttle Body Fuel Injected Battery 3 18 Seren 3 58 Battery Terminal 3 19 Generator Timing citta 3 58 Battery Not Operating 3 20 Description and Operation 3 59 Battery Electrical Drain Parasitic Load 3 24 Starting System Description 3 59 Current Drain 2 004 3 24 Cranking 3 59 Battery Hydrometer Displays Dark or Yellow Dot 3 24 Starter Motor enin ann 3 59 Battery is Undercharged or Overcharged 3 24 Starting System Circuit Description 3 59 Engine Cranks Cranks Slowly but Does Not Start 3 27 Bat
12. XULIO S342 SASS Gel Industrial 3 0L 3 8 Engine Electrical sec Hd d 52 4 Se 13138 000 Back Gun fare IT WO Sl 70 rd 19000 dis 31 HER 79363004 Engine Electrical 3 9 Industrial 3 0L ser SNAM THOS 10802 Hu WIND we 2 086 3 5 ONMIM ER ce ERE WTR V8 aa LL ade ied ipw 081 XVI8 RM 600 I Ga cos J al en ul s a OTR 00024 9000 HABE mm meen A ALIO SANO i Eus 4 Eod J MBHOSESN i Ang io Busen NA YOOTHALNI BILLS 1 wow 7 nase 5 ale eb j t SNEH NEN vo
13. NOLOANNOD YOSNAS Ns N anid Ape i n ln vend 1NY1000 i A QuMIAVO AOTIHA N 12271 i NM io Au ALIAVO A KIANA XovaH a i wel Beer zi qu E ses PON i NATALI Np ee AOLANNOD XVI XTA ES v d YOSNAS b i 7 NITAD IONVAO t LHOIT N Sunssmid i HOLVOIGNI i Du YOLOSNNOO XOV TH E ANIONG JO ACIS WON noa ara CAMHIA SENOLLV LO HNIONH HOLOSNNOO XOV Id dWnlvWadWaL ami e INY TOOO i 808 DIS 79363008 Engine Electrical 3 13 Industrial 3 0L uu A eee aes an as ak a at a a ae Nal cite BE a ae ea a a Cat a he a al TANT WD TO C waa SNOISNERIC ODLLWOSO N u pus OMVSHOS ow ILE De ONIAVC SIHLNO OLSIHDRLTVIINIGHNOO HSUABEIHIEO CHE SSTINN SES T8LH OLLVINHHOS HLINZZ EAV LANOYE SAVIO ONISNOLLMIOSYENOE sy ara NOSHHOOWS NOLLVOI IddV ONISNOLL TOS AMOJ asus den SALON v X8 NOWRA SCH SALON Gacy Y AE 200 Bi ACK gt o 101 eene 79363009 Industrial 3 0L 3 14 Engine Electrical LLL ANO Od TIND
14. 3 60 Engine Electrical Industrial 3 0L Batteries PSI does not supply batteries to equipment manufac turers However on the previous pages you will find some generic methods used to diagnosis common battery problems You may need to contact the equipment manufacturer for specific procedures and specifications for the battery you are working with 181056 Built in Hydrometer If Equipped A built in temperature compensation hydrometer is molded into the top of some maintenance free batter ies When observing the hydrometer make sure the battery top is clean Use a light in poorly lit areas Under normal operating conditions one of three indications can be observed 1 Any green appearance in the hydrometer is interpreted as a green dot This means the battery is ready for testing 2 A dark dot is visible If the green dot is not visible and there is a complaint about cranking refer to Battery Not Operating Properly or Battery Electri cal Drain Parasitic Load 3 Aclear or light yellow dot means the electrolyte level is below the bottom of the hydrometer and is too low for diagnosis When you find a battery in this condition this may indicate high charging voltages caused by a faulty charging system Because of this the charging and electrical systems must be checked Refer to Charging System Check The yellow dot may have been caused by the following conditions Excessive or prolonged charging A broken
15. Coolant Tester Use the coolant testers J 26568 with the Centigrade scale or J 23688 with the Fahrenheit scale in order to check the antifreeze protection of the coolant Make sure that the hydrometer markings are correct Unless J 26568 or J 23688 has a provision for temperature correction test the temperature at which the coolant testers are calibrated If the coolant is warmer or colder the reading may be incorrect Follow the manufacturer s directions in order to use the J 26568 or the J 23688 Clean the coolant tester before each use with the following procedure 1 Swing back the plastic cover at the slanted end of the tester in order to expose the measuring window and the bottom of the plastic cover J 23688 or J 26568 13712 2 Wipe the coolant tester dry with a tissue or a clean soft cloth 3 Close the plastic cover Testing Do not remove the clear plastic pump from the tester Use the following procedure to test the coolant 1 Release the tip of the pump from the tester housing Engine Cooling 2 7 13709 2 Insert the tip into the radiator filler neck Insert the tip below the level of the coolant 3 Press and release the bulb in order to draw a sample 4 Bend the plastic tube around and insert the tip into the cover plate opening 5 Press the bulb and inject a few drops of the coolant into the measuring surface Do not open the plastic cover when you take the readings because water eva
16. vmes ve me Caution Refer to Battery Cautions on page 3 15 1 Turn the ignition key to the OFF position 2 Attempt to rotate the negative battery cable connector clockwise with light finger pressure Does the negative connector rotate Go to Step 2 Go to Step 3 Use a torque wrench in order to verify the torque to loosen 10 Nem the negative battery terminal bolt 84 Ib in Is the torque above the specified value Go to Step 4 Go to Step 3 Disconnect the negative battery cable Is the cable disconnected Go to Step 5 Ensure the negative battery cable is disconnected Inspect for the following conditions and repair as needed The cable bolt is too long or misformed at the end There is foreign material present inside the nut in the battery terminal Damage to the battery terminal face or cable connector ring Is the repair complete Go to Step 5 Rotate the positive battery cable connector clockwise with light finger pressure Does the positive connector rotate Go to Step 6 Go to Step 7 Use a torque wrench in order to verify the torque to loosen the positive battery terminal bolt Is the torque above the specified value 10 Nem 84 Ib in Go to Step 8 Go to Step 7 Disconnect the positive battery cable Is the cable disconnected Go to Step 9 1 Ensure the positive battery cable is disconnected 2 Inspect for the following conditions and repair as needed The cable bo
17. 1 2 3 4 Industrial 3 0L Intake Exhaust Manifold Disassemble and Assemble If necessary to replace either the intake or exhaust manifold separate them as follows Remove the one attaching bolt and the two nuts at the center of the assembly 2 Reassemble manifolds using a new gasket Tighten Tighten the bolts to 27 34 Nem 20 25 Ib ft Intake Exhaust Manifold Clean and Inspect Clean and inspect the following areas The manifold bolts and studs All manifold sealing surfaces Any old RTV from the manifold Water Pump Removal Make sure the coolant is drained 1 Remove the water pump bolts Remove the water pump and gasket Discard the water pump gasket Inspect the water pump for the following Gasket sealing surfaces for excessive scratches or gouges Excessive side to side play in the pulley shaft Leakage at the water inlet housing or rear cover gaskets areas Leakage at the water pump vent hole A stain around the vent hole is acceptable If leakage occurs at the vent hole with the engine running and the cooling system pressurized replace the pump Industrial 3 0L Engine Mechanical 1 21 Crankshaft Pulley Removal Tools Required J 24420 C Universal Crankshaft Pulley Remover 1 Usethe J 24420 C in order to remove the crankshaft pulley J 24420 C VE018 3L Valve Rocker Arm Cover Removal 1 Remove the valve rocker arm cover bolts 2 Remove the valve rocker arm cover 3 Remove the ga
18. 18 5 T ALIM AOLIENNOD Nid ELEND 8 ALIAD Lo jol SIND WIT te B 0r dnd N dind BATTS ABAJI 90018 EIERN 3XN VOL s 39Nral 6619 p aa ASTAVI A MINI N3339 501A ALAND rd SUSNSS 3enlvaschal 11000 0014 AY Hea uma i p 79363002 Jo eich Kd SUJAN uu J 297 dan 059 ARS 2 AND SALNWLS ND ORLS i CORB TZIA OL ANN is jars OL AN i O 633 2109 038 00 S GL HLINJZ WOYs SNIIISR NI N ISSIMidd LA0HEIA S3SDdarld ONIANLYANAYH 304 3B AVH ADLLIQURSE ANY BON LI vH ONICHFLSAONN 38340 MI IONI 37301307 AF SHSINBTA Si ONE 073 m mm BED U NOLDMWAOJAT Agvl3Iadfdd SNIV NUT Engine Electrical 3 7 Industrial 3 0L Bir AcE 79363003 OATH AE
19. 3 40 ns Generator Usage Engine Generator Rated Output Rotor Field Rotation Load Test Application Series Amperes Resistance Viewing Drive Amps Ohms at 80 F End Spark Plug Usage Engine Application Spark Plug Type Spark Plug Gap English 3 0L Industrial AC Delco R45TS Engine Electrical 3 5 Industrial 3 0L 77 Ws l ISNY ld sema als ONTMVAD STVIS LON 00 0104 521 4010 N d Nid 21 HISLNSO UTSCH ASNS INO T Serr 31811373 NONII AONO po En M eu iD DE 0 8 OLIO m EM EHE uu IW wet uus e El hie E mau 13778 gus Q1 Dei Sy NOS DOTES 5 dDL23NNJ E AL THM E 8 Ra 20064 LS SM 38 Gon 7 EIE lala INGAND JONET 8 ALG 19 Ar SATA 30055388 ID AT d eid NSW 304 LAID 59 Aldd vf
20. Is the repair complete 6V Ensure that the battery terminals and the battery 0 5 V terminal bolts are tight and are not corroded Connect a digital multimeter from the negative battery terminal to the engine block Turn the ignition switch to the START position 4 Observe the voltage while cranking the engine Notice Never operate the starter motor for more than 30 seconds at a time Allow it to cool at least two minutes before cranking again Excessive cranking can cause overheating which will cause serious damage to the starter motor Does the voltage measure more than 0 5 volts Go to Step 5 Go to Step 6 1 Inspect the battery cable for a high resistance connection at the engine block 2 If the connection is OK replace the negative battery cable Refer to Battery Cable Replacement Caution Before servicing any electrical component the ignition key must be in the OFF and all electrical loads must be OFF unless instructed otherwise in these procedures If a tool or equipment could easily come in contact with a live exposed electrical terminal also disconnect the negative battery cable Failure to follow these precautions may cause personal injury and or damage to the vehicle or its components Is the repair complete System OK Industrial 3 0L Engine Electrical 3 35 Starter Solenoid Clicks Engine Does Not Crank or Cranks Sowy cont d 1 Connect a digital multimeter from the positiv
21. When the engine is running the voltmeter indicates the condition of the charging system Indications between the low and high warning zones represent the normal operating range Readings in the low warning zone may occur when a large number of electrical accesso ries are operating in the vehicle and the engine is left at an idle for an extended period This condition is normal since the charging system is not able to provide full power at engine idle As engine speeds are increased this condition should correct itself as higher engine speeds allow the charg ing system to create maximum power Continuous readings in either warning zone indicate problems if any of the following conditions occur Any abnormal charging condition System voltage is too high or too low IL u sis NIN Sis Engine Electrical 3 61 7936011 181768 3 62 Engine Electrical Industrial 3 0L Voltage Regulator The integral voltage regulator protects the unit s operating accessories from receiving high voltage and the battery from being overcharged No current regulation is needed because it determined by the design of the generator The regulator is an extremely reliable device composed of two circuits One of these circuits is used to sense voltage and control the other circuit which cycles the field current on and off to prevent voltage from going to high The regulator limits system voltage by controlling the rotor
22. wires 1 attached and tighten the two mounting 5 Crews Set the base ignition timing Refer to Setting Ignition Timing in this section Engine Electrical 3 53 VEO10 3L 3 54 Engine Electrical VEO11 3L Industrial 3 0L Ignition Coil Replacement Removal Procedure 1 Disconnect the primary and secondary wiring from the coil 2 Remove the ignition coil bracket attaching bolts 3 Remove the ignition coil 4 Ifthe ignition coil is being replaced drill out the rivets holding the coil to the bracket Installation Procedure Important The replacement coil kit comes with two screws to attach the coil to the bracket 1 Install the ignition coil to the bracket if removed 2 Install the ignition coil and bracket 3 Install the ignition coil bracket attaching bolts Tighten Tighten the attaching bolts to 22 Nem 16 Ib ft 4 Connect the primary and secondary wiring to the coil Industrial 3 0L Distributor Module Replacement Removal Procedure Important It is not necessary to remove the distributer from the engine in order to replace the distributor module 1 Remove the distributer cap and the rotor 2 Disconnect the primary ignition wire connector from the module 3 Remove the two module mounting screws 4 Remove the module from the distributor 5 Noting color codes on leads disconnect the pick up coil connector from the module Important If the module is being re us
23. 2 2 3 Fastener Tightening Specifications 2 3 Engine Cooling System Specifications 2 3 Diagnostic Information and Procedures 2 4 Engine 2 4 LOSS Of 2 5 Thermostat Diagnosis 2 5 Engine Fails To Reach Normal Operating Temp 2 6 Coolant Concentration Testing 2 7 Cooling System Leak Testing 2 8 Repair 5 2 9 Draining and Filling Cooling System 2 9 Cooling System Flushing see 2 9 Cooling System Scale 2 9 Radiator Hose Replacement 2 10 Drive Belt 2 11 Cooling Fan 2 11 Fan Shroud Replacement 2 12 Fan Guard Replacement 2 13 Coolant Thermostat Replacement 2 13 Coolant Thermostat Housing Replacement 2 14 Coolant Inlet Housing Replacement 2 15 Water Pump Replacement 2 16 Drain Cock Replacement
24. Allow it to cool at least two minutes before cranking again Excessive cranking can cause overheating which will cause serious damage to the starter motor 4 Repair the charging system Is the repair complete Replace the battery Refer to Battery Replacement 1 Disconnect the engine shutoff solenoid Do not Is the repair complete System OK Replace the starter motor Refer to Starter Motor Replacement Is the repair complete System OK Go to Step 10 Go to Step 13 Use a digital multimeter to measure the voltage between the battery negative terminal and the engine block while cranking the engine Notice Never operate the starter motor for more than 15 seconds at a time Allow it to cool at least two minutes before cranking again Excessive cranking can cause overheating which will cause serious damage to the starter motor Is the voltage greater than the specified value 1 Inspect the battery and negative battery cable to determine if there is a high resistance connection at either end 2 Ensure that there is a clean connection between the starter mounting surface and the engine block Was a high resistance connection found Go to Step 11 Go to Step 12 3 28 Engine Electrical Industrial 3 0L Engine Cranks Cranks Slowly but Does Not Start cont d m seme 00702 System OK Repair the high resistance connection Is the repair complete Replace the negative battery cable Refer
25. Connecting rod to the crankshaft journal Connecting rod to bearing cap Crankshaft main and connecting rod bearings Camshaft and valve lifters Valve lifters guides pushrods pivot supports and rocker arms Valve to the valve guide Valve spring and shim Engine block main bearing cap location and direction Oil pump drive and driven gears Tools and Equipment Special tools are listed and illustrated throughout this section with a complete listing at the end of the section These tools or their equivalents are specially designed to quickly and safely accomplish the operations for which they are intended The use of these special tools will also minimize possible damage to engine components Some precision measuring tools are required for inspection of certain critical components Torque wrenches and a torque angle meter are necessary for the proper tightening of various fasteners To properly service the engine assembly the following items should be readily available Approved eye protection and safety gloves Aclean well lit work area A suitable parts cleaning tank Acompressed air supply Traysor storage containers to keep parts and fasteners organized Anadequate set of hand tools Approved engine repair stand Anapproved engine lifting device that will adequately support the weight of the components 1 80 Engine Mechanical Special Tools and Equipment J 791 Camshaft Sprocket Remo
26. Connectthe primary ignition harness 4 to the ignition coil 4 Connectthe secondary ignition wires 1 to the spark plugs and the ignition coil cit VEO10 3L 1 74 Engine Mechanical Industrial 3 0L Engine Flywheel Installation Important Note the position and direction of the engine flywheel before removal The flywheel center alignment hole is a tapered fit to the crankshaft The engine flywheel must be reinstalled to the original position and direction The engine flywheel will not initially seat against the crankshaft flange but will be pulled onto the crankshaft by the engine flywheel bolts 1 Install the engine flywheel 2 Install the engine flywheel bolts Tighten Tighten the flywheel bolts to 88 65 Ib ft VE009 3L Engine Block Coolant Plug Oil Filter Installation 1 Install the left rear engine block coolant plug VE008 3L 2 Install the right rear engine block coolant plug VE007 3L Industrial 3 0L Engine Mechanical 1 75 3 Install the oil filter 4 Install the oil pan drain plug Tighten Tighten the oil pan drain plug to 25 Nem 18 lb ft VE005 3L 1 76 Engine Mechanical Industrial 3 0L Description and Operation Engine Component Description Engine Block The engine block has four cylinders arranged in an in line construction Starting at the front of the engine the cylinders are numbered 1 2 3 4 The firing order of the cylinders is 1 3 4 2
27. NatonalP pe Thread Fne Oxygen Oxygen Sensor xddaton Converter C atalytr O pportuniy Charge S tation O utside D im eter O utputD rye M odub OrgnalEquim ent O rgnalEqupm entM anufacturer O verhead C am shaft 3 Open Loop O utofLi is OxHaton R eductbn Converter O range On BoariRefuelng VaporRecovery OutputS haftS peed Ounce s Poyakyne yool Puked Secondary Ar td 5 Pressure Contool Prnted C Pressure ContiolSobnodi Positve Crankcase Ventibton General Information 0 13 Abbreviations and Their Meanings cont d Pm Poveriverertodue Pemanentitagetgenemen 5 anb PN P ibtO peated Absolute Positive Position Potentom eter Varabk Resston PPL psi pt L PPE ppm PatsperMibn Pounds perSquare hch Pounds persquare nchAbsohw Pounds perSquare moh Gauge pe ee qt Quarts Ref RearE xchanger RH RghtHand Read OnyMemory Pem anent mem ory devre m em ory contents are yetaned when power 5 oved 0 14 General Information Industrial 3 0L Abbreviations and Their Meanings cont d Revoltbns hut Engne Speed RPO RegukrP wductin pton RR RghtRear sewmag SI System htematpnal M odem Versin ofM etric System Soknod SP SPO Pe ee ee TAC Abbreviations and Their Meanings cont d TDC Top
28. Remove the two bolts the washers if present and the shims that hold the starter to the engine 5 Remove the starter from the engine 6 Remove the starter shield if equipped 79363012 Installation Procedure 1 Install the shield to the starter motor if equipped Notice Refer to Fastener Notice on page 3 2 2 Install the two bolts through the washers and through the starter to the engine Tighten Tighten the starter bolts to 50 Nem 37 Ib ft 3 Install the two mounting nuts the mounting bolt and the starter rear bracket Tighten Tighten the rear bracket mounting bolt to 50 Nem 87 Ib ft Tighten the rear bracket mounting nuts to 9 Nem 80 Ib in 4 Install the positive battery cable and wires to the starter solenoid with the nut Tighten 79363012 Tighten the battery positive cable starter solenoid nut to 16 Nem 12 Ib ft e Tighten the S terminal nut to 9 Nem 80 Ib in 5 Install the negative battery cable to the battery Tighten Tighten the battery side terminal bolts if applicable to 12 Nem 106 Ib in Tighten the top terminal nuts if applicable to 18 Nem 13 Ib ft Industrial 3 0L u 79363011 79363011 Engine Electrical 3 51 Generator Replacement Removal Procedure The removal and installation instructions serve only as a guide Additional operations may be required on some equipment to remove other equipment in order to gai
29. 4 wire distributor connector is not populated Check the chart below for the correct engine timing Generator Timing PSI GM engines operating on generators are timed at 1800 RPM Timing procedures are the same as for Carbureted engines Check the chart below for the correct engine timing for the type of fuel being used Ignition Timing in Degrees BTDC Except Generators Fuel Management System Timing Specification Gasoline Carbureted 0 Dual Fuel Gasoline Throttle Body Injected TBI 0 LPG 10 4 Europe N G 10 Ignition Timing in Degrees BTDC Generators 1800 RPM Fuel Management System Timing Specification LPG 26 N G 36 Industrial 3 0L Description and Operation Starting System Description Cranking Circuit The cranking circuit consists of the following compo nents The battery starter motor e ignition switch All related electrical wiring For detailed schematics of the starting system refer to Schematic and Routing Diagrams Starter Motor The 3 0 L gas engine uses a PG 260L starter motor This starter motor uses a gear reduction system in order to drive the pinion The armature shaft gear drives an internal gear at the gear reduction end of the driveshaft at a speed of one driveshaft revolution for each 3 9 revolutions of the armature The starter has an over running roller type clutch and an enclosed shift lever The solenoid is sealed in o
30. 8 lt N OGIN3SNI JNV SIMIM INHA TENE END IUSVS m rg ONS CJN3IA 591287802 SOLI3NND ANDAI i lt d AR 1 a aiid Tan AHLEN AHA 10218 ele 8 Z Sand 1112 L DI SOLIGANE JAILISEd SDLJaNNDI 941 ug 4340230 021 SEN 48 ALAND HEN Od Ye MAN a WW VN Us V I 5 l AV mE VM T AA 311p 50014 M I sl N 1 SDLIaNDJ IIM Wit 3888 IN Ma MAG 3 4 IONAT 318 088 2105 SOSN3S IAMLYAEAWIL AIV 97 SOTA amg 3 2074 E Yu 2 B 01 30V 8 m 0303AN 38 LON AM H ET re 4 T a Di TERR On MET de IND UE TN 30010 dy 2 IR Odi Me MAD 48 N3368 17 S0E 4 QU AULYNSSL 19 NU A S0SN3S di E um DL I a JAVA 002 TET 8009 N SI BA SCF aJa A gu SM 2010 3380 OL ALINJ WO SNLITSK NI NOESSIRESE 5350904 ONISDLWACNwA alla DEN 28 AW NULLJdDBH8 ANY SON 11 BORITJN SNIONYISSGUNT SddAlUlUdd Aid 03593 99 3Hi AON AINIDIANOI NI QAHSINAN ST ONY 590 NOISTARS az 532030 NDELFWAOSNI AMYldisdDBd SNEVINOJ IN3HIDER SIHL Engine Electrical 3 11 Industrial 3 0L KNOLL NISTAD er ILOS TIS LAS HOIVNIN3D 10
31. CENDNYSO 9 NTA NI OBAZT SA MOLIANT ER CONTI 2 NN NI 2AZL4 908 Aa IE E HERES US S SDLISANDD Nid 8 Ya ALIAKA aa 10000 HaBO VOLO ALINJ Nid 8 HISLTER en alle MIN wa 08 zooa INAN NOTLINDI Aldd 214 LLL a TOR 20019 Ald 018 RE e RR 7 09545 TENISA G 89 O ee KU MGR RUNE 09385 WETS BY SNR EOF ONIS 1815 Ra xis 0018 m LU 58 e ANNI 0934 Y ANANI 09855 NRODLTHS 38755344 TID 28 Ve ALLAN 2 TR SI4T 19 5 CSS 3enivasaial AI 3 w gr DENN NIE m 2 A MIN AN 305810 S108 ALIWI ALAND tie a pI UNE HSS E M SNJS 22 8 ALAY C BERT ce acces diea 028 p ELE EMEN ee TEE 2018 HOLE AUTAA vOl SN 02 HIINGZ 1811198 NI NOISSIREIG NOHLIM 535098 NIANIA 303 SN 38 AVH 7000593 ANY SON 1I 5991198 LHL ONIONYISS3UNTI SSIM 3H YSGNT DNGUIJNDJ NI DAHSINAN 51 NW NOLLWWAQANT 19189080 SNTYINC 0 SIAL 79363001 Industrial 3 0L 3 6 Engine Electrical chia ia Zeil AGFA 13 2
32. Charging off before connecting or disconnecting a carbon pile System Check load tester to the battery Otherwise sparking could ignite battery gasses which are extremely flammable and may explode violently 1 Disconnect the J 39200 DMM 2 Turn OFF the load in the carbon pile tester 3 Turn the ignition switch to LOCK to stop the engine 4 Disconnect the carbon pile tester cables from the battery Inspect the ground circuit for high resistance from the battery negative terminal to the generator housing Disassemble and clean all connections Assemble the connections and tighten to specifications Refer to Fastener Tightening Specifications Is the repair complete 15 Replace the voltage regulator Go to Charging Is the repair complete System Check Industrial 3 0L Engine Electrical 3 31 Generator Assembly Bench Check This test requires both a fully charged battery and a generator test stand to operate the generator The generator can be tested quicker and easier while it is still on the equipment Refer to Generator Not Operat ing Properly 1 Ensure the carbon pile is off before making connec tions as shown The ground polarity of the generator and battery must be the same The battery must be fully charged Use a 30 500 ohm resistor between the 30 500n battery and the BAT terminal of the generator Terminal 2 Slowly increase the generator speed and observe the voltage If the voltage is uncon
33. Distributor Hold Down Bolt Oil Level Indicator Tube Oil Level indicator Primary Ignition Harness Ignition Coil Bolt Ignition Coil Washer Ignition Coil Ignition Coil Wire Spark Plug Wire Retainer Spark Plug Wire Harness Spark Plug Valve Pushrod Valve Rocker Arm Valve Rocker Arm Ball Valve Rocker Arm Nut Engine Mechanical 1 11 1 12 Engine Mechanical Industrial 3 0L Lower Engine Block and Components VE002 3L Industrial 3 0L Legend Engine Block Piston Pin Piston Ring Kit Piston Connecting Rod Connecting Rod Bolt Connecting Rod Bearing Kit Connecting Rod Cap Connecting Rod Nut Oil Nozzle Camshaft Bearings Camshaft Camshaft Retainer Camshaft Retainer Washer Camshaft Sprocket Camshaft Retainer Bolt Camshaft Woodruff Key Crankshaft Pulley Engine Front Cover Seal Engine Front Cover Bolt Engine Front Cover Engine Front Cover Gasket Crankshaft Sprocket Crankshaft Keyway Oil Pump Oil Pump Bolt Crankshaft Bearing Kit Crankshaft Crankshaft Bearing Cap Crankshaft Bearing Cap Bolt Oil Pan Gasket Oil Pan Oil Pan Washer Oil Pan Bolt Oil Drain Plug Washer Oil Drain Plug Crankshaft Rear Oil Seal Housing Pin Crankshaft Rear Oil Seal Housing Crankshaft Rear Oil Seal Housing Stud Crankshaft Rear Oil Seal Housing Bolt Clutch Pilot Bearing Engine Flywheel Bolt Engine Flywheel Crankshaft Rear Oil Seal Crankshaft Rear Oil Seal Housing Bolt Crankshaft Rear Oil Seal H
34. Does not apply to engines with DIS ignition Approximate Fluid Capacities etre 3 0L With Radiator 11 4L Engine Crankcase 3 0L with Filter 3 0L Without Filter Industrial 3 0L Engine Mechanical 1 1 Section 1 Engine Mechanical Engine Mechanical 3 0L 1 4 Specifications 1 4 Fastener Tightening Specifications 1 4 Sealers Adhesives and Lubricants 1 4 Engine Mechanical Specifications 1 5 Diagnostic Information and Procedures 1 7 Base Engine Noise Diagnosis 1 7 Engine Compression 1 8 Engine Noise 1 8 Knocks Cold and Continues for 2 to Minutes 1 8 Knocks on Start Up but Only Lasts a Few Seconds 1 8 Knocks at Idle HOt 1 8 Valve Train 1 8 Oil Consumption Diagnosis 1 8 Low or No Oil Pressure Diagnosis and Testing 1 9 Oil Leak Diagnosis eeeeeeene 1 9 Component Locator 1 10 Disassembled Views 1 10 Upper Engine Block
35. Engine Mechanical Specifications Industrial 3 0L Camshaft Bearing Removal Tools Required J 6098 01 Camshaft Bearing Remover Installer 1 Remove the camshaft rear bearing hole plug 2 UsetheJ 6098 01 in order to remove the inner camshaft bearings Repeat the following procedure for each of the inner camshaft bearings 2 1 2 2 2 3 2 4 2 5 With the nut 4 and the thrust washer 3 installed to the end of the puller screw threads index the pilot 2 in the camshaf front bearing and install the puller screw through the pilot 2 and the bearing to be removed Install the bearing tool 1 with the shoulder toward the bearing Using two wrenches hold puller screw 5 while you turn the nut 4 in order to draw the bearing out of the bore When the bearing has been pulled from the bore remove the bearing tool and the bearing from the puller screw Index the pilot in the rear camshaft bearing in order to remove the rear inner camshaft bearing 3 Use the J 6098 01 in order to remove the front and rear camshaft bearings 3 1 3 2 Assemble the bearing tool to the driver Drive the front and rear camshaft bearings out of the block bore Drive inward toward the center of the engine block Engine Mechanical 1 37 J 6098 01 4 ELA n De ae VE054 3L J 6098 01 VE055 3L 1 38 Engine Mechanical Industrial 3 0L Distributor Lower Bushin
36. Every 100 hrs Every 200 hrs Every 400 hrs Every 800 hrs Reg 1 Check Engine Oil Level Check Coolant Level Check for Fluid Leaks 2 3 4 Governor Mechanical Check oil level 2 Change Engine Oil amp Filter 1 Battery Check Charge amp Fluid Level Inspect amp Clean Radiator Exterior Clean Battery Cables Check Belts and Belt Tension Lubricate Throttle Governor amp Choke Linkage Carbureted Engines Only Check amp Adjust Idle Speed Carbureted Engines Only Inspect and Clean Air Cleaner Element Replace Primary Air Cleaner Element 1 Replace Safety Air Cleaner Element Check Coolant Protection amp Tighten Hose Clamps Replace Engine Coolant 3 Replace Gasoline Fuel Filter 4 Replace LPG Filter Zenith EFI 4 Replace PCV Valve If Equipped Check PCV Hoses Tubes and Fittings Replace Spark Plugs 3 Distributor Cap amp Rotor 5 Secondary Ignition Wires PS Ps Adjust Throttle amp Governor 3 Check All Engine Bolts amp Nuts for Tightness 1 More frequent intervals may be required in dusty or dirty operating conditions 2 Mechanical governor belt driven 3 To be performed at specified interval or annually whichever occurs first 4 More frequent intervals may be required with dirt in the fuel system 5
37. Go to Step 14 1 Reconnect the distributor harness connector 2 Disconnect the black ignition coil electrical connector 3 Turn the ignition switch ON 4 Probe the coil electrical connector between terminal B and a good ground 5 Turn the ignition switch OFF after test Was the voltage above the specified value Go to Step 15 Go to Step 17 Reconnect the distributor harness connector Disconnect the black ignition coil electrical connector Turn the ignition switch ON Probe the coil cavity terminal A to a good ground Turn the ignition switch OFF after test Was the voltage above the specified value Go to Step 16 Go to Step 17 Refer to the applicable Schematic and Routing Diagram in this section Locate and repair the open circuit in the white wire between terminal A of the ignition coil connector and terminal B of the distributor connector 3 Reconnect the ignition coil electrical connector Are repairs complete System OK Refer to the applicable Schematic and Routing Diagram in this section Locate and repair the open circuit in the pink wire between terminal B of the ignition coil connector and terminal A of the distributor connector 3 Reconnect the white ignition coil electrical connector Are repairs complete System OK Disconnect the gray ignition coil electrical connector Go to Ignition Coil Turn the ignition switch ON Not Operating Probe the coil electrical connector between terminal B tis pu
38. Housing Bolts 192 DrainCocktoRadiator 2158 13 Fan Blade to Water Pump Bots 15 8 Fan Guard Mounting Bots 0 1 5 O Fan Shroud Mounting Bots 60 1 5 Radiator Hose Clamps 22 2 Radiator Mounting Bracket Bots 18 Water Pump to Block Bots 20 15 7 Engine Cooling System Specifications Application Metric Engish 3 0 L w o radiator 3 78 liters 3 0 L wiradiator 11 34 liters 2 4 Engine Cooling Industrial 3 0L Diagnostic Information and Procedures Engine Overheating valet 1 Check the coolant level Is the coolant level low Go to Step 2 Go to Step 3 2 Add coolant to the system Does the engine still overheat Go to Step 3 System OK 3 Pressure test the system and check for visual leaks Go to Loss of Are there any external leaks in the system Coolant Go to Step 4 4 Check the condition of the drive belt Adjust or replace Is the drive belt loose or unserviceable the drive belt Go to Step 5 Check the hoses Have the hoses collapsed Go to Step 6 Go to Step 7 Replace the hoses Refer to Radiator Hose Replacement Does the engine still overheat Go to Step 7 System OK Check the temperature level of the thermostat Is the temperature level high Go to Step 8 Go to Step 9 o et o Replace the thermostat Refer to Thermostat Replacement Does the engine still overheat Go to Step 9 System OK Check the radiator Go to Coolin
39. If the proper clearance cannot be obtained select another piston and measure for the clearances If the proper fit cannot be obtained the cylinder bore may require boring or honing Refer to Cylinder Boring and Honing When the piston to cylinder bore clearance is within specifications permanently mark the top of the piston for installation to the proper cylinder Piston and Connecting Rod Assemble Tools Required J 24086 C Piston Pin Removal Set Important When assembling the piston and connecting rod the flange or the heavy side on the connecting rod must face toward the front of the piston stamped arrow in top of the piston head 1 Install the piston pin and connecting rod assembly 1 1 Lubricate the piston pin holes in both the piston and the connecting rod assembly 1 2 Press the piston pin into the piston and connecting rod assembly using the J 24086 C 1 3 Inspect for freedom of movement of the piston on the piston pin Engine Mechanical 1 45 VE072 3L VE073 3L J 24086 C VE064 3L 1 46 Engine Mechanical Industrial 3 0L Important When installing the piston rings onto the piston use a ring expanding plier type tool Do not roll the piston rings into the grooves of the piston Use caution and care to expand the piston rings only sllightly larger than the Outside Diameter OD of the piston 2 Using piston ring pliers install the piston rings onto the piston 2 1 In
40. Inspect the solenoid assembly for a cut or torn boot If the boot is damaged replace the solenoid assembly 4 Inspect the clutch drive assembly Replace the clutch drive assembly as necessary Look for the following damage The pinion gear turns roughly or turns in both directions e The pinion gear teeth are broken or show evidence of step wear The shift lever collar shows deep scoring or other damage Component Electrical Testing Perform the following electrical tests in order to determine the serviceability of the starter assemblies 1 Using an ohmmeter check the windings of the solenoid assembly for continuity using the following procedure e Check the resistance of the solenoid pull in and hold in windings in a series by measuring the resis tance between the motor terminal and the solenoid case e A resistance reading well above 1 95 ohms indicates a break or fault in the winding continuity e A resistance reading well below 1 95 ohms indicates a short or ground in the winding circuit Replace the solenoid assembly if the resistance reading is extremely high or very low 2 Check the armature for shorts opens and grounds using the following procedure Replace armature if it is shorted grounded or has any evidence of an open circuit 2 1 Rotate the armature in a growler 2 2 Hold a steel strip such as a hacksaw against the armature 2 3 Ifthe steel strip vibrates in an area a short is present Using a self powered test lamp or ohm
41. Intake Exhaust Manifold Installation 1 Install the intake exhaust manifold gasket over the locating pins on the cylinder head 2 Install the bolts and clamps while holding the manifold in place Tighten Tighten the two center bolts to 27 34 Nem 20 25 lb ft Tighten the end bolts to 20 27 Nem 15 20 lb ft VE014 3L Spark Plug Installation 1 Install the spark plugs er Tighten aD Tighten the spark plugs to 30 22 Ib ft M gt Lift Bracket Installation 1 Install the lift bracket 2 Install the lift bracket bolts Tighten Tighten the lift bracket bolts to 54 Nem 40 Ib ft VE012 3L Industrial 3 0L Engine Mechanical 1 73 Ignition Coil Installation 1 2 Install the ignition coil bracket attaching bolts Tighten Install the ignition coil Tighten the attaching bolts to 22 Nem 16 Ib ft VE011 3L Distributor Installation Important To ensure correct ignition timing the distributor must be installed in the correct position Position the engine at top dead center on number one cylinder The distributor cap must be removed in order to position the rotor when installing the distributor 1 Install the distributor 2 and new gasket 3 making sure the distributor rotor is pointing to number one tower on the distributor cap 2 Install the distributor hold down 5 and bolt 6 Tighten Tighten the hold down bolt to 27 20 Ib ft 3
42. Nem 65 Ib ft Crankshaft Rear Oil Seal and Housing Installation Tools Required J 35621 Crankshaft Rear Oil Seal Installer Important Always use a new crankshaft rear oil seal and new crankshaft rear oil seal housing gasket when you install the crankshaft rear oil seal housing 1 Install the new gasket and the crankshaft rear oil seal housing on to the studs 2 Install the rear oil seal housing nuts and bolts Tighten Tighten the crankshaft rear oil seal housing nuts and bolts to 15 Nem 135 Ib in 3 Coatthe new oil seal entirely with clean engine oil Install the seal onto the J 35621 5 Install the J 35621 onto the rear of the crankshaft Tighten the screws snugly in order to ensure that the seal will be installed squarely over the crankshaft 6 Install the crankshaft rear oil seal onto the crankshaft and into the crankshaft rear oil seal housing Tighten the wing nut onthe J 35621 until the oil seal bottoms 7 Remove the J 35621 from the crankshaft rear oil seal housing gt J 35621 Engine Mechanical 1 61 VE104 3L 1 62 Engine Mechanical Industrial 3 0L Piston Connecting Rod and Bearing Installation Tools Required FACING FRONT OF J 5239 Guide Set ER J 8037 Piston Ring Compressor Important The piston and cylinder bore have been measured and the bore has been sized for the proper clearance Install the piston and connecting rod assembly into the proper cylinder bore The pis
43. The cylinders are encircled by coolant jackets Cylinder Head The cylinder head has one intake and one exhaust valve per cylinder A spark plug is located between the valves in the side of the cylinder head The valve guides are integral and the valve rocker arms are retained on individual threaded studs Crankshaft The crankshaft is cast nodular iron and is supported by five crankshaft bearings The bearings are retained by crankshaft bearing caps that are machined with the engine block for proper alignment and clearences Camshaft A billet steel one piece camshaft is supported by three full round sleeve type bearings These bearings are a press fit into the engine block The camshaft timing gear is mounted to the front of the camshaft and is driven the crankshaft timing gear Pistons and Connecting Rods The pistons are made of cast aluminum alloy using two compression rings and one oil control ring assembly The piston pins are a press fit in the connecting rods and a floating fit in the pistons Valve Train The valve train is a ball pivot type Motion is transmitted from the crankshaft through the valve lifter and valve pushrod to the valve rocker arm The valve rocker arm pivots on its ball and transmits the camshaft motion to the valve The valve lifters keep all parts of the valve train in constant contact Each lifter acts as an automatic adjuster and maintains zero lash in the valve train This eliminates the need for periodic va
44. Use only the recommended spark plug or an equivalent as described in the General Specifications Spark plug gap should be adjusted as recommended in the General Specifications When removing spark plugs always note which cylinder each plug came out of Look at the porcelain around the center electrode of each plug You can detect many engine problems from the color and type of deposits that have built up on the white porcelain For example if the deposits are a glossy brown that cylinder is burning excess oil If the deposits are a very dark gray or sooty black color your engine is running rich and you are burning excess fuel The optimum color of the deposits on the porcelain is light tan or light brown This shows optimum fuel mixture and proper engine running conditions If the deposits are almost white the engine may be running excessively lean Lean running is very detrimental to your engine life and should be corrected immediately If one or more cylinders are burning oil the smoke from the engine will be a blue gray color Most common causes are piston rings worn out or not broken in and valve stem seals cut nicked or worn out If the engine is running rich the exhaust smoke will be a sooty black color and it will smell like gasoline on gasoline engines Industrial 3 0L General Information 0 19 MAINTENANCE SCHEDULE 3 0L ENGINE Initial Start Up Sequence Checks Operation Daily Weekly Every 50 hrs
45. by adjusting the alternator position or through a mechanical belt tensioner The belt is generally correctly tensioned when there is an inch of depression on the belt between the water pump and the crankshaft pulley FUEL DELIVERY SYSTEM MAINTENANCE Fuel Filter Replacement Carbureted Engines On carbureted engines an in line fuel filter is incorporated into the fuel supply line It is recommended that this filter be changed every 250 hours or every 6 months which ever occurs first TBI Engines On PSI Fuel Injection or Fuel Injection Dual Fuel two fuel filters are used in the gasoline fuel supply line to the engine TBI unit A coarse fuel filter is located in the supply line between the fuel tank and the electric fuel pump This filter protects the fuel pump from debris in the fuel tank This filter must be changed every 200 hours or every 6 months which ever occurs first A primary fuel filter is located between the fuel pump and the TBI unit on the engine This filter protects the injectors from microscopic particles in the fuel which can cause plugging of the injectors This filter MUST be changed every 500 hours or annually which ever occurs first Zenith Z E E M S TBI Fuel Injection Zenith Z E E M S TBI Fuel Injection requires an in line fuel filter in the fuel supply line from the fuel tank to the TBI unit ahead of the electric fuel supply pump This filter must be changed every 200 hours or every 6 months which ever occurs firs
46. case Excessive tipping f the battery has a yellow or clear hydrometer replace the battery if a cranking complaint exists Industrial 3 0L Charging System Description The charging system consists of the following compo nents The battery The generator The voltmeter gauge All related electrical wiring The generator supplies the electrical power for charg ing the battery and for operating the accessories SI Series Generators All PSI 3 0 L industrial engines use Delco Remy Diode Rectified AC generator Since these units have an integral voltage regulator they are referred to as a System Integral Charging Unit or SI for short The 3 0 L engine uses a model 7 SI which provides the proper current output up to 70 amperes to meet the needs of various industrial applications A terminal marked P on the rear of the generator is available to provide a speed input to the tachometer if needed The generator has an internal regulator and does not have a diode trio The delta stator 1 the rectifier bridge 4 and the rotor with slip rings and brushes 3 are electrically similar to other Delco Remy generators The generator uses a conventional fan and pulley An internal fan cools the slip rings the end frame the rectifier bridge and the regulator The voltmeter gauge indicates the battery s state of charge in DC volts when the ignition switch is in the RUN position and the engine is not running
47. crankshaft bearings for dirt or debris imbedded into the bearing material XS XS Engine Mechanical 1 33 VE047 3L H VEO39 3L H VE040 3L 1 34 Engine Mechanical Industrial 3 0L 8 Inspect the crankshaft bearings for improper seating indicated by bright polished sections of the bearing If the lower half of the bearing is worn or damaged both the upper and lower halves must be replaced VE048 3L 9 Measure the crankpins for out of round taper or undersize with a micrometer Refer to Engine Mechanical Specifications VE049 3L 10 Support the crankshaft front and rear journals on V blocks 11 Measure the crankshaft run out at front and rear intermediate journals with J 7872 Refer to Engine Mechanical Specifications 12 Replace or recondition crankshaft if measurements are not within specifications VE050 3L Industrial 3 0L Engine Mechanical 1 35 Crankshaft and Bearings Clean and Inspect Main Bearing Clearance Important Crankshaft main bearings are a precision insert type Main bearing caps are machined with the engine block for proper clearance and cannot be shimmed or filed for bearing fit Crankshaft bearing clearances are critical If the clearances are found to be excessive new bearings and or engine block and cap repair may be required Do not rotate the crankshaft while gauging plastic is between the crankshaft journal and the bearing surface 1 Remove the cra
48. each tester clamp must make the correct contact Ensure that the red clamp is connected to the positive terminal and the black clamp is connected to the negative terminal fthe adapters or the bolts appear corroded rock the clamps back and forth in order to ensure a correct connection Use a wire brush in order to clean the adapters or cable bolts if needed Does the tester display now read SELECT TEST Go to Step 17 Go to Step 12 3 22 Engine Electrical Industrial 3 0L Battery Not Operating Properly cont d Ae vae Use a J 39200 digital multimeter DMM in order to test the 5 5V battery voltage with the J 42000 tester connected Is the voltage at or below the specified value Go to Step 25 Go to Step 29 Use the scroll keys on the J 42000 tester to select either Go to Step 11 Go to Step 12 IN VEHICLE for on equipment testing or OUT OF VEHICLE for off equipment testing depending on the Go to Step 13 Go to Step 37 Go to Step 13 Go to Step 37 following conditions Use IN VEHICLE testing if the battery cables are connected to the battery Go to Step 22 Go to Step 15 Go to Step 25 Go to Step 16 Use OUT OF VEHICLE testing if the battery Go to Step 29 Go to Step 17 cables are disconnected and the terminal adapters are installed Go to Step 26 Go to Step 18 Go to Step 28 Go to Step 19 Was IN VEHICLE testing selected Go to Step 30 Go to Step 20 The display on the tester will s
49. either gravity or splash from other direct feed components Timing gears are lubricated by oil supplied through a passage from the front of the camshaft to a calibrated nozzle above the crankshaft gear Thread Repair Tools Required General purpose thread repair kits These kits are available commercially VE122 3L 5 Thread the insert onto the mandrel of the installer Engage the tang of the insert onto the end of the mandrel Important The insert should be flush to one turn below the surface 6 Lubricate the insert with light engine oil except when installing in aluminum and install the insert If the tang of the insert does not break off when backing out the installer break the tang off with a drift VE121 3L 1 78 Engine Mechanical Industrial 3 0L Cleanliness and Care Throughout this section it should be understood that proper cleaning and protection of machined surfaces and friction areas is part ofthe repair procedure This is considered standard shop practice even if not specifically stated When any internal engine parts are serviced care and cleanliness is important When components are removed for service they should be marked organized or retained in a specific order for reassembly Refer to Separating Parts At the time of installation components should be installed in the same location and with the same mating surface as when removed An engine is a combination
50. field current When the field current is on the regulator switches the rotor field on and off at a fixed rate of about 400 cycles per second By varying the overall on off time correct average field current for proper system voltage control is maintained At high speeds the on time may be 10 percent and the off time may be 90 percent At low speeds and with high electrical loads the on off time may be 90 percent and 10 percent respectively The regulator has four terminals The terminals are P L I and S These letters are stamped on the regulator Generally in SI generators the S terminal senses the state ofthe battery and allows field current flow when the switch is closed When the battery voltage rises to predetermined level the sensing circuit tells the regulator to turn OFF This decreases the magnetic field around the field coil and generator voltage is limited to a safe value When the battery voltage drops below a predetermined level the sensing circuit tells the regulator to turn ON This increases the magnetic field around the field coil and generator voltage begins to charge the battery 375662 Charging System Circuit Description The generator provides voltage that operates the electrical system of the vehicle and that also charges the battery and the secondary battery A magnetic field is created when current flows through the rotor The field rotates as the rotor is driven by the engine creating an A
51. include exhaust manifolds head gasket or other surfaces where gasket eliminator is specified Follow all safety recommendations and directions that are on the container To remove the sealant or the gasket material Refer to Replacing Engine Gaskets Apply a continuous bead of pipe joint compound to one sealing surface Sealing surfaces to be resealed must be clean and dry Tighten the bolts to specifications Do not overtighten Industrial 3 0L RTV Sealer Room Temperature Vulcanizing RTV sealant hardens when exposed to air This type sealer is used where two nonrigid parts such as the oil pan and the engine block are assembled together Do not use RTV sealant in areas where extreme temperatures are expected These areas include exhaust manifolds head gasket or other surfaces where gasket eliminator is specified Follow all safety recommendations and directions that are on the container Toremove the sealant or the gasket material Refer to Replacing Engine Gaskets Apply RTV to a clean surface Use a bead size as specified in the service procedure Run the bead to the inside of any bolt holes Do not allow the sealer to enter any blind threaded holes as it may prevent the bolt from clamping properly or cause damage when the bolt is tightened Assemble components while RTV is still wet within three minutes Do not wait for RTV to skin over Tighten the bolts to specifications Do not overtigh
52. normal range Refer to the appropriate symptom diagnostic table for the applicable abnormal result Starting System Check se Aston 7 Normal Aonormal Result 1 1 Disengage any power The voltmeter shows approximately Charging System Check transmission component if 12V applicable 2 Turn the ignition switch to RUN leaving the engine off Turn the ignition switch to START The engine cranks normally and the Starter Solenoid Does Not Click starter does not make unusual Starter Solenoid Clicks Engine noises Does Not Crank Starter Motor Noise Diagnosis Refer to the appropriate symptom diagnostic table for the applicable abnormal result Industrial 3 0L Engine Electrical 3 17 Battery Common Causes of Failure e e e e The battery may be damaged Cracked case Corroded battery cable terminals Loose battery cable connections Loose battery hold down There may be a mechanical problem Loose or slipping drive belt Structural failure of aftermarket mounting brackets Misaligned pulleys There may be an electrical drain caused by a parasitic load The electrical load may be greater than the output of the generator There may be an electrical problem in the charging system Poor ground circuits Electrical shorts Faulty generator Battery Cautions Caution Batteries produce explosive gases Batteries contain corrosive acid Batteries supply levels of electrical c
53. piston out of the engine block 6 Usea hammer and tap lightly on the end of the connecting rod guide tool to remove the piston and connecting rod assembly from the cylinder bore Crankshaft and Bearings Clean and Inspect Connecting Rod Bearing Clearance Important Connecting rod bearings are a precision insert type Connecting rods are of a powdered metal design and cannot be shimmed or filed for bearing fit If clearances are found to be excessive a new bearing and or connecting rod are required Do not rotate the crankshaft while gauging plastic is between the crankshaft journal and the bearing surface 1 Remove the connecting rod nuts 2 Remove the connecting rod cap and bearing 3 Inspectthe crankshaft bearings for craters or pockets Flattened sections on the bearing halves also indicate fatigue XS Engine Mechanical 1 29 VE038 3L VE037 3L VEO39 3L 1 30 Engine Mechanical Industrial 3 0L 4 Inspect the crankshaft bearings for excessive scoring or discoloration 5 Inspect the crankshaft bearings for dirt or debris imbedded into the bearing material i VE040 3L XS 6 Install the gauging plastic 1 onto the connecting rod bearing journal Install the gauging plastic the full width of the journal VE041 3L 7 Install the connecting rod and bearing Tighten Tighten the nuts evenly to 61 Nem 45 lb ft VE037 3L Industrial 3 0L 8 Remov
54. properly connected implying that the battery will not accept a charge Most chargers have an override or a bypass function so that the charger will turn ON and charge a low voltage battery Important If the charging current is not measurable at the end of the charging time replace the battery If the charging current is measurable during the charging time the battery is good The required battery charge time varies according to the voltage capabilities of the battery charger Charging time at various voltages may be as follows e 16 0 volts or more up to 4 hours e 14 0 15 9 volts 8 hours 4 13 9 volts or less 16 hours 4 In order to determine the amount of hours the battery may need to be charged the following calculation can be made The reserve capacity rating on the battery label is the number of ampere hours of charge required in order to produce the green hydrometer dot e After the meter on the charger starts to show current flow note the number of amps being accepted Determine the reserve capacity of the battery Refer to Battery Usage Divide the reserve capacity by the number of amps shown on the meter in order to determine how many hours of charging is needed 5 When the green dot appears in the hydrometer discontinue charging 6 If the green hydrometer dot is not visible after an ampere hour charge equal to twice the reserve capacity rating replace the battery Refer to Battery Replacement 7 After charging load test
55. pump Refer to Radiator Hose Replacement 3 Remove the fan guard Refer to Fan Guard Replacement 4 Remove the drive belt Refer to Drive Belt Replacement 5 Remove the fan and fan pulley Refer to Cooling Fan Replacement Remove the water pump bolts Remove the water pump and gasket Discard the water pump gasket Inspect the water pump for the following Gasket sealing surfaces for excessive scratches or gouges Excessive side to side play in the pulley shaft Leakage at the water inlet housing or rear cover gaskets areas Leakage at the water pump vent hole A stain around the vent hole is acceptable If leakage occurs at the vent hole with the engine running and the cooling system pressurized replace the pump 9 7005 4209 VE017 3L Installation Procedure 1 Position the water pump and a new gasket to the engine block 2 Install the water pump bolts Tighten Tighten the water pump bolts to 20 Nem 15 Ib ft 3 Install the coolant fan and fan pulley Refer to Cooling Fan Replacement 4 Install and adjust the drive belt Refer to Drive Belt Replacement 5 Install the fan guard Refer to Fan Guard Replacement 6 Install the lower radiator hose to the water pump Refer to Radiator Hose Replacement 7 Fill the cooling system Refer to Draining and Filling Cooling System VE017 3L Industrial 3 0L Drain Cock Replacement Removal Procedure 1 Drain the cooling system R
56. pump bolts to 14 Nem 120 Ib in Oil Pan Installation Important Apply the sealer 25 mm 1 0 in in either direction of the radius cavity of the junctions 1 Apply a small amount of sealer GM P N 1052914 or equivalent 10 mm 0 393 in wide and 20 mm 0 787 in long at the engine front cover to engine block junction 2 Apply a small amount of sealer GM P N 1052914 or equivalent 25 mm 1 0 in long at the crankshaft rear oil seal housing to engine block junction 3 Install the new oil pan gasket 4 Install the oil pan 5 Install the nuts and bolts to the oil pan Tighten Tighten the rear oil pan nuts to 19 Nem 165 lb in Tighten the oil pan bolts to the crankcase to 9 Nem 80 Ib in VE111 3L Tighten the oil pan bolts to the front cover to 5 Nem 45 Ib in Tighten the oil pan studs to the oil seal retainer to 2 Nem 15 Ib in Industrial 3 0L Crankshaft Pulley Installation Tools Required J 8792 Crankshaft Pulley Installer 1 Coatthe front cover oil seal contact area ofthe crankshaft pulley with clean engine oil 2 Assemble the J 8792 as shown 3 Install the J 8792 onto the crankshaft pulley 4 Position the pulley on the crankshaft and drive into position until it bottoms against the crankshaft sprocket Cylinder Head Installation 1 Install the new cylinder head gasket over the locating pins 2 Install the cylinder head over the locating pins and the gasket Engine Mechanical 1 67 en
57. run at slow idle 800 to 1000 rpm 3 Connect the alligator clip to a B terminal This connection cancels the programmed timing advance from the distributor module You will notice a change in engine sound and rpm when making this connection 4 Connect an electronic timing light to the No 1 spark plug wire The front cylinder on the 3 0L engine 5 Check and adjust the distributor as necessary viewing the timing mark on the crankshaft pulley in relation to the pointer on the engine timing cover 6 Refer to the chart below for the initial timing specification for your engine and type of fuel being used PSI Fuel Injected and Dual Fuel engines For engines equipped with this type of fuel system the engine timing may be controlled by the ECM Engine Control Module Checking the initial timing on engines equipped with PSI fuel injected and dual fuel engines incorporating an ECM can only be accomplished when using a laptop computer or a hand held diagnostic meter It will be necessary to contact the OEM or PSI for the necessary equipment and instructions for checking and adjusting the engine timing Notice Failure to follow the correct specified procedures when checking and adjusting the engine timing can cause severe damage to the engine Zenith Z E E M S Throttle Body Fuel Injected Engines Engine timing for Zenith TBI fuel injected engines is checked and adjusted following the procedures noted under Setting Ignition Timing only when the
58. starter is still held engaged The sound is similar to a siren if the engine is revved while the starter is engaged The starter motor clutch is worn 1 Remove the starter motor Refer to Starter Motor Replacement 2 Check the clutch Refer to Starter Motor Inspection Rumble Growl or a Knock DEFINITION A rumble growl or a knock in severe cases as the starter is coasting down to a stop after starting the engine The starter armature is bent or unbalanced 1 Remove the starter motor Refer to Starter Motor Replacement 2 Check the clutch Refer to Starter Motor Inspection Starter No Load Test Tools Required e J 35590 Current Clamp e J 39200 Digital Multimeter or Equivalent Notice Never operate the starter motor more than 15 seconds at a time without pausing in order to allow it to cool for at least 2 minutes Overheating will damage the starter motor Important Verify that the battery is in good condition Refer to Battery Check 1 Disable the fuel system Refer to Engine Controls 2 Calculate the current draw by doing the following 2 1 Select the 200 amp or the 2000 amp scale on the J 35590 a J 39200 2 2 Zero the current clamp 2 3 Clamp the current clamp to the battery negative cable 182233 2 4 Crank the engine and observe the meter readings The reading should be 65 95 amps e amperage is over 95 amps an internal starter failure may be the cause e Ifthe amperage is und
59. terminal to the battery positive terminal Is the voltage above the specified value Go to Step 13 Go to Step 12 1 Maintain the engine speed at 2500 RPM and continue to operate the generator at the load test value 2 Connect a J 39200 DMM from the generator metal housing to the battery negative terminal Is the voltage above the specified value Go to Step 15 3 30 Engine Electrical Industrial 3 0L Generator Not Operating Properly cont d Ame Caution Make sure that the load is completely turned Go to Charging off before connecting or disconnecting a carbon pile System Check load tester to the battery Otherwise sparking could ignite battery gasses which are extremely flammable and may explode violently Disconnect the digital multimeter Turn OFF the load in the carbon pile tester Turn the ignition switch to OFF to stop the engine Disconnect the carbon pile tester cables from the battery Disconnect the battery negative terminal 6 Inspect the circuit between the battery positive terminal and the generator output terminal for a high resistance connection Disassemble and clean all connections in this circuit Assemble the connections and tighten to specifications Connect the battery negative terminal Tighten to specifications Refer to Fastener Tightening Specifications Is the repair complete Caution Make sure that the load is completely turned Go to
60. test Did the test light blink Go to Step 24 Go to Step 20 Replace the pick up coil Are repairs complete System OK the distributor module Are repairs complete Industrial 3 0L Ignition Coil Not Operating Properly Testing Procedure Tools Required J 39200 Digital Multimeter or Equivalent 1 Ensure that the ignition switch is OFF 2 Disconnect the distributer lead and the wiring from the coil Notice Do not insert the multimeter probe into the ignition coil electrical connectors The female terminals could be deformed resulting in intermittent operation Only make contact with the front edge on each of the terminals 3 Connect an ohmmeter as shown in 1 on the illustration Use the high scale f the reading is not infinite replace the ignition coil 4 Connect an ohmmeter as shown in 2 on the illustration Use the low scale The reading should be 0 1 ohm or less If not replace the ignition coil 5 Connect an ohmmeter as shown in 3 on the illustration Use the high scale f the reading is not 5k ohms to 25k ohms replace the ignition coil 6 Connect the distributer lead and the wiring to the coil Spark Plug Wires Not Operating Properly 1 Check the routing of the wires Improper routing can cause cross firing 2 Check each wire for any signs of cracks or splits in the wire 3 Inspect each boot for signs of tears piercing arc through or carbon tracking If the boot ne
61. the fuse for the circuit which is causing the excessive drain Using the schematic as a guide disconnect the components of the faulty circuit one at a time until the faulty component is located When the cause of excessive current draw has been located and repaired remove the current drain test switch and connect the negative battery cable to the negative battery terminal 122 12 3 12 4 3 26 Engine Electrical Industrial 3 0L Battery Hydrometer Displays Dark or Yellow Dot The maintenance free battery has a built in hydrom eter which consists of a ball floating in the electrolyte The hydrometer is temperature compensated The color of the hydrometer indicates the condition of the battery e A green dot appearing on the hydrometer means that the battery is ready for testing hydrometer with no green visible means that the battery has a low charge Refer to Charging System Check or Battery Electrical Drain Parasitic Load A clear or light yellow color means that the battery fluid level is below the bottom of the hydrometer Replace the battery if its condition affects the cranking system A low fluid level can be caused by any of the following conditions An excessive charge Tipping the battery A faulty charging system Refer to Charging System Check Battery Is Undercharged or Overcharged gt v 1 Disconnect the generator connector 2 Probe the generator con
62. the mixture chart on the container for additional antifreeze protection information DO NOT use alcohol or methanol antifreeze or mix them with the specified coolant Plain water may be used in an emergency except in freezing temperatures but replace it with the specified coolant as quickly as possible to avoid damage to the system Radiator Inspect the exterior of the radiator for obstructions Remove all bugs dirt or foreign material with a soft brush or cloth Use care to avoid damaging the core fins If available use low pressure compressed air or a stream of water in the opposite direction of the normal air flow Radiator Hoses Check all hoses and connections for leaks If any of the hoses are cracked frayed or feel spongy they must be replaced Fan Belts The water pump is usually belt driven The same belt may also drive the fan and or the alternator The drive belts should be properly adjusted at all times A loose belt can cause improper alternator fan and water pump operation in addition to overheating Serpentine Belt Some GM Powertrain engines utilize serpentine belts on the front of the engine This type of belt system incorpo rates a belt tensioning device which keeps the belt at the proper tension This belt should be checked routinely for cracks or checking on the groove side of the belt If cracks or checking are apparent the belt must be changed V Type Belt V Type belts are generally tensioned
63. this is not possible recharge the battery every 30 45 days until the green dot is visible Industrial 3 0L Engine Electrical 3 47 Battery Charge Low or Completely Discharged Tools Required J 39200 Digital Multimeter DMM or Equivalent Caution Refer to Battery Cautions on page 3 17 Notice Always turn the ignition OFF when connecting or disconnecting battery cables battery chargers or jumper cables Failing to do so may damage the Electronic Control Module ECU or other electronic components Important Tighten the adapters against the lead terminals of the battery in order to keep the resistance between the adapters and the battery terminals to a minimum Use the following procedure in order to recharge a very low or completely discharged battery Carefully follow the procedure in order to avoid the replacement of a usable battery 1 Measure the battery voltage at the battery terminals using the multimeter e A reading of less than 11 volts indicates that the initial charging will be very low e It could take some time before the battery accepts current in excess of a few milliamperes 2 Set the battery charger on the high setting 3 If necessary disable the polarity protection circuitry This circuitry available on most chargers prevents charging unless the charger leads are properly connected to the battery terminals Acompletely discharged battery may not have enough voltage to activate this circuitry even though the leads are
64. to Battery Cable Replacement Is the repair complete 1 Inspect the starter to determine if there is a high resistance connection at the starter B terminal If the battery positive terminal was not previously inspected examine the positive terminal and terminal bolt for corrosion which would indicate a high resistance connection Was there a high resistance connection found Go to Step 14 Go to Step 15 1 Repair the high resistance connection 2 Connect the distributor electrical connector System OK System OK d Is the repair complete Replace the positive battery cable Refer to Battery Cable Replacement Is the repair complete Generator Noise Test Generator noise may be caused by the following A worn rectifier bridge conditions If the pulley and the mounting bolts are snug and the A loose drive pulley noise continues remove the generator for replacement Loose mounting bolts or for inspection and repair Refer to Generator Re Worn or dirty bearings placement worn stator Generator Not Operating Properly NOTE The following procedure is generic and applies to most commercial Charging System Testers Read the instructions in the Operator s manual for the equipment before beginning this procedure Perform the charging system check Refer to Charging Go to Charging System Check System Check Has the charging system check been performed Go to Step 2 12V Use a digital multimeter t
65. 1 3 The intake valves 1 2 4 3 4 Adjust the correct valves as follows 3 4 1 3 4 2 3 4 3 3 4 4 Back off the valve rocker arm nut until the lash is felt in the valve pushrod Tighten the valve rocker arm nut until all the lash is removed Zero lash can be felt by moving the valve pushrod up and down between your thumb and forefinger until there is no more movement When all the free play is gone tighten the valve rocker arm nut 1 additional turn 360 degrees Engine Mechanical 1 69 N V l 7 CYS DILL LE 1 70 Engine Mechanical Wi Industrial 3 0L 3 5 Turn the crankshaft 1 revolution until the mark on the crankshaft pulley lines up with 0 on the timing tab This is number 4 top dead center 3 6 With the engine at number 4 top dead center adjust the following valves The exhaust valves 2 4 The intake valves 3 3 6 1 Back off the valve rocker arm nut until the lash is felt in the valve pushrod 3 6 2 Tighten the valve rocker arm nut until all the lash is removed 3 6 3 Zero lash can be felt by moving the valve pushrod up and down between your thumb and forefinger until there is no more movement 3 6 4 When all the free play is gone tighten the valve rocker arm nut 1 additional turn 360 degrees Wf Al Pushrod Cover Installation 1 Install the pushrod cover gasket 2 Install the
66. 1 778 mm 1 524 2 032 mm 0 0254 0 06858 mm 0 01778 0 06858 mm 0 09398 mm Maximum 0 002 in Maximum 0 050 0 070 in 0 060 0 080 in 0 001 0 0027 in 0 0007 0 0027 in 0 0037 in Maximum 0 0047 in Maximum 2 06 in 100 110 Ib at 1 61 in 208 222 Ib at 1 22 in 1 65 in 1 65 in Stem Clearance Exhaust Service Limit 0 1193 mm Maximum Valve Spring Free Length 52 324 mm Valve Spring Pressure Closed 444 490 N at 40 89 mm 41 91 mm 41 91 mm 11 25 mm 0 443 in 11 25 mm 0 443 in 0 0762 mm Cylinder Head Deck measuring the overall length of the cylinder head 0 1778 mm Valve Spring Pressure Open 925 987 N at 30 99 mm Industrial 3 0L Engine Mechanical 1 7 Diagnostic Information and Procedures Base Engine Noise Diagnosis With the engine running try to determine if the noise is timed to the crankshaft speed or the camshaft speed 2 Using a timing light two knocks per flash is the crankshaft or one knock per flash is the camshaft Is the noise timed to the crankshaft speed Goto Step 2 Go to Step 3 Remove the rod bearings and inspect the bearings and the journals for wear 2 Ifthe parts are OK remove the crankshaft and inspect the main bearings and journals for wear 3 Replace the parts as necessary Does the engine continue to knock Goto Step 3 System OK Check to see if the noise is timed to the camshaft speed Is the noise timed to the camshaft speed Go to Step 5 Go to Step 4 Inspect for loose accessory a
67. 14 4 Sa e Ea a or Ea Industrial 3 0L Engine Electrical 3 23 Battery Not Operating Properly cont d Press the CODE button on the J 42000 For warranty purposes write the displayed code on the repair order Is the green dot if applicable visible in the battery s Go to Step 24 Go to Step 23 hydrometer Charge the battery Refer to Battery Charging Is the green dot if applicable visible in the hydrometer Go to Step 24 Go to Step 39 The battery is OK Install the battery Refer to Battery Replacement Is the action complete System OK 1 Press the CODE button on the J 42000 tester 2 For warranty purposes write the displayed code on the repair order 3 Charge the battery Refer to Battery Charging Is the green dot if applicable visible in the hydrometer Go to Step 24 i G G Notice Always turn the ignition switch OFF when connecting or disconnecting batteries battery chargers or jumper cables Failure to do so may damage the electronic control unit or other electrical components 1 Turn the ignition switch to the OFF position 2 Disconnect the negative battery cable 3 Disconnect the positive battery cable Go to Siep 3 Are the actions complete 1 Press the CODE button on the J 42000 2 For warranty purposes write the displayed code on the repair order 3 Replace the battery Refer to Battery Replacement Is the action complete Go to Step 2 1 Press the CODE but
68. 99 SHOISKIIQ SL5 PBi3 moman IWS JO 00 SYI WE zu ANVNNSL JTLYWGHIS SNTaIA VIT mo JW ul XI E ETT 00 Fak MEDWE p SER LE HOTS NI 0115 PUE BONIS ND IS ETEME 1 i f m RANG JOACL RE JOMI DL i i pom 19 Lp NRI E 1 Mm EV Be E We L fel 3 i al Jo E 10 8 1 9 un os Y 20018 d a m n ELBE 510 NN 90 8 E a Ned J 20004 TES 20008 px Be oO lo pe t E N Aldi 98 SIIANI DOR Z INANI 09845 Sb B 3H ODAGOO 18 IIT 5 HONS OS 8318015 EA m 8 tes A83 80010 ONY NIS NI NOT ZR al ALS E 204 1
69. Are repairs complete System OK Go to Step 7 Go to Step 8 7 Replace the distributor rotor Are repairs complete System OK Remove the distributor and make the necessary repairs Are repairs complete System OK Using a digital multimeter measure the resistance of the coil 1000 inch wire The resistance should be approximately the specified Is the resistance approximately the specified value Go to Step 11 Go to Step 10 10 Replace the coil wire Are repairs complete System OK 1 With the distributor cap removed crank the engine 2 Observe the distributor rotor Did the distributor rotor turn Inspect the distributor cap and check for one or more of the following conditions and replace if necessary Moisture Cracks Carbon runs Physical damage Were any of these conditions found Go to Step 5 Go to Step 6 Industrial 3 0L Engine Electrical 3 39 Engine Cranks But Fails to Start Continued Disconnect the electrical harness connector from the distributor Turn the ignition switch ON Probe the distributor harness connector between pin A pink wire and a good ground Turn the ignition switch OFF after test Was the voltage above the specified value Go to Step 12 Go to Step 13 1 Turn the ignition switch ON 2 Probe the distributor harness connector between pin B white wire and a good ground 3 Turn the ignition switch OFF after test Was the voltage above the specified value Go to Step 19
70. C voltage in the stator windings The rectifier bridge converts the AC voltage to DC and this goes to the electrical system at the terminal to the battery The digital regulator of the generator uses digital techniques in order to supply the rotor current Be cause of this the digital regulator controls the output voltage The rotor current is proportional the width of the electrical pulses supplied from the electrical system through the RED wire connected between the battery and S terminals on the generator When the ignition switch is turned to the RUN position current from the battery flows through the closed contacts of the switch to the voltmeter gauge on the instrument panel the voltage regulator and through the field coil of the generator rotor With current applied to the digital regulator the regula tor turns on Narrow width pulses go to the digital rotor circuit creating a weak magnetic field When the engine starts the digital regulator senses the rotation of the generator by detecting AC voltage at the stator through an internal wire Once the engine is running the digital regulator varies the field current by control ling the pulse width This regulates the output voltage of the generator for proper charging of the battery and operation of the electrical system Industrial 3 0L 7936013 VEO11 3L 7936020 Engine Electrical 3 63 IGNITION SYSTEM DESCRIPTION The 3 0 liter engine uses a battery c
71. Compression builds up quickly and evenly to specified compression on each cylinder 2 Piston Rings Compression low on first stroke Tends to build up on the following strokes but does not reach normal Improves considerably with addition of oil 3 Valves Compression low on first stroke Does not tend to build up on the following strokes Does not improve much with addition of oil Use approximately three squirts from a plunger type oiler Engine Noise Diagnosis There are four steps to diagnosing engine noise You must determine the following conditions Typeof noise The exact operating condition under which the noise exists Determine the rate and location of the noise Compare the sounds in other engines to make sure you are not trying to correct a normal condition Identify the type of noise For example a light rattle or low rumble Remember engine noises are generally synchronized to either engine speed caused by the crankshaft pistons or connecting rods or one half engine speed valve train noise Try to determine the rate at which the noise is occurring Knocks Cold and Continues for 2 to 3 Minutes Engine flywheel contacting the splash shield Reposition the splash shield Loose or broken crankshaft balancer or drive pulleys Tighten or replace as necessary Excessive piston to bore clearance Replace the piston Cold engine knock usually disappears when the specific cylinder secondary ignition c
72. Dead Center TEM P m v V V T e T T TV C TWC OC Catalytic TX Them alExpanspn Vale Vols Voltage Volage ifference Vacuum Dehby Vake Three W ay xdaton Converter Industrial 3 0L General Information 0 15 MAINTENANCE AND LUBRICATION Initial Start Up Maintenance The initial start up checks must be made before putting the engine into service Please refer to Maintenance Schedule 3 0L Engine on page 0 19 and perform the initial start up operations in the sequence shown in column 1 Routine Maintenance Routine maintenance provides the best solution for making sure that the engine is ready when you are The following are some routine service points Keep the fuel tank filled A full tank of fuel reduces the possibility of condensation forming in the fuel tank and moisture entering the fuel system Make frequent checks of the engine oil and coolant levels Repair any oil or coolant leaks immediately e Check battery condition and cables frequently Keep the engine air filter clean e Monitor engine coolant temperature Monitor engine oil pressure e Check voltmeter and charging system Scheduled Preventive Maintenance Refer to the Maintenance Schedule 3 0L Engine on page 0 19 to ensure that all of the maintenance items listed are checked and replaced as recommended at the hours shown Engine Oil Level Check The engine oil level should be checked daily It is recommended that
73. IUE ANSY aa ORLLIWOSD VOEEOO0EE Ue NOINE SNUYWISHINONOINTRDATTWOLSEDRUAREN QD ESLARIGELO AAV LITIIONE SWIVIO SNOLLNTOS WIMOd DOE T 598 78 4 DLLVANHHOS HIINSZ __ JNISNOLLYIOS WHAOd 00 2 mm TIOGQNVT NOLLVOTIddV y P HEN NOLROSId LV AR SSHION _ Sex SELON E ACE ALK A03 TR M LIS 555 79363010 Industrial 3 0L Engine Electrical 3 15 Component Locator Engine Electrical Components Battery Determined by customer usage and application Generator At the RH front of the engine Engine Electrical Pages 3 5 through Component Views 3 10 Ignition Switch Mounted to the instrument panel Engine Electrical Pages 3 5 through Component Views 3 10 Instrument Panel Determined by customer usage and application Engine Electrical Pages 3 5 through Component Views 3 10 Starter Motor At the lower RH side of the engine Engine Electrical N A Component Views Starter Solenoid On the starter at the lower RH side of the Engine Electrical Pages 3 5 through engine Component Views 3 10 Engine Electrical Component Locator Views 79363011 79363013 79363012 3 16 Engine Electrical Industrial 3 0L Diagnostic Information and Procedu
74. LITUISIGQ UIVOEA 3U Oe sert ores i NQF OAS OL Tadd OL 44 58 ES T 1 N 17 16 00000000 7936015 Industrial 3 0L Testing Pick up Coil 1 2 3 8 9 Remove the distributer cap Remove the distributer rotor Disconnect the pick up coil leads from the distributor module Connect an ohmmeter as shown in 1 on the illustration While watching the ohmmeter reading flex the leads by hand to check for intermittent problems The reading should be infinite at all times Connect an ohmmeter as shown in 2 on the illustration While watching the ohmmeter reading flex the leads by hand to check for intermittent problems The reading should be one steady value between 5000 and 1500Q at all times If the pick up coil does not match the values shown in steps 5 and 7 replace it Connect the pick up coil leads to the distributor module 10 Install the distributer rotor 11 Install the distributor cap Engine Electrical 3 43 7936016 3 44 Engine Electrical Industrial 3 0L REPAIR INSTRUCTIONS Battery Cable Replacement Notice Always turn the ignition switch OFF when connecting or disconnecting batteries battery chargers or jumper cables Failure to do so may damage the electronic control unit or other electrical components Removal Procedure Important Whenever battery cables are replaced always use
75. NISNOLLTIOS To pnm WEITER MEER VER Men mn ment meg i Les Bub i i SNOLLNTOS HA Od YELLS dE ply Aldand NDI i Ad NOLLARISSIG i i H TVNINYEL ANNONO Tr al NEM REM i so TANVd INIWNALSNI N a IHM d 7 HOLOHNNOO HIIHA i Z ANALLVE ann ovid E ie SSINUVH peu an 1 1 B LAG t ANNOND N ae bd Pe dS dnd INIHOSVD WI dWNd aNITOSVD IAOTTIA H bd S Eu A i af 2 x i gt ONLLNOY TAM DATA NAVAS en P 08520201 AM and 8N 10SVO JO INOW E x i n YOLNaTrals d i AOLOINNOI 1 GDIVIS YOLVALOV vo eu XVI 2 YONWAAOD X Fe meer MOTIaA Eu ALIAVO JOVTS CI RIAM JO 3015 AVTA MOM i WOXI GHAMIA SV NMOHS INTNIM TANVd INAWNALSNI NMOUG MN YOLOINNOO AVEO HNIIOSVO 7 E FONVYO y ety ze 5 3 Wa 2 Mum ama 8 7 87 NOSNJS i jl TAN LV aad i HOIOSNNOO YOSNAS EE HOLIAS INYI009 i ui m f i HOLIAS GAFAS i i Cv 1 SONO ONIAN PESE pe MOTHDIH ER Wa cee a M x e ot i
76. NY N ONKISE3ON 893203 3HL E3UNTI NI THING 8 ONY NOUSMEENI ABB SIEGE IN3HRCOU SIKL 79363005 Industrial 3 0L
77. ORIGINAL ISSUE DATED JUNE 2002 PUBLICATION NUMBER 36100010 3 0L INDUSTRIAL ENGINE SERVICE MANUAL POWER SOLUTIONS INC Table Of Contents General Information Section 0 Engine Mechanical Section 1 Engine Cooling Section 2 Engine Electrical Section 3 No part of this publication may be reproduced without the written permission of Power Solutions Inc At the time of publication all of the information included in this publication is accurate to the best of our knowledge Power Solutions Inc cannot be responsible for information that has changed after this book was published Industrial 3 0L General Information 0 1 Section 0 General Information Fastener Notice 0 2 General Information 3 01 0 3 Conversion English Metric 0 3 Equivalents Decimal and 0 3 Arrows and Symbols 04 0 4 Engine ID Location 0 5 Labels How to Obtain Replacement 0 5 Fa Stee S oc rene Dea tese terii DR 0 5 Metric Fasteners nenne 0 5 Fastener Strength 0 6 Prevailing Torque Fasteners 0 7 Prevailing Torque Specifications Metric 0 8 Prevailing Torque Specifications English 0 8 T
78. Replacement Is there still a loss of coolant Go to Step 4 System OK 4 Check the hoses for stains or wetness Are the hoses stained or wet Go to Step 5 Go to Step 6 5 Repair or replace the hoses as necessary Refer to Radiator Hose Replacement Is there still a loss of coolant Go to Step 6 System OK Check the water pump for stains or wetness Is the water pump stained or wet Go to Step 7 Go to Step 8 7 Repair or replace the water pump Use any of the following procedures Refer to Water Pump Replacement Is there still a loss of coolant Go to Step 8 System OK Check the coolant recovery reservoir if equipped Does the coolant overflow after you stop the engine Go to Step 9 Check the radiator cap for pressure retention 48 kPa Is the radiator cap retaining the proper pressure 7 psi Go to Step 10 Go to Step 11 Check the temperature reading 10 Go to Engine Is the temperature too high Overheating Go to Step 12 11 Replace the radiator cap Refer to Pressure Cap Description Is there still a loss of coolant Go to Step 12 System OK 12 Check the coolant gravity for glycol concentration Refer to Coolant Concentration Testing Is the glycol concentration too low Go to Step 13 System OK 13 System OK Use the following procedure to check for engine overheating boiling or poor engine cooling Hang the thermostat on a hook in order to perform an operational check of the thermostat Hang the thermostat in a 33 percent glyc
79. Step 10 Go to Step 9 Locate and repair the open circuit in the WHITE wire between the ignition switch B terminal and the starter solenoid B terminal Is the repair complete System OK 10 Replace the ignition switch Is the repair complete System OK 4 Does the voltage measure more than the specified value 5 Locate and repair the open circuit in the BLUE wire between the ignition switch S terminal and the starter solenoid S terminal OV OV 12V 12V 3 34 Engine Electrical Industrial 3 0L Starter Solenoid Clicks Engine Does Not Crank or Cranks Slowly sel Rein ve Ye Ww 1 Was the Starting System Check performed Go to Step2 Go to Starting System Check 2 1 Disconnect the ignition coil connector 9 2 Connect a digital multimeter from the battery positive terminal to the battery negative terminal Turn the ignition switch to the START position Crank the engine for 15 seconds 5 Measure the voltage at the end of cranking Notice Never operate the starter motor for more than 30 seconds at a time Allow it to cool at least two minutes before cranking again Excessive cranking can cause overheating which will cause serious damage to the starter motor Does the voltage measure less than 9 6 volts Go to Step 3 Go to Step 4 1 Do the battery load test s Refer to Battery Not System OK Operating Properly 2 If the battery passes the load test replace the starter motor Refer to Starter Motor Replacement
80. Tighten the top terminal nuts if applicable to 18 Nem 13 lb ft 3 52 Engine Electrical Industrial 3 0L Ignition System Service Precautions 1 When performing compression checks disconnect the electrical connector at the distributor When disconnecting the connector do not use a screwdriver or a tool to release the locking tab as this may damage the connector 2 No periodic lubrication of the distributor is required Engine oil lubricates the lower bushing and an oil filled reservoir provides lubrication for the upper bushing 3 The A terminal on the distributer white wire is the tachometer TACH terminal on the distributor module Notice Never allow the tach terminal to touch ground as damage to the distributor or ignition coil is likely to occur 4 Some tachometers currently in use are not compatible with the high energy ignition system Contact the manufacturer of the tachometer if questions arise 5 Dwell adjustment is controlled by the distributor module and is not adjustable 6 The material used to construct the spark plug wires is very soft The cables will withstand more heat and carry a higher voltage but scuffing and cutting become easier The spark plug wires must be routed correctly to prevent scuffing and cutting When disconnecting a spark plug wire twist the boot back and forth on the spark plug while pulling directly on the boot or use a special tool designed for that purpose Do not pull dire
81. Washer Installation Tools Required J 9535 Distributor Lower Bushing Installer 1 Usethe J 9535 in order to drive the thrust washer if removed into the cylinder block 2 UsetheJ 9535 with the driver bolt in the driver handle 3 Install the driver into the new bushing from the large inside diameter 4 Drive the new bushing into the cylinder block until the 9535 bottoms against the cylinder block Piston and Connecting Rod Disassemble Tools Required J 24086 C Piston Pin Removal Set 1 Remove the piston rings from the pistons J Engine Mechanical 1 41 VE063 3L 1 42 Engine Mechanical Industrial 3 0L 2 Remove the pin from the piston Notice After the J 24086 C Installer bottoms on the support assembly do not exceed 34 475 kPa 5000 psi or the tool may be damaged J 24086 C VE064 3L Piston and Connecting Rod Clean and Inspect 1 Clean the piston ring grooves with a groove cleaner Caution Wear safety glasses in order to avoid eye damage 2 Clean the connecting rod in cleaning solvent WEISSER 3 Clean the varnish from the piston skirts and the pins with cleaning solvent 4 Dry the components with compressed air 5 Do not use a wire brush in order to clean any part of the piston 6 Clean the piston oil ring holes and the slots 7 Inspect the connecting rod for twisting nicks and cracks Replace any damaged connecting rods 8 Inspect the pistons for the following co
82. a replacement cable that is the same type diameter and length Always route the replacement cable in the same manner as the original cable Always disconnect the negative cable from the battery first Caution Refer to Battery Cautions on page 3 17 1 Remove the negative battery cable from the battery 2 Remove the positive battery cable from the battery 3 Remove the battery cable routing ties if applicable 4 Remove the starter solenoid nut and the positive battery cable 5 Remove the bolt and the negative battery cable from the engine block Installation Procedure Caution Refer to Battery Cautions on page 3 17 Notice When installing the positive battery cable to the starter solenoid the inner nut on the solenoid battery terminal must be tightened before the battery cable and the other leads are installed in the equipment Failure to do so will result in damage to the solenoid terminal and or the solenoid Notice Refer to Fastener Notice on page 3 2 1 Install the positive battery cable to the starter solenoid with the nut Tighten Tighten the battery positive cable starter solenoid nut to 16 Nem 12 lb ft 2 Install the negative battery cable to the engine block or cylinder head with the bolt Tighten Tighten the battery negative cable bolt to 40 Nem 30 lb ft 3 Install the positive battery cable to the battery Tighten Tighten the battery side terminal bolts if applicable to 12 Ne
83. al of the booster battery Attach the remaining end of the jumper cable to a solid ground at least 450 mm 18 in from the booster battery Start the engine of the equipment with the booster battery Turn off all electrical accessories Start the engine of the equipment with the discharged battery Disconnect the jumper cable from the ground Disconnect the other end of the jumper cable from the negative terminal of the booster battery Remove the jumper cable connecting the positive terminals ro OANA Industrial 3 0L Engine Electrical 3 49 Starter Motor Inspection Cleaning Procedure Notice Do not use grease dissolving solvents for cleaning the overrunning clutch or armature Solvents dissolve the grease packed in the clutch and damage the armature and the field coil insulation Clean all starter motor parts with a soft cloth prior to testing Inspection Procedure Inspection in the following steps refers to visual inspection of the starter motor parts and assemblies in order to determine the serviceability of the parts 1 Inspect all parts for cracks distortion or other structural damage Replace parts and assemblies that are cracked bent or otherwise damaged 2 Inspect the threaded parts for stripped crossed or otherwise damaged threads Replace parts as necessary e Replace the parts with thread damage that cannot be cleaned up using a suitable tap or die e Replace any hardware items that have damaged threads 3
84. and Components 1 10 Lower Engine Block and Components 1 12 Cylinder Head and Components 1 14 Oil Pump and 1 15 Repair Instructions 1 16 Draining Fluids and Oil Filter Removal 1 16 Engine Flywheel Removal 1 17 Distributor Removal see 1 18 Ignition Coil 4 42024 1 18 Lift Bracket Removal eeene 1 19 Spark Plug 1 19 Intake Exhaust Manifold Removal 1 19 Intake Exhaust Manifold Disassemble and Assemble ener 1 20 Intake Exhaust Manifold Clean and Inspect 1 20 Water Pump 1 20 Crankshaft Pulley 1 21 Valve Rocker Arm Cover Removal 1 21 Pushrod Cover 1 21 Valve Rocker Arm and Pushrod Removal 1 22 Measuring Camshaft Lobe Lift 1 22 Valve Train Components Inspect Cylinder Head 1 23 Valve Lifter Removal eee 1 23 Cylinder Head
85. asive and has been known to cause internal engine damage 4 Assembling components When assembling components use only the sealant specified or equivalent in the service procedure Sealing surfaces should be clean and free of debris or oil Specific components such as crankshaft oil seals or valve stem oil seals may require lubrication during assembly Components requiring lubrication will be identified in the service procedure When applying sealant to a component apply the amount specified in the service procedure Do not allow the sealant to enter into any blind threaded holes as it may prevent the bolt from clamping properly or cause component damage when tightened Tighten bolts to specifications Do not overtighten Use of RTV and Anaerobic Sealer Important Three types of sealer are commonly used in engines These are RTV sealer anaerobic gasket eliminator sealer and pipe joint compound The correct sealer and amount must be used in the proper location to prevent oil leaks DO NOT interchange the three types of sealers Use only the specific sealer or the equivalent as recommended in the service procedure Pipe Joint Compound Pipe joint compound is a pliable sealer that does not completely harden This type sealer is used where two nonrigid parts such as the oil pan and the engine block are assembled together Do not use pipe joint compound in areas where extreme temperatures are expected These areas
86. ation 1 Nm bf bon CamshaftRetainerBots 9 Crankshaft Rear Oil Seal Housing Retainer Nuts 15 Intake Exhaust Manifold to Head 2 center Intake Exhaust Manifold to Head outer Oil Pan Nuts rear Oil Pan Bolts to crankcase Oil Pan Bolts to front cover Spark Plugs Water Pump Bolts Sealers Adhesives and Lubricants 1052365 Valve train component prelube 1052080 Valve rocker arm stud threads 1052080 Sealant Oil level indicator tube Industrial 3 0L Engine Mechanical 1 5 Engine Mechanical Specifications Application Engish O L4 3 0L 181 CID 101 60 mm 4 000 in 91 44 mm 3 60 in 9 251 13 42 0 9 0 035 in Oil Pressure Minimum Hot 41 4kPa at 6 0 psig at 1 000 engine rpm 1 000 engine rpm 124 1 kPa at 18 0 psig at 2 000 engine rpm 2 000 engine rpm 165 5 kPa at 24 0 psig at 4 000 engine rpm 4 000 engine rpm 3611 4 00 ats Gear Driven 3 9995 4 0025 in 0 001 in Maximum 0 002 in Maximum 0 0008 in Maximum 0 001 in Maximum 0 0005 in Maximum 0 001 in Maximum Runout Rear Face of Block to Crankshaft Center Line 0 002 in Maximum Piston 2 0 0025 0 0035 in 0 0035 in Maximum 0 03048 0 07366 mm 0 0012 0 0029 in 0 0012 0 0029 in 0 0039 in Maximum 0 01 0 02 in 0 017 0 025 in 0 035 in Maximum 0 001 0 006 in 0 007 in Maximum 0 01 0 03 in 0 04 in Maximum 23 545 23 548 mm 0 9270 0 927 in Clearance in Piston Prod
87. ber hose Coolant passes from the pump through the coolant passages in the block and cylinder head This is done in order to absorb and carry away excess engine heat Thermostat Description A pellet type thermostat in the coolant outlet passage controls the flow of the engine coolant This allows proper engine warm up and regulates coolant temperature A wax pellet element in the thermostat expands when heated and contracts when cooled The pellet connects through a piston to a valve When the pellet heats the valve opens As the pellet cools the contraction allows a spring to close the valve The valve remains closed while the coolant is cold This prevents circulation of coolant through the radiator When the engine warms and the thermostat valve opens coolant flows through the radiator In the radiator heat is exchanged through the radiator into the surrounding air This opening and closing of the thermostat permits enough coolant to enter the radiator in order to keep the engine within operating limits Special Tools and Equipment ___ Tool Number Description J 223688 Coolant Tester Fahrenheit Scale J 24460 01 Radiator Pressure Tester Industrial 3 0L Engine Electrical 3 1 Section 3 Engine Electrical Fastener NOCO 3 2 Voltmeter Gauge Inaccurate or Inoperative 3 37 Engine Electrical 3 0L 3 3 Engine Cranks But Fails to Start
88. contact between each valve and its seat in the cylinder head is necessary to ensure that the heat in the valve head is properly carried away Regardless of what type of equipment is used it is essential that the valve guide bores are free from carbon or dirt to ensure the proper centering of the pilot in the guide The valve seats should be concentric to within 0 0508 mm 0 002 in total indicator reading Reface pitted valves on a valve refacing machine in order to ensure the correct relationship between the head and the stem Replace the valves that show excessive wear or are warped Replace the valve if the edge of the head is less than 0 8 mm 0 031 in thick after grinding Several different types of equipment are available for reconditioning valves and valve seats Use the manufacturers recommendations of equipment to obtain the proper results Engine Mechanical 1 57 VE098 3L VE096 3L t T VE099 3L 1 58 Engine Mechanical Industrial 3 0L Rocker Arm Stud Removal and Installation Tools Required J 5802 01 Rocker Arm Stud Remover J 6880 Rocker Arm Stud Installer Rocker arm studs with damaged threads or with loose fit in J 5802 01 cylinder head should be replaced with new oversize studs 1 Remove the old stud by placing J 5802 01 over the stud installing nut and flat washer and removing the stud by turning out VE100 3L 2 Ream the hole for the oversize stud Important Do
89. ctly on the spark plug wire Distributor Replacement Removal Procedure 1 Disconnect the primary ignition harness 4 from the distributor electrical connector 2 Remove the distributor cap with secondary wires 1 attached by loosening the two mounting screws 3 Remove the distributor hold down clamp 5 and mounting bolt 6 4 Noting the position of the rotor pull the distributor upward until the rotor stops turning counterclockwise 5 Again note the rotor position 6 Remove the distributor 2 and gasket 3 from the engine block VEO10 3L Industrial 3 0L Distributor Replacement Continued Installation Procedure Important To ensure correct ignition timing the distributor must be installed in the correct position Ifthe crankshaft has been turned with the distributor removed position the engine attop dead center on number one cylinder The distributor cap must be removed in order to position the rotor when installing the distributor 1 2 Install the distributor 2 and new gasket 3 making sure the distributor rotor is pointing in the same position noted during removal or to number one tower on the distributor cap ifthe crankshaft has been moved Install the distributor hold down 5 and bolt 6 Tighten Tighten the hold down bolt to 27 Nem 20 Ib ft 3 Connect the primary ignition harness 4 to the distributor electrical connector Install the distributor cap with secondary
90. dge from the valve pushrods and the valve rocker arms 2 2 valve stems and heads on a buffing wheel 2 3 cylinder head and engine block gasket surfaces 2 4 The bolt holes and threads in the cylinder head and the engine block Inspect the following areas 3 1 The cylinder head for cracks in the exhaust ports and the combustion chambers 3 2 The cylinder head for external cracks in the water chamber 3 3 The valves for burned heads cracked faces or damaged stems Industrial 3 0L Engine Mechanical 1 55 4 Usethe J 9666 and a flex bar torque wrench in order to measure the valve spring pressure Replace the valve spring if the spring pressure is less than 444 N 100 Ib at 40 9 mm 1 61 in Refer to Engine Mechanical Specifications LATE EH VE093 3L 5 Excessive valve stem to bore clearance will cause excessive oil consumption and may cause a valve to break Insufficient clearance will result in noisy and sticky functioning of the valve and will disturb the engine assembly smoothness 5 1 Install the valve into the guide 5 2 Install the J 8520 onto the cylinder head 5 3 Locate the indicator so that the movement of the valve stem from side to side crosswise to the cylinder head will cause a direct movement of the indicator stem 5 4 The indicator stem must contact the side of the valve stem just above the valve guide 5 5 Drop the valve head about 1 6 mm 0 0064 in off the
91. e 0 5 V battery terminal to starter solenoid terminal B 2 Turn the ignition switch to the START position 3 Observe the voltage while cranking Notice Never operate the starter motor for more than 30 seconds at a time Allow it to cool at least two minutes before cranking again Excessive cranking can cause overheating which will cause serious damage to the starter motor Does the voltage measure more than 0 5 volts Go to Step 7 Go to Step 8 System OK 7 Inspect the battery cable for a high resistance connection at the starter solenoid B terminal If the connection is OK replace the positive battery cable Refer to Battery Cable Replacement Caution Before servicing any electrical component the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF unless instructed otherwise in these procedures If a tool or equipment could easily come in contact with a live exposed electrical terminal also disconnect the negative battery cable Failure to follow these precautions may cause personal injury and or damage to the vehicle or its components Is the repair complete System OK Replace the starter motor Refer to Starter Motor Replacement Is the repair complete 3 36 Engine Electrical Industrial 3 0L Voltmeter Gauge Displaying Higher or Lower Than Normal Voltage een DEFINITION The voltmeter gauge in the instrument cluster is accurate and it correctly
92. e converted for LPG or NG fuels MUST use oils labeled FOR GASOLINE ENGINES Do not use oils that are specifically formulated for Diesel Engines only CC or CD classification oils even when labeled Heavy Duty or for Natural Gas Engines ARE NOT ACCEPTABLE 0 16 General Information Industrial 3 0L Engine Oil Recommendation Multi viscosity oils are recommended SAE 10W30 is recommended for your engine from 0 degrees F 18 degrees or above If ambient temperatures are consistently below 0 degrees SAE 5W30 oil can be used Synthetic oils are not recommended for industrial or stationary engines Oil Filter The PSI GM Powertrain engines use an AC Delco oil filter as original equipment An equivalent oil filter must be used when servicing the engine see Engine Specifications for the recommended oil filter for your engine The filter protects your engine from harmful abrasive or sludgy particles without blocking the flow of oil to vital engine parts To replace the filter use a proper filter wrench to remove the filter Clean the filter mounting base and lightly coat the gasket surface of the new filter with engine oil Hand tighten the filter until the gasket contacts the base then tighten another 72 turn Fill the engine with the correct amount of oil run the engine and check for oil leaks at the drain plug and oil filter gasket Tighten as necessary to stop any oil leakage noted Engine Air Cleaner The engine air clea
93. e engine flywheel Coolant Inlet and Coolant Thermostat Removal 1 Remove the two thermostat housing bolts 1 Remove the coolant thermostat housing 2 Remove the coolant thermostat 3 and gasket 4 Discard the coolant thermostat gasket Remove the coolant inlet bolts 6 Remove the coolant inlet housing 5 and gasket 7 Discard the coolant thermostat gasket Noc ROI Engine Mechanical 1 17 VE008 3L 79362005 1 18 Engine Mechanical Industrial 3 0L Distributor Removal 1 Disconnect the secondary ignition wires 1 from the spark plugs and the ignition coil 2 Disconnect the primary ignition harness 4 from the ignition coil Do not remove the wires from the distributor unless it is necessary 3 Remove the distributor hold down bolt 6 4 Remove the distributor 2 and gasket 3 VE010 3L Ignition Coil Removal 1 Remove the ignition coil bracket attaching bolts 2 Remove the ignition coil VE011 3L Industrial 3 0L Lift Bracket Removal 1 Remove the lift bracket bolts 2 Remove the lift bracket Spark Plug Removal 1 Remove the spark plugs Intake Exhaust Manifold Removal 1 Remove the intake exhaust manifold bolts 2 Remove the intake exhaust manifold 3 Remove the intake exhaust manifold gaskets Engine Mechanical 1 19 VE012 3L VE013 3L VE014 3L 1 20 Engine Mechanical VE015 3L VE016 3L VEO17 3L
94. e reinstalled into an engine return the components to their original location position and direction Refer to Separating Parts During assembly lubricate all moving parts with clean engine oil or engine assembly lubricant unless otherwise specified This will provide initial lubrication when the engine is first started Refer to Sealers Adhesives and Lubricants Crankshaft Bearings and Bearing Cap Installation Important Crankshaft bearing caps must be installed to the proper location and direction When installing the crankshaft bearings align the locating tabs on the bearings with the locating notches in the engine block journal bore and the bearing cap Always install crankshaft bearings with their machined partner Do not file bearings or mix bearing halves 1 Install the crankshaft bearings into the engine block and the crankshaft bearing caps at the crankshaft bearings with clean engine oil 3 Install the crankshaft Industrial 3 0L 4 Installthe crankshaft bearing caps with the crankshaft bearings 5 Besurethat the cap directional arrows point toward the front of the engine block and the cap is in its original position 6 Install the crankshaft bearing cap bolts 7 Thrustthe crankshaft rearward in order to set and align the thrust bearings and the bearing caps 8 Thrust the crankshaft forward in order to align the rear faces of the rear crankshaft bearings Tighten Tighten all of the bolts to 88
95. e the connecting rod nuts 9 Remove the connecting rod cap and bearing 10 Measure the gauging plastic at its widest area using the scale supplied with the plastic gauging kit 11 Compare the measurements to Engine Mechanical Specifications Crankshaft Rear Oil Seal and Housing Removal 1 Remove the crankshaft rear oil seal housing bolts 2 Remove the crankshaft rear oil seal housing seal and gasket Engine Mechanical 1 31 VE043 3L 1 32 Engine Mechanical Industrial 3 0L 3 Remove the crankshaft rear oil seal from the crankshaft rear oil seal housing Crankshaft Bearings and Bearing Cap Removal 1 Remove the crankshaft bearing cap bolts 2 Remove the crankshaft bearing caps 3 Remove the crankshaft 4 Remove the crankshaft bearings from the bearing caps and from the engine block VE046 3L Industrial 3 0L Crankshaft and Bearings Clean and Inspect Tools Required J 7872 Magnetic Base Indicator Set Caution Wear safety glasses in order to avoid eye damage 1 2 3 4 5 Clean the crankshaft in solvent Inspect the crankshaft oil passages for restrictions Dry the crankshaft with compressed air Inspect the crankpins for scoring or wear Inspect the crankshaft bearings for craters or pockets Flattened sections on the bearing halves also indicate fatigue Inspect the crankshaft bearings for excessive scoring or discoloration Inspect the
96. e which relieves pressure and the other to compensate for coolant contraction when the engine is off The radiator cap on this system has a 48kPa 7 psi rating Radiator Maintenance Radiators need special attention to prevent leakage and airflow restrictions Check the outside of the radiator for bent fins or leakage Leaking radiator cores should be repaired immediately not just sealed temporarily with a sealer type antifreeze or coolant additive Remove the radiator cap and look for plugging and scale on the inside of the tank A badly plugged radiator may have to be replaced If scale is found remove it Refer to Cooling System Scale Removal Industrial 3 0L 107487 1375 Engine Cooling 2 19 Pressure Cap Description Radiator Cap Caution As long as there is pressure in the cooling system the temperature can be considerably higher than the boiling temperature of the solution in the radiator without causing the solution to boil Removal of the radiator cap while the engine is hot and the pressure is high will cause the solution to boil instanta neously and possibly with explosive force spewing the solution over the engine the equipment and person removing the cap The pressure vent radiator cap allows a buildup of 48 kPa 7 psi in the cooling system Do not remove the radiator cap to check the engine coolant level until the engine is cool Add coolant to the radiator only after the system cools The radiat
97. ean water There are various types of flushing compounds available commercially Obtain the compounds from a reliable source Most compounds attack metals and should not remain in the engine block for more than a few minutes Use a neutralizer in the cooling system immediately after you use a descaling solvent Use a stronger solution for extremely hard stubborn coat ings such as lime scale The corrosive action of a stronger solution affects the thin metals of the radiator which reduces the operating life of the radiator A complete flush and rinse of the radiator is mandatory and must be accomplished skillfully Drain the entire system after the solvent and neutralizer are used and the cooling system is flushed Fill the system with 48 52 mixture of distilled water and an ethylene glycol based coolant Check for coolant leaks in the radiator the hose and the engine 2 10 Engine Cooling Industrial 3 0L 79362008 79362009 Radiator Hose Replacement Removal Procedure 1 Drain the coolant from the radiator so that the level of the coolant is below the hose that is being removed 2 Remove the radiator hose clamps 3 Remove the upper radiator hose from the radiator and the coolant thermostat housing 4 Remove the lower radiator hose from the radiator and the water pump Installation Procedure 1 Install the lower radiator hose to the radiator and to the water pump 2 Install the upper radiator hose to the
98. ed do not wipe the silicone lubricant off of the module or the distributer base Installation Procedure Notice If anew module is being installed a package of silicone grease will be included with it Spread the grease on the metal face of the module and the area on the distributor base where the module mounts This grease is necessary for module cooling 1 Noting color codes on leads connect the pick up coil connector to the module 2 Position the module on the distributor base Install the two module mounting screws 4 Connect the primary ignition wire connector to the module 5 Install the distributor cap and wires Engine Electrical 3 55 RETAINER PICKUP MODULE 7936017 MODULE APPLY SILICONE LUBRICANT 7936018 3 56 Engine Electrical Industrial 3 0L Pick up Coil Replacement Removal Procedure Important It is necessary to remove the distributor from the engine in order to replace the pick up coil 1 Remove the distributor from the engine Refer to Distributor Replacement in this section Remove the rotor Position the distributor in a suitable holding fixture Drive the roll pin out of the drive gear and shaft Mark the drive gear and shaft for correct assembly Remove the drive gear from the shaft Remove the drive shaft from the distributor a gt 7936019 8 Disconnect the pick up coil electrical connector from the distributor module 9 Rem
99. eds to be replaced twist it a half turn in each direction to Engine Electrical 3 41 A Scrape clean metal ground 7936014 Spark Plug Wire Resistance Test Tools Required J 39200 Digital Multimeter or Equivalent 1 Disconnect both ends of the wire that you wish to check Important Ensure that the wire terminals are clean before proceeding Connect an ohmmeter lead to each end of the spark plug wire Gently twist the wire while observing the ohmmeter reading If the ohmmeter reads above 30 000 ohms no matter how long the wire is or fluctuates from infinity to any value replace the wire Spark Plug Wire Routing break the seal before pulling on the boot to disconnect the wire Wire routing must be kept intact during service and followed exactly when wires have been disconnected or when replacement of the wires becomes necessary Failure to route the wires can result in cross firing of the spark plugs or shorting of the wires to ground The correct routing of the spark plug wires in shown in the illustration on the next page ial 3 0L Industr ine Electrical 3 42 Eng INIDN3 710 PERINSFIA ANSY Yad SNOISNAWIG O141AWOID 00000000 0595145 onunou 0107 39V 0 000 1 AIO dO V d anm ISIMYIHLO 031412345 SSIINN ONIM VNG SIHL NO NOLLYWYOANI TIY OL SLHOR TVIINACINOD uva hay ER 13199039 SWIVO ONT SNOLLNIOS 83904 LU SNOILO TIOS YAM Od 319110 NOF
100. efer to Draining and Filling Cooling System 2 Remove the drain cock from the left hand side of the radiator lower tank Installation Procedure Notice Refer to Fastener Notice 1 Install the drain cock to the radiator Tighten Tighten the drain cock to 18 N m 13 Ib ft 2 Fillthe cooling system Refer to Draining and Filling Cooling System 3 Start the engine and check for leaks Radiator Replacement Removal Procedure 1 Drain the cooling system Refer to Draining and Filling Cooling System 2 Disconnect the radiator hoses from the radiator Refer to Radiator Hose Replacement 3 Remove the fan guard Refer to Fan Guard Replacement Remove the upper radiator bracket and mounting bolts Remove the lower radiator mounting bolts Remove the radiator Remove the fan shroud Refer to Fan Shroud Replacement nb eom Installation Procedure 1 Install the fan shroud Refer to Fan Shroud Replacement 2 Position the radiator on the equipment Notice Refer to Fastener Notice 3 Install the lower radiator mounting bolts finger tight 4 Install the radiator upper brackets and mounting bolts Tighten Tighten all radiator mounting bolts to 25 Nem 18 Ib ft 5 Install the fan guard Refer to Fan Guard Replacement 6 Connectthe radiator hoses to the radiator Refer to Radiator Hose Replacement 7 Fillthe cooling system Refer to Draining and Filling Cooling System 8 Start the engine and check for
101. el 550 3 7 Battery Replacement 3 47 Genie 5125 Dual Fuel 3 8 Jump Starting in Case of Emergency 3 48 Genie 580 585 Dual 3 9 Jump Starting Procedure 3 48 Shuttle Lift Dual Fuel nennen 3 10 Starter Motor Inspection 3 49 3 0L Generator Set Engine 3 11 Cleaning 3 49 Zenith TBI Wood 3 12 Component Electrical Testing 3 49 Broderson 784 835 Dual Fuel 3 13 Armature Bearing Replacement 3 49 Landoll E784 86S LPG Only 3 14 Starter Motor Replacement 3 50 Component Locator 3 15 Generator Replacement 3 51 Engine Electrical Components 3 15 Ignition System Service Precautions 3 52 Engine Electrical Component Locator Views 3 15 Distributor Replacement 3 52 Diagnostic Information and Procedures
102. ely around its ring groove on the piston 12 2 Dress the groove with a fine cut file ifthe ring groove causes binding 12 3 Replace the piston ring if a distorted piston ring causes binding VE070 3L 12 4 Use a feeler gauge in order to measure the side clearance of the piston ring and groove 12 5 Try another piston ring if the side clearance is too small VEO71 3L Piston Selection Important Measurements of all components should be taken with the components at normal room temperature For proper piston fit the engine block cylinder bores must not have excessive wear or taper A used piston and pin set may be reinstalled if after cleaning and inspection they are within specifications 1 Inspect the engine block cylinder bore Refer to Cylinder Block Clean and Inspect 2 Inspect the piston and piston pin Refer to Piston and Connecting Rod Clean and Inspect 3 Use a boring gauge in order to measure the cylinder bore diameter at a point of 66 mm 2 5 in from the top of the cylinder bore VE060 3L Industrial 3 0L 4 Measure the bore gauge with a micrometer and record the reading With a micrometer or caliper at a right angle to the piston measure the piston 11 mm 0 433 in from the bottom of the skirt Subtract the piston diameter from the cylinder bore diameter in order to determine piston to bore clearance For proper piston to bore clearance Refer to Engine Mechanical Specifications
103. ely discharged light duty battery e Temperature Colder batteries require more time to recharge e Cold batteries accept only very low current at first during charging The cold battery will accept a higher charging rate as the battery warms e Charger Capacity A charger with higher amperage charges batteries in less time e State Of Charge A completely discharged battery requires more than twice as much charge as a one half charged battery The electrolyte in a completely discharged battery is nearly pure water so the electrolyte is a very poor conductor In this condition the battery accepts very low current at first Later as the charging current increases the acid content of the electrolyte the charging current also increases Any battery discharged by parasitic current drain and then allowed to stand in this condition for a period of time may not readily accept a charge However recharged long enough many batteries will return to a usable condition Prolonged periods in a discharged state can result in permanent damage to the battery This damage can accelerate under changing temperatures Batteries that are extremely discharged can freeze at temperatures as high as 7 C 20 F This results in permanent damage Disconnect the negative battery cable of equipment that is not going to be in service within a 30 day period This will remove the constant drain on the battery This can prevent damage to the battery and recharge problems If
104. emove the fan blade mounting bolts and washers 3 Remove the fan pulley and spacer if equipped 79362002 2 12 Engine Cooling Industrial 3 0L 79362002 79362003 79362003 Installation Procedure 1 Position fan pulley and spacer if equipped onto the water pump shaft Notice Refer to Fastener Notice 2 Install the fan blade mounting bolts and washers Tighten Tighten the lower generator mounting bolt to 30 Nem 22 lb ft 3 Install the fan guard Refer to Fan Guard Replacement Fan Shroud Replacement Removal Procedure 1 Remove the fan guard Refer to Fan Guard Replacement 2 Disconnect the radiator overflow hose clamps from the fan shroud 3 Remove the fan shroud mounting bolts and washers Remove the radiator upper support brackets at the radiator 5 Tilt the radiator forward and remove the fan shroud Installation Procedure 1 Tilt the radiator forward and position the fan shroud over the cooling fan blades Notice Refer to Fastener Notice 2 Install the fan shroud mounting bolts and washers Tighten Tighten the fan shroud mounting bolts to 16 20 N m 12 15 Ib ft Notice Refer to Fastener Notice 3 Install the radiator upper support brackets to the radiator Tighten Tighten the radiator upper support bracket mounting bolts to 16 25 Nem 18 Ib ft 4 Install the fan guard Refer to Fan Guard Replacement 5 Connect the radiator overflow hose clamps to the fan s
105. en the coolant inlet housing bolts to 34 40 Nem 25 03 Ib ft 3 Notice Refer to Fastener Notice Drain the cooling system Refer to Draining and Filling Cooling System Remove the upper radiator hose from the thermostat housing Refer to Radiator Hose Replacement Remove the two thermostat housing bolts 1 Remove the coolant thermostat housing 2 Remove the coolant thermostat 3 and gasket 4 Discard the coolant thermostat gasket 4 Remove the coolant inlet housing mounting bolts 6 Remove the coolant inlet housing 5 and gasket 7 Discard the coolant inlet housing gasket 7 79362005 Install coolant inlet housing 5 and a new gasket 7 to the cylinder head Install the two coolant inlet housing bolts 6 Install the coolant thermostat 3 coolant thermostat housing 2 and a new gasket 4 onto the coolant inlet housing 5 4 Install the two coolant thermostat housing bolts 1 Tighten Tighten the thermostat housing bolts to 24 31 Nem 18 23 Ib ft 79362005 5 Connect the upper radiator hose to the coolant thermostat housing 2 Refer to Radiator Hose Replacement 6 Fill the cooling system Refer to Draining and Filling Cooling System 7 Start the engine and Check for leaks 2 16 Engine Cooling Industrial 3 0L Water Pump Replacement Removal Procedure 1 Drain the cooling system Refer to Draining and Filling Cooling System 2 Remove the lower radiator hose from the water
106. en valve spring Sticking valves Lifters worn dirty or faulty Camshaft lobes worn Worn valve guides Worn or damaged valve keys Bentpushrods Oil Consumption Diagnosis Excessive oil consumption not due to leaks is the use of 1 9L 2 qts or more of engine oil within 50 hours of use The causes of excessive oil consumption include the following conditions Industrial 3 0L External oil leaks Tighten bolts and or replace gaskets and oil seals as necessary Incorrect oil level or improper reading of oil level indicator With the engine at a level surface allow adequate drain down time and check for the correct oil level Improper oil viscosity Use a recommended SAE viscosity for the prevailing temperatures Continuous high speed operation and or severe usage Crankcase ventilation system restrictions or malfunctioning components Possible improper PCV valve Valve guides and or valve stem oil seals worn or the seal omitted Ream guides and install oversize Service valves and or new valve stem oil seals Piston rings broken improperly installed worn or not seated properly Allow adequate time for rings to seat Replace broken or worn rings as necessary Piston improperly installed or mis fitted Low or No Oil Pressure Diagnosis and Testing Low oil level Fill to full mark on oil level indicator Incorrect or malfunctioning oil pressure switch Incorrect or malfunctioning oil pr
107. ent Clean the area well then dry the area Run the engine for several minutes at normal operating temperature and varying speeds After running the engine visually check the suspected area If you still cannot locate the leak try using the powder or black light and dye method Perform the following steps in order to perform the powder method 1 Clean the suspected area 2 Apply an aerosol type powder such as foot powder to the suspected area 3 Runthe engine under normal operating conditions 4 Visually inspect the suspected area You should be able to trace the leak path over the white powder surface to the source Perform the following steps in order to use the black light and dye method Tools Required J 39400 Leak Detector 1 Pour specified amount of dye into the leaking component 2 Runthe engine under normal operating conditions as directed by the J 39400 3 Directthe light toward the suspected area The dyed fluid will appear as a yellow path leading to the source Repairing the Leak Once the origin of the leak has been pinpointed and traced back to its source the cause of the leak must be determined in order for it to be repaired properly If a gasket is replaced but the sealing surface is damaged the new gasket will not repair the leak Before attempting to repair a leak be sure that the gasket and sealing surfaces are correct Perform the following steps in order to check for gasket leaks 1 In
108. er 65 amps a battery cable or connection may be the cause Industrial 3 0L Engine Electrical 3 33 Starter Solenoid Does Not Click ap ont Has the Battery Check been performed 1 Probe the starter solenoid with a digital multimeter from terminal S to engine ground ow Go to Battery Go to Step 2 Check 2 Turn the ignition switch to the START position Does the voltage measure more than the specified value Go to Step 3 Go to Step 4 Ensure that the battery terminals are clean and tight Remove the starter Clean the starter motor mounting bolts the starter motor and the mounting surface Install the starter Attempt to start the engine If the engine does not start replace the starter motor Refer to Starter Motor Replacement Is the repair complete System OK terminal S to engine ground 2 Turn the ignition switch to the START position 1 Probe the ignition switch with a digital multimeter from Go to Step 5 Go to Step 6 System OK Is the repair complete Probe the starter solenoid with a digital multimeter from terminal B to engine ground Is the voltage equal to or more than the specified value Locate and repair the open circuit in the positive battery cable between the battery and the starter solenoid B Is the repair complete System OK Probe the ignition switch with a digital multimeter from terminal B to ground Is the voltage equal to or more than the specified value Go to
109. erminal nuts if applicable to 18 Nem 13 lb ft Jump Starting in Case of Emergency Do not try to jump start equipment if you are unsure of the voltage or ground of the other equipment or if the voltage and ground of the other equipment is different Be careful of the booster battery and the discharged battery when using jumper cables Be careful in order to avoid causing sparks Notice To protect the electronic control module do jump the battery with Hot Shot over 14 V charging aids Do not disconnect the battery while the engine is running to verify charging system operation Jump Starting Procedure Caution Refer to Battery Cautions on page 3 17 Notice Always turn the ignition OFF when connecting or disconnecting battery cables battery chargers or jumper cables Failing to do so may damage the Electronic Control Module ECU or other electronic components 1 If equipped check the built in hydrometer If the hydrometer is clear or light yellow 3 do not jump start the battery Replace the battery Refer to Battery Replacement 2 Ensure the jumper cables do not have loose or missing insulation 3 Position the equipment with the booster good battery so that the jumper cables will reach but DO NOT let the equipment touch 4 Connect one jumper cable to the positive terminal of the booster battery and the positive terminal of the dis charged equipment Attach one end of the other jumper cable to the negative termin
110. essure gauge mproper oil viscosity for the expected temperature Oil pump worn or dirty Malfunctioning oil pump pressure regulator valve Plugged oil filter Oil pump screen loose plugged or damaged Excessive bearing clearance Replace as necessary Cracked porous or restricted oil galleys Repair or replace the engine block Oilgalley plugs missing or incorrectly installed Install the plugs or repair as necessary Oil diluted by moisture or unburned fuel mixtures Cil Leak Diagnosis Most fluid oil leaks are easily located and repaired by visually finding the leak and replacing or repairing the necessary parts On some occasions a fluid leak may be difficult to locate or repair Use the following steps in order to find the leak 1 Identify the fluid determine whether it is engine oil transmission fluid or power steering fluid 2 Atwhat point is the fluid leaking from After running the engine at normal operating temperature place a large sheet of paper under the engine After a few minutes you should be able to find the approximate location of the leak by the drippings on the paper Engine Mechanical 1 9 3 Visually check around the suspected component Check around the gasket mating surfaces for leaks A mirror is useful for finding leaks in areas that are hard to reach 4 Ifthe leak still cannot be found it may be necessary to clean the suspected area with a degreaser steam or spray solv
111. etects that the battery temperature may 1 aor 82 F Use the temperature of the battery to which the battery has been exposed for the past several The tester will briefly display the RETESTING message and the CCA rating selected for the test The test results Go to Step 14 Go to Step 37 1 The tester detects that an electrical load is present such as a light is on or the ignition key is not in the hours in order to estimate the temperature 2 Push the ENTER key will then show on the display Do the test results show on the display OFF position 2 Turn OFF all of the system electrical loads Are all of the system electrical loads OFF The J 42000 automatically retests the battery A the display alternates up to 5 Five minutes while all the tester Are the test results displayed on the tester An undetected load or parasitic drain can cause the to continue for more than 5 Five minutes Disconnect the J 42000 tester Electrical Drain Parasitic Load Are all electrical loads and parasitic drains eliminated Go to Step 35 u RETESTING message and SYSTEM NOISE message on circuits power down The test results will then display on Go to Step 14 Go to Step 36 alternating RETESTING and SYSTEM NOISE messages 1 Di 2 Eliminate all electrical parasitic drains Refer to Battery Go to Step 2 A J 42000 problem is indicated Inspect the tester for correct operation Is the tester operating properly G
112. fies the OE metric fasteners except cross recess head screws The number also indicates the strength of the fastener material A Posidrive R or Type 1A cross recess identifies a metric cross recess screw For best results use a Type 1A cross recess screwdriver or equivalent in Posidrive R recess head screws General Motors Engineering and North American Industries have adopted a portion of the ISO defined standard metric fastener sizes The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size For example the metric M6 0 X 1 screw with nearly the same diameter and 25 4 threads per inch replaced the English 1 4 20 and 1 4 28 screws The thread pitch is midway between the English coarse and fine thread pitches 79300002 0 6 General Information Industrial 3 0L Fastener Strength Identification 171891 Legend 1 English Bolt Grade 2 Strength Class 4 English Bolt Grade 8 Strength Class 2 English Bolt Grade 5 Strength Class 5 Metric Nut Strength Class 9 3 English Bolt Grade 7 Strength Class 6 Metric Bolts Strength Class Increases as Numbers Increase The most commonly used metric fastener strength metric standards of countries other than the United property classes are 9 8 and 10 9 The class identifica States and may exhibit the following defects tion is embossed on the head of each bolt The En glish inch strength classes range from g
113. front cover 3 Remove the gasket 4 Discard the gasket 5 Remove the oil seal from the front cover Clean the engine front cover in solvent 7T Inspect the engine front cover for damage to the gasket surface or the oil seal surface 1 25 VE128 3L VE031 3L 1 26 Engine Mechanical Industrial 3 0L Measuring Crankshaft and Camshaft Sprocket Runout Tools Required J 8001 Dial Indicator 1 Usethe J 8001 in order to measure the crankshaft and camshaft sprocket runout Refer to Engine Mechanical Specifications 2 Ifthe sprocket runout exceeds specifications clean and remove any burrs from the shaft or replace the sprocket Measuring Timing Sprocket Teeth Backlash Tools Required J 8001 Dial Indicator 1 Usethe J 8001 in order to measure the backlash between the timing sprocket teeth 2 Referto Engine Mechanical Specifications Crankshaft Sprocket Removal Tools Required 1699F J 6978 Crankshaft Sprocket Puller 1 Use the J 6978 in order to remove the crankshaft sprocket 2 Ifnecessary remove the crankshaft keys VE034 3L Industrial 3 0L Camshaft Removal 1 Remove the two camshaft retainer bolts working through the holes in the camshaft sprocket Important All camshaft journals are the same diameter so care must be used in removing the camshaft to avoid damage to the bearings 2 Carefully rotate and pull the camshaft out of the bearin
114. g Is the radiator clogged System Flushing Go to Step 10 Check the engine block Go to Cooling Is the engine block clogged System Flushing Go to Step 11 Check for bubbles in the coolant Are there bubbles in the coolant Perform a Compression Test Refer to Engine Mechanical Were results OK Go to Step 12 Go to Step 13 Go to Engine Go to Step 13 Mechanical Go to Step 15 Go to Step 14 System OK System OK Check the water pump Does coolant flow 7 10 11 12 13 4 1 Replace the water pump Refer to Water Pump Replacement Does the engine still overheat 5 Check the radiator fan Is the radiator fan operating normally Check for any of the following conditions that may contribute to the engine overheating An overloaded condition Excess engine oil Blocked air flow through the radiator Extreme air temperatures Does the engine still overheat _ SQ Replace the radiator fan Refer to Cooling Fan Replacement Does the engine still overheat Industrial 3 0L Engine Cooling 2 5 Loss of Coolant vae ves wo 1 Pressure test the cooling system and visually check the system for a coolant loss Check the ground under the equipment Is there coolant on the ground Go to Step 2 2 Check the radiator for stains and wetness Is the radiator wet or stained Go to Step 3 Go to Step 4 3 Repair or replace the radiator as necessary Use any of the following procedures Refer to Radiator
115. g System Specifications for the cooling system capacity The filling may be slowed due to the thermostat being closed 5 Fill the cooling system to 13 mm 1 2 in below the fill line Engine Cooling 2 9 6 Start the engine and allow the cooling system to warm up When the thermostat opens the coolant level may drop If the level drops add coolant until the level is up to the top 7 Replace the radiator cap 8 Check the coolant level in the radiator surge tank if equipped Add coolant as needed Flushing Notice If the engine is damaged internally and a new engine assembly is installed make sure all foreign material is completely flushed out of the cooling system The oil cooler system should also be flushed out Failure to rid the oil or cooling system of debris can result in damage to the replacement engine Important Remove the thermostat before you flush the cooling system Various methods and equipment can be used in order to flush the cooling system If you use special equipment such as a back flusher follow the equipment manufacturer s instructions Cooling System Scale Removal In order to remove hardened scale a direct chemical action is necessary Add a flushing compound in a dissolved solution at the specified rate of 30 grams per liter 4 oz per gallon of radiator capacity to the coolant water Do this while the water is running Operate the engine for 15 minutes Then drain and flush the system with cl
116. g and Thrust Washer Removal Tools Required J 9534 Distributor Lower Bushing Remover J 6585 Slide Hammer 1 Install the J 9534 into the distributor lower bushing 2 Use the J 6585 in order to remove the bushing 3 Use adrift punch up through the bushing bore in order to drive the thrust washer if installed out of the bore 4 Clean the bushing bore in the cylinder block and inspect for burrs or damage VE057 3L Oil Filter Bypass Valve Removal and Installation 1 Check the spring and fiber valve for operation 2 Inspect for a cracked or broken valve 3 Use a screwdriver in order to pry the valve out 4 Use a 9 16 in thin wall deep socket in order to tap the new bypass valve in place VE058 3L Industrial 3 0L Cylinder Block Clean and Inspect 1 Clean the following areas The engine block in solvent removing all sludge dirt or debris Caution Wear safety glasses in order to avoid eye damage Dry the block with compressed air The gasket surfaces The coolant passages The oil passages The main bearing caps 2 Inspect the following areas The cylinder walls for excessive scratches gouging or ring ridge The coolant jackets for cracks The valve lifter bores for excessive scoring or wear The crankshaft bearing webs for cracks The gasket sealing surfaces for excessive scratches or gouging The oil passages for restrictions All threaded bolt holes for thread damage Cylinder Bore Measurements Too
117. ginal location referring to the table below Tighten the fastener within specifications 0 8 General Information Industrial 3 0L Prevailing Torque Specifications Metric Size Fasteners Application Metric English 4 lb in 4 lb in 7 lb in 12 Ib in 18 Ib in 27 Ib in 37 Ib in 62 Ib in 11 Ib in 21 Ib in 30 Ib in 50 Ib in 14 Ib in Prevailing Torque Specifications English Size Fasteners Application English Albin 5 Ib in 12 Ib in 16 lb in 21 Ib in 28 Ib in 37 Ib in 62 Ib in 0 562 in 23 Ib in 0 625 in 30 Ib in 0 750 in 49 Ib in Industrial 3 0L THREAD INSERTS Repair Procedure Tools Required General purpose thread repair kits These kits are available commercially Caution Wear safety glasses in order to avoid eye damage Important Refer to the thread repair kit manufacturer s instructions regarding the size of the drill and tap to use Avoid any buildup of chips Back out the tap every few turns and remove the chips 4962 1 Determine the size the pitch and the depth of the damaged thread If necessary adjust the stop collars on the cutting tool and tap to the required depth 2 Drill out the damaged threads Clean out any chips 3 Lubricate the tap with light engine oil Tap the hole Clean the threads General Information 0 9 4963 4 Thread the thread insert onto the mandrel of the installer Engage the tang of the insert onto the end of the mandrel Im
118. gs Crankshaft and Camshaft Sprocket Inspect The camshaft and crankshaft sprockets for wear One edge of worn teeth or that are no longer concentric The valley between worn teeth The keys and crankshaft keyways for wear Engine Mechanical 1 27 VE035 3L VE125 3L VE126 3L 1 28 Engine Mechanical Industrial 3 0L Timing Gear Oil Nozzle Removal 1 Remove the oil nozzle with pliers VE127 3L Piston Connecting Rod and Bearing Removal Tools Required J 5239 Connecting Rod Guide Tool J 24270 Ridge Reamer 1 Remove the ring ridge as following 1 1 Turn the crankshaft until the piston is at the bottom of the stroke 1 2 Place acloth on top of the piston 1 3 Use the J 24270 to remove the cylinder ring ridge 1 4 the crankshaft so the piston is at the top of the stroke 1 5 Remove the cloth 1 6 Remove the cutting debris VE036 3L Important Place matchmarks or numbers on the connecting rods and the connecting rod caps Upon removal of the piston and connecting rod assembly install the connecting rod caps to the matching connecting rods 2 Remove the connecting rod nuts 3 Remove the connecting rod cap 4 Remove the connecting rod bearings Keep bearings with the original connecting rod and connecting rod cap Wipe the oil from the bearings Wipe the oil from the crankpins VE037 3L Industrial 3 0L 5 UsetheJ 5239 in order to remove the connecting rod and the
119. gt DRIVER 3 LAMP 2 I VE112 3L VE113 3L VE114 3L 1 68 Engine Mechanical Industrial 3 0L 3 Install the cylinder head bolts finger tight Tighten Tighten the cylinder head bolts in sequence to 122 Nem 90 Ib ft GM 4 181 VE115 3L Valve Lifter Installation 1 Coatthe bottom of the valve lifters with prelube GM P N 1052365 or equivalent 2 Ifreusing the valve lifters install in their original location 3 Install the valve lifters Valve Rocker Arm and Pushrod Installation Important Be sure to keep parts in order Parts must be installed from where they were removed 1 Install the valve pushrods Be sure that the valve pushrods seat in the valve lifter sockets Industrial 3 0L 2 Install the following components 2 1 The valve rocker arms 3 2 2 The valve rocker arm balls 2 2 3 The valve rocker arm nuts 1 Adjust the valve rocker arm nuts as follows 3 1 Turn the crankshaft until the mark on the crankshaft pulley lines up with 0 on the timing tab and number 1 cylinder is at top dead center 3 2 Place fingers on the number 1 valves as the mark approaches 0 If the valves move as the mark approaches 0 the engine is on number 4 top dead center and should be rotated one more revolution in order to reach number 1 top dead center 3 3 With the engine at number 1 top dead center adjust the following valves The exhaust valves
120. he voltage above the specified value Go to Step 9 Go to Step 8 1 Recheck the connections that were made in Step 7 2 Correct the connections if they were reversed Go to Step 9 Caution Make sure that the load is completely turned 70A off before connecting or disconnecting the carbon pile load tester to the battery Otherwise sparking could ignite battery gasses which are extremely flammable and may explode violently 1 Prior to connecting a carbon pile load tester ensure that the load dial of the carbon pile tester is turned completely to the OFF position Connect the cable leads of the carbon pile tester to the battery terminals Start the engine and allow it to idle briefly Increase the engine speed to 2500 RPM While maintaining the engine speed at 2500 RPM increase the load until the generator output is within 10 amps of the rated output load test value given in Generator Usage As the load is increased is the generator capable of producing the rated output value load test current specified Replace or repair in Generator Usage within 10 amps Go to Step 10 the generator Maintain the engine speed at 2500 RPM and continue to 13 5 V to operate the generator at the load test value 15 1V Is the voltage within the specified value Generator OK Go to Step 11 1 Maintain the engine speed at 2500 RPM and continue 0 5 V to operate the generator at the load test value 2 Connect a digital multimeter between the generator output
121. how ALWAYS TEST AT Go to Step 33 Go to Step 21 BATTERY TERMINAL and then change to SELECT Go to Step 34 Go to Step 37 RATING Does the display read SELECT RATING For off equipment testing the display on the tester will show USE TERMINAL ADAPTERS and then change to SELECT RATING Does the tester display read SELECT RATING Does GOOD BATTERY appear on the J 42000 display Does GOOD RECHARGE appear on the tester display Does CHARGE amp RETEST appear on the tester display Does REPLACE BATTERY appear on the tester display Does BAD CELL REPLACE appear on the tester display Does SURFACE CHARGE DETECTED appear on the tester display Does SELECT TEMP appear on the tester display Does SYSTEM NOISE CHECK LOADS alternating with RETESTING appear on the tester display 13 Important Refer to the Battery Usage Chart or Equipment manufacturer s specifications for the correct rating for the original equipment OE battery If a battery with a lower cold cranking amperage CCA rating has been installed on the equipment the battery may not perform properly during the use of the vehicle even if the battery passes the test using the J 42000 tester 1 Use the scroll keys on the J 42000 tester to select the CCA rating on the battery label 2 Press the ENTER key on the tester TESTING will appear briefly on the display followed by the results of the test Are the results of the test displayed Go to Step
122. hr ad Inserts nce ener ern Ree n 0 9 Abbreviations and Their Meanings 0 9 Maintenance and Lubrication 0 15 Initial Start Up Maintenance 0 15 Routine Maintenance 0 15 Scheduled Preventive Maintenance 0 15 Engine Oil Level Check oo ceteris 0 15 Adding Engine Oil erie 0 15 Engine Oil and Filter 0 15 Engine Oil Quality seem 0 15 Engine Oil 0 15 Oil EG idi e e rr 0 16 Engine Air Cleaner sessirnar 0 16 Safety El ment eee 0 16 Cooling System Maintenance 0 16 Coolant Level td rete 0 16 Radiator itecto gr rais 0 17 Radiator HOSES n nin eter 0 17 Fan Belts pter etat ah 0 17 Serpentine Bell rete e 0 17 V Type Belt itte 0 17 Fuel Delivery System Maintenance 0 17 Fuel Filter Replacement 0 17 Carbureted Engines 0 17 TBI Engines nee 0 17 Zenith Z E E M S TBI Fuel Injection 0 17 Ignition Systems uo 0 18 Types of Ignition 0 18 Ignition T M N 205 4 na 0 18 Spark Plugs ec rite men 0 18 Maintenance Schedule 3 0L Engine
123. hroud Industrial 3 0L Fan Guard Replacement Removal Procedure 1 Disconnect the upper radiator hose from the radiator Refer to Radiator Hose Replacement 2 Remove the fan guard mounting bolts and washers 3 Remove the fan guard Installation Procedure 1 Position the fan guard over the cooling fan blades Notice Refer to Fastener Notice 2 Install the fan guard mounting bolts and washers Tighten Tighten the fan guard mounting bolts to 16 20 Nem 12 15 Ib ft 3 Connect the upper radiator hose to the radiator Refer to Radiator Hose Replacement 4 Fillthe cooling system Refer to Draining and Filling Cooling System Coolant Thermostat Replacement Removal Procedure 1 Drain the cooling system Refer to Draining and Filling Cooling System 2 Remove the upper radiator hose from the thermostat housing Refer to Radiator Hose Replacement Remove the two thermostat housing bolts 1 Remove the coolant thermostat housing 2 Remove the coolant thermostat 3 and gasket 4 Discard the coolant thermostat gasket 4 ee Engine Cooling 2 13 79362004 79362004 79362005 2 14 Engine Cooling Industrial 3 0L 79362005 79362005 79362005 Installation Procedure 1 Install the coolant thermostat 3 coolant thermostat housing 2 and a new gasket 4 onto the coolant inlet housing 5 Notice Refer to Fastener Notice 2 Install the two coolant thermostat housi
124. indicates a high or low voltage condition Turn off any electrical loads Start the engine and let it idle briefly Use a digital multimeter to measure the voltage from the battery positive terminal to the battery negative terminal Compare the digital multimeter voltage with a simultaneous reading of the voltmeter gauge in the instrument cluster Is the difference in voltage more than the specified value Perform the charging system check and make any repairs indicated by the charging system check Refer to Charging System Check Is the charging system OK 3 While the engine is operating does the voltmeter gauge indicate a higher than normal voltage Locate and repair the high resistance connection in the RED wire between the generator S terminal and the starter solenoid B terminal Is the repair complete 1 Turn the ignition switch to the RUN position engine not running 2 Measure the voltage at the power side of the fuse in the instrument panel Is the voltage lower the specified value Repair the high resistance or intermittent open circuit on fuse between the alternator S terminal and the power side of the fuse Is the repair complete Repair the high resistance or intermittent open circuit between the voltmeter gauge and the fuse Is the repair complete Go to Volt Gage Inaccurate or 1V Inoperative Go to Step 2 Nl Go to Step 3 System 12V Go to Step 6 Go to Ste
125. ircuit is grounded out Cold engine piston knock which disappears in 1 5 minutes should be considered acceptable Knocks on Start Up but Only Lasts a Few Seconds Improper oil viscosity Install recommended oil viscosity for expected temperatures Excessive piston to bore clearance Excessive piston pin to piston clearance Excessive crankshaft end clearance Excessive crankshaft bearing clearance Knocks at Idle Hot Detonation or spark knock Check operation of ignition controls or knock sensor circuit Loose flywheel bolts Exhaustleak at manifold Tighten the exhaust manifold bolts and or replace the gasket Excessive connecting rod bearing clearance Replace the bearings as necessary Excessive piston pin clearance Excessive crankshaft thrust bearing clearance Bentconnecting rod Valve Train Diagnosis A light tapping at one half engine speed or any varying frequency can indicate a valve train problem These tapping noises increase with engine speed Before attempting to judge the valve train noises thoroughly warm up the engine By doing this you will bring all engine components to a normal state of expansion Also run the engine at various speeds and listen for engine noise The causes of the valve train noise include the following conditions Incorrectly adjusted valve lash Low oil pressure Loose valve rocker arm attachments Worn valve rocker arm and or pushrod Brok
126. is operating properly If there is coolant flow after the mark begins to melt the problem is caused by something other than a faulty thermostat A temperature stick is a pencil like device that has a wax material containing certain chemicals These chemicals melt at a certain temperature Use a temperature stick in order to determine a thermostat s operating temperature by rubbing the 86 6 C 188 F and the 96 6 C 206 F sticks on the thermostat housing The marks made by the sticks should melt when the coolant temperatures of 86 6 C 188 F to 96 6 C 206 F are reached These temperatures are the normal operating range of the thermostat If the coolant flows as indicated in the preceeding procedures the thermostat is considered to be operating properly Engine Fails to Reach Normal Operating Temperature wes v m DEFINITION The engine fails to reach the normal operating temperature of 86 6 C 188 F to 96 6 C 206 F 1 Check the thermostat Is the thermostat stuck open or was the wrong type of thermostat previously installed Go to Step 2 2 Replace the thermostat Is the problem corrected System OK Industrial 3 0L Coolant Concentration Testing Hydrometer Due to changes in commercially available anti freeze the use of a hydrometer may give an incor rect reading The hydrometer should be used to test an ethylene glycol based antifreeze only Ethylene glycol based antifreeze is recommended for year round use
127. ker arms and ball at the mating surfaces These surfaces should be smooth and free of scoring or other damage The valve pushrod sockets and valve stem mating surfaces These surfaces should be smooth with no scoring or exceptional wear The valve pushrods for bends or scored ends Valve Lifter Removal Tools Required e J 3049 Valve Lifter Remover Plier Type e J 9290 01 Valve Lifter Remover Slide Hammer Type 1 Usethe J 3049 in order to remove the valve lifters J 3049 A 2 Ifthe valve lifters cannot be removed with the J 3049 use the J 9290 01 in order to remove the valve lifters VEO25 3L 1 24 Engine Mechanical 2 3 4 Industrial 3 0L Cylinder Head Removal 1 Notice After removal place the cylinder head on two wood blocks to prevent damage 2 Remove the cylinder head 3 Remove the gasket 4 Discard the gasket Remove the cylinder head bolts Oil Pan Removal 1 Remove the oil pan bolts Remove the oil pan Remove the gasket Discard the gasket Oil Pump Removal 1 Remove the bolts that attach the oil pump to the engine block Remove the oil pump and gasket Discard the gasket Industrial 3 0L Oil Level Indicator and Tube Removal 1 Remove the oil level indicator from the tube 2 Use a drift punch in order to remove the oil level indicator tube from the engine block Engine Front Cover Removal 1 Remove the engine front cover bolts 2 Removethe engine
128. l at 34 to 172 inches below the filler neck seat of the radiator when the coolant is cold When ever coolant level checks are made inspect the condition of the radiator cap rubber seal Make sure it is clean and free of any dirt particles which would keep it from seating on the filler neck seat Rinse off with clean water if neces sary Also make sure that the filler neck seat is free of any dirt particles Caution Never remove the radiator cap under any conditions while the engine is operating Failure to follow these instruction could result in damage to the cooling system engine or cause personal injury To avoid having scalding hot coolant or steam blow out of the radiator use extreme caution when removing the radiator cap from a hot radiator If possible wait until the engine has cooled then wrap a thick cloth around the radiator cap and turn slowly to the first stop Step back while the pressure is released from the cooling system When all the pressure has been released press down on the cap and remove it slowly Notice DO NOT add coolant to any engine that has become overheated until the engine cools Adding coolant to an extremely hot engine can result in a cracked block or cylinder head Industrial 3 0L General Information 0 17 Coolant Level Continued Use only a permanent type coolant when refilling or flushing the coolant system Recommended ethylene glycol mix 52 48 is normal up to a maximum of 60 glycol 40 water Refer to
129. leaks Engine Cooling 2 17 79362010 79362006 79362006 2 18 Engine Cooling Industrial 3 0L Description and Operation Cooling System Description Cooling System This equipment has a pressure type engine cooling system The system has thermostatic control of the coolant circulation The cooling system is sealed by a pressure type radiator cap The cap causes the system to operate at a pressure higher than atmospheric pressure The high pressure operation raises the boiling point of the coolant which increases the cooling efficiency of the radiator The 104 kPa 15 psi pressure cap raises the boiling point of the coolant to about 125 C 257 F at sea level Engine Coolant Always fill the system with ethylene glycol based coolant to the radiator Do not pre mix the coolant and water Fill the remainder of the radiator with clean drinkable water in order to equal a 52 48 mix Refer to the mixture chart on the container for additional antifreeze protection information DO NOT use alcohol or methanol based antifreeze or mix them with the specified coolant Notice Antifreeze can be added to raise the boiling point of the coolant but too much will affect the freezing point Do not use a solution stronger than 60 percent glycol 40 percent water as the freeze level rises rapidly after this point Pure antifreeze will freeze at 22 C 8 F Approximate values Uncommon Cooling System Problems The following p
130. ls Required J 8087 Cylinder Bore Gauge 1 Usethe J 8087 in order to check cylinder bore taper and out of round as follows 1 1 1 2 1 3 1 4 Set the gauge so that the thrust pin must be forced in about 1 4 in to enter the gauge in the cylinder bore Center the gauge in the cylinder and turn the dial to 0 Work the gauge up and down to determine the taper Turn the gauge to different point around the cylinder to determine the out of round condition Refer to Engine Mechanical Specifications Engine Mechanical 1 39 VE059 3L VE060 3L 1 40 Engine Mechanical Industrial 3 0L Cylinder Boring and Honing 5 Boring Procedure 1 Before you start the honing or reboring process measure all new pistons with the micrometer contacting at points exactly 90 from the piston pin centerline Refer to Piston Selection Select the smallest piston for the piston fitting Slightly varied pistons in a set may provide correction in case the first piston is too loosely fitted Before you use any type of boring bar file the top of the cylinder block in order to remove any dirt or burrs If you do not check the cylinder block the boring bar may be tilted this could result in the rebored cylinder wall being at incorrect right angles from the crankshaft Carefully follow the instructions furnished by the manufacturer regarding the use of the equipment 9 When you rebore cylinders make sure all crank
131. lt is too long or misformed at the end There is foreign material present inside the nut in the battery terminal Damage to the battery terminal face or cable connector ring i Is the repair complete Go to Step 9 Clean and wire brush the lead face of both battery terminals and the metal contact rings in both cable connectors Remove the bolts from the cable connectors in order to provide access to the connector rings as needed If either the battery terminals or the cable rings excessively damaged or corroded replace as needed Are the metal connecting parts clean and in good condition Go to Step 10 3 20 Engine Electrical Industrial 3 0L Battery Terminal Check cont d vals 1 Connect the positive battery cable to the battery 12 Nem positive terminal 2 Tighten the cable bolt to the specified value Is the cable bolt properly tightened 106 Ib in Go to Step 11 1 Connect the negative battery cable to the battery 12 Nem negative terminal 2 Tighten the cable bolt to the specified value 106 Ib in Battery Terminals Is the cable bolt properly tightened Battery Not Operating Properly Notice Always turn the ignition switch OFF when connecting or disconnecting batteries battery chargers or jumper cables Failure to do so may damage the electronic control unit or other electrical components Important The battery test using the J 42000 Battery Tester
132. lve adjustment Industrial 3 0L Engine Mechanical 1 77 Lubrication Caution Wear safety glasses in order to avoid eye The oil pump is gear driven from the camshaft Oil is drawn Gamage from the oil through a pickup screen and tube The 1 Determine the size pitch and depth of the damaged gear type oil pump has a pressure regulator valve which thread If necessary adjust the stop collars on the controls the lubrication system pressure by bypassing cutting tool and tap to the required depth excess oil back to the oil pan sump 2 Drill out the damaged thread Clean out any chips Pressurized oil from the oil pump flows to the full flow filter 3 Avoid any buildup of chips Back out the tap every A bypass valve allows oil to bypass the filter if it becomes few turns and remove the chips clogged or restricted Oil then flows into an oil passage that 4 Tap the hole Lubricate the tap with light engine oil runs along the right side of the block and intersects the Clean the thread lifter bosses Oil from this passage is routed to the crankshaft main bearings and camshaft bearings through smaller drilled passages Oil is supplied to the connecting rod bearings by holes drilled in the crankshaft Oil is supplied to the rocker arms through holes in the hydraulic lifters which feed oil up the pushrods to the rocker arms The oil is metered by discs under the pushrod seat Many internal engine parts have no direct oil feed and are supplied by
133. m 106 Ib in Tighten the top terminal nuts if applicable to 18 Nem 13 lb ft 4 Install the negative battery cable to the battery Tighten Tighten the battery side terminal bolts if applicable to 12 Nem 106 Ib in Tighten the top terminal nuts if applicable to 18 Nem 13 lb ft 5 Install the battery cable routing ties if applicable Industrial 3 0L Battery Charging Basic Rules When charging the battery follow these basic rules e Use a charger with an end of charge voltage of 16 0 volts The charger should have a voltme ter that is accurate within 1 percent e Ambient temperature should be 15 38 60 100 F An extremely cold battery may not accept measurable current after several hours of charging charging area should be well ventilated On batteries with a built in hydrometer e Do not charge the battery if the built in hydrometer is clear or light yellow 8 If crank ing problems exist replace the battery e Do not charge a battery that seems to be frozen Replace the frozen battery Abattery with a green dot showing in the hydrometer 1 does not require charging unless the battery has been discharged such as from cranking Charging Procedure Caution Refer to Battery Cautions on page 3 17 Notice Always turn the ignition OFF when connecting or disconnecting battery cables battery chargers or jumper cables Failing to do so may damage the Electronic Control Module ECU or o
134. m surface finish marks in a cross hatch pattern at 45 65 degrees The finish marks should be clean but not sharp The finish marks should be free from imbedded particles and torn or folded metal By measuring the piston to be installed at the sizing point specified and by adding the average of the clearance specification you can determine the finish hone cylinder measurement Refer to Engine Mechanical Specifications Measure the block and the piston at normal room temperature True up the refinished cylinder bores to have less than the specified out of round or taper You must final hone each bore in order to remove all stone or cutter marks and in order to provide a smooth surface For piston to bore tolerance specifications Refer to Engine Mechanical Specifications After final honing and before the piston is checked for fit clean the bores with hot water and detergent Scrub the bores with a stiff bristle brush and rinse the bores thoroughly with hot water Do not allow any abrasive material to remain in the cylinder bores This abrasive material will wear the new rings the cylinder bores and the bearings lubricated by the contaminated oil After you wash the bore brush the dry bore clean with a power driven fiber brush Permanently mark the piston for the cylinder to which the piston has been fitted Apply clean engine oil to each bore in order to prevent rusting Industrial 3 0L Distributor Lower Bushing and Thrust
135. meter check for continuity between the armature shaft and any point on the commutator Continuity indicates a ground Inspect the points where the armature conductors join the commutator for signs of arcing or burning These signs indicate opens Armature Bearing Replacement Notice Ball bearings that are removed from the armature must be replaced with new bearings The removal proce dure causes internal damage to the bearings Removal Procedure Remove the commutator end or drive end bearings from the armature assembly using a suitable bearing puller Installation Procedure 1 Install the new commutator end and or drive end bearings to the armature assembly using a tube that bears only on the bearing inner race 2 Press on the bearing until the inner race bottoms out against the shoulder of the armature shaft 3 50 Engine Electrical Industrial 3 0L Starter Motor Replacement Removal Procedure Notice Never operate the starter motor more than 15 seconds at a time without pausing to allow itto cool for at least 2 minutes Overheating caused by excessive cranking will damage the starter motor Starter motors do not require lubrication except during overhaul Caution Refer to Battery Cautions on page 3 13 1 Disconnect the negative battery cable 2 Disconnect the wires and the positive battery cable from the starter solenoid 3 Remove the two mounting nuts the mounting bolt and the starter rear bracket 4
136. n access to the generator the drive belt and the brackets Caution Failure to observe Step 1 in this proce dure may result in an injury from the live battery lead at the generator Caution Refer to Battery Disconnect Caution in Cautions and Notices 1 Disconnect the negative battery cable 2 Disconnect the electrical connectors from the generator 3 Disconnect the battery lead from the back of the generator Disconnect the generator ground wire 5 Remove the drive belt Refer to Drive Belt Re placement in Engine Mechanical 6 Remove the upper generator mounting bolt 7 Remove the lower generator mounting bolt and nut 8 Remove the generator from the generator mount ing bracket gt Installation Procedure 1 Install the generator into the generator mounting bracket Notice Refer to Fastener Notice on page 3 2 2 Install the generator mounting bolts Tighten Tighten the top mounting bolt to 50 Nem 37 Ib ft Tighten the bottom mounting bolt and nut to 50 Nem 37 Ib ft 3 Install the drive belt Refer to Drive Belt Heplace ment in Engine Mechanical 4 Install the generator ground wire 5 Connect the electrical connectors to the generator 6 Connect the battery lead to the back of the generator Tighten Tighten to battery terminal nut to 8 Nem 71 Ib in 7 Connect the negative battery cable to the battery Tighten Tighten the battery side terminal bolts if appli cable to 12 Nem 106 Ib in
137. n pressure testing the cooling system Pressures over 138 kPa 20 psi will damage the radiator J24460 01 Some core leaks are detected by adding water to the radiator Clean the core using the following procedure so that the damaged area can be found 11658 E ue 1 2 n i Pressure test the radiator with the J 24460 01 While the nozzle Excessive water pressure could damage system is at a cool temperature remove the radiator cap the fins Connect the gauge and apply the normal system operating a pressure Do not exceed 138 kPa 20 psi Watch the er SETUD MIE core nha Seile Brust using gauge needle for an indication of a leak Examine the CEAN vig deer radiator and other cooling system parts for escaping gent coolant Repair the hose and the hose connections as required Check the radiator cap in order to ensure that the cap will maintain the correct pressure If the radiator leaks during the pressure test mark the leak area Industrial 3 0L Repair Instructions Draining and Filling Cooling System Draining Procedure Caution The radiator cap should be removed from a cool engine only If the radiator cap is removed from a hot cooling system serious personal injury may result Caution As long as there is pressure in the cooling system the temperature can be consider ably higher than the boiling temperature of the solution in the radiator without causing the solution to boil Removal of
138. nd Metric cont d Arrows and Symbols This service manual uses various symbols in order to Fraction in describe different service operations You may find 33 64 some or all of these symbols used in the manual 17 32 35 64 9 16 37 64 19 32 39 64 5 8 41 64 21 32 43 64 11 16 45 64 23 32 47 64 3 4 49 64 25 32 51 64 3 16 53 64 21 32 55 64 7 8 57 64 196216 Industrial 3 0L General Information 0 5 Engine ID Location In addition the GM serial number is stamped on the An identification label is affixed to the right side of the right side of the cylinder block just to the rear of the engine on the rocker cover when looking at the engine distributor from the flywheel end 79300003 79300001 FASTENERS The engine serial number is also stamped into the left side of the cylinder block near the engine flywheel The Metric Fasteners label contains the engine model number i e 3 0L 4 3L 5 7L etc and a serial number which identifies the engine from other GM Powertrain engines provided by Power Solutions Inc The engine model and serial number are required when seeking information con cerning the engine and or ordering replacement service parts The 3 0L engine is dimensioned in the metric system Most metric fasteners are very close in diameter to well known fasteners in the English inch system Replace fasteners with those of the same nominal diameter thread pitch and strength A number marking identi
139. nditions Cracked ring lands skirts or pin bosses Nicks or spurs in the grooves that may cause binding Warped or worn ring lands Scuffed or damaged skirts Eroded areas at the top of the piston Worn piston bores and piston pins 9 Replace pistons that are damaged or show signs of excessive wear VE066 3L Industrial 3 0L 10 Measure the pin bore to piston clearance 10 1 The piston pin bores and the piston pins must be free of varnish or scuffing when being measured 10 2 Use a micrometer in order to measure the piston pin 10 3 Use an inside micrometer in order to measure the piston pin bore Replace the piston and piston pin if the clearance is in excess of 0 0254 mm 0 001 in 10 4 Match the piston and piston pin Do not service separately 11 Measure the piston compression ring end gap Important Fit each compression ring to the cylinder in which it will be used 11 1 Place the compression ring into the cylinder bore 11 2 Push the compression ring into the cylinder bore approximately 6 5 mm 0 25 in above the ring travel The ring must be square to the cylinder wall 11 3 Use a feeler gauge in order to measure the end gap 11 4 Select another size ring set if the end gap exceeds specifications Engine Mechanical 1 43 VE067 3L VE069 3L 1 44 Engine Mechanical Industrial 3 0L 12 Measure the piston ring side clearance 12 1 Rollthe piston ring entir
140. nector with a digital 10V multimeter from the generator BAT terminal to ground 3 Measure the voltage Does the voltage measure less than 10 volts Locate and repair the open in the WHITE wire between the starter solenoid S terminal and the generator BAT terminal Is the repair complete 1 Probe the generator connector with a digital multimeter from cavity S to ground 2 Measure the voltage Does the voltage measure less than 10 volts Locate and repair the open in the RED wire between the Turn the ignition switch to the RUN position Probe the generator connector with a digital multimeter from cavity to ground 3 Measure the voltage Does the voltage measure less than 10 volts Locate and repair the open in the YELLOW wire between the terminal on the ignition switch and the generator connector cavity I Is the repair complete Turn the ignition switch to the OFF position Connect the generator connector Start the engine Run the engine at fast idle Probe the battery with a digital multimeter from the positive terminal to the negative terminal 6 Measure the voltage Does the voltage measure between 13 16 volts 1 Do a Generator Bench Test Refer to Generator Assembly Bench Check 2 If the generator is OK do a battery load test Refer to Battery Not Operating Properly Is the repair complete generator BAT terminal and the generator connector cavity S Is the repair complete Sy
141. ner filters air entering the engine intake system and acts as a silencer and flame arrester when assembled to the intake system Air that contains dirt and grit produces an abrasive fuel mixture and can cause severe damage to the cylinder walls and piston rings Damage to the cylinder walls and piston rings will cause high oil consumption and shorten engine life A restricted or dirty air cleaner will also cause a rich fuel mixture Thus it is extremely important that the air cleaner be serviced properly at the recommended intervals CAUTION Service the air cleaner more frequently under severe dusty or dirty conditions Remove the primary air cleaner element from the air cleaner assembly and inspect the element for foreign material restrictions or signs of excessive wear or damage Replace the element if necessary Remove all dust and foreign matter from the air cleaner housing Reinstall the air cleaner element Reinstall the air cleaner cup and securely fasten the retaining clips Safety Element If your engine is equipped with an air cleaner which utilizes a safety element ensure that the element is properly in place before installing the primary element Change the safety element annually COOLING SYSTEM MAINTENANCE Coolant Level Check the coolant level of the radiator daily and only when the engine is cool Generally a good time to do this is just prior to starting the engine for the first time each day Maintain the coolant leve
142. ng bolts 1 Tighten Tighten the thermostat housing bolts to 24 31 Nem 18 23 lb ft 3 Connect the upper radiator hose to the coolant thermostat housing 2 Refer to Radiator Hose Replacement 4 Fill the cooling system Refer to Draining and Filling Cooling System Coolant Thermostat Housing Replacement Removal Procedure 1 Drain the cooling system Refer to Draining and Filling Cooling System 2 Remove the upper radiator hose from the thermostat housing Refer to Radiator Hose Replacement Remove the two thermostat housing bolts 1 Remove the coolant thermostat housing 2 Remove the coolant thermostat 3 and gasket 4 Discard the coolant thermostat gasket 4 HER D 65 Installation Procedure 1 Install the coolant thermostat 3 coolant thermostat housing 2 and a new gasket 4 onto the coolant inlet housing 5 Notice Refer to Fastener Notice 2 Install the two coolant thermostat housing bolts 1 Tighten Tighten the thermostat housing bolts to 24 31 Nem 18 23 Ib ft 3 Connect the upper radiator hose to the coolant thermostat housing 2 Refer to Radiator Hose Replacement 4 Fill the cooling system Refer to Draining and Filling Cooling System 5 Start the engine and check for leaks Industrial 3 0L Engine Cooling 2 15 Coolant Inlet Housing Replacement Removal Procedure 1 D Qo Seb OY BG Installation Procedure 1 Notice Refer to Fastener Notice 2 Tighten Tight
143. nkshaft bearing cap bolts 2 Remove the crankshaft bearing caps VE045 3L 3 Install gauging plastic 1 onto the crankshaft journal Install the gauging plastic the full width of the crankshaft bearing journal 4 Install the bearing bearing cap and bolts Tighten Tighten the crankshaft bearing cap bolts to 88 Nem 65 Ib ft VE045 3L 1 36 Engine Mechanical VE053 3L 10 Industrial 3 0L Remove the crankshaft bearing cap bolts Remove the crankshaft bearing caps Measure the gauging plastic at its widest area using the scale supplied with the plastic gauging kit Compare the measurements to Engine Mechanical Specifications If the gauging plastic shows irregularity in the journal exceeding 0 025 mm 0 001 in remove the crankshaft and measure the journal with a micrometer If the clearance is greater than Engine Mechanical Specifications select and install an undersized bearing set Measure the clearance with gauging plastic If clearance cannot be brought to specifications grind the crankshaft for use with the next undersized bearing Use a dial indicator or feeler gauge in order to measure end play between the front of the rear of the crankshaft bearing cap and the crankshaft thrust surface in order to determine the crankshaft end play If you use a feeler gauge measure between the thrust surface of the crankshaft bearing and the crankshaft Refer to
144. not attempt to install an oversize stud without reaming the stud hole VE101 3L Industrial 3 0L Engine Mechanical 1 59 3 Coat the press fit area of the stud with Perfect Seal 4 Install the new stud using J 6880 as a guide VE102 3L Cylinder Head Assemble Tools Required J 8062 Valve Spring Compressor Install the valve 788 into the proper port Lubricate oil seal 5 with clean engine oil Install the oil seal onto the valve stem Install the valve spring 4 Install the valve stem oil shield 3 Install the cap on the valve spring 2 amp Oar gt VE090 3L 1 60 Engine Mechanical Caution 8 1 VE089 3L 8 2 8 3 Industrial 3 0L Wear safety glasses in order to avoid eye damage 7 Use the J 8062 in order to compress the valve spring 8 Install the valve stem keys Use grease to hold the keys in place while disconnecting the J 8062 Make sure that the keys seat properly in the upper groove of the valve stem Tap the end of the valve stem with a plastic faced hammer in order to seat the keys if necessary Service Prior to Assembly 2 Co Dirt or debris will cause premature wear of the rebuilt engine Clean all components Refer to Cleanliness and Care Use the proper tools to measure components when checking for excessive wear Components that are not within the manufacturers specifications must be repaired or replaced When components ar
145. o check the voltage between the generator output BAT terminal and the generator metal Go to step 6 Go to Step 3 Is the voltage above the specified value Use a digital multimeter to check the voltage between the battery terminals Go to Step 5 Go to Step 4 Go to Step 7 Is the voltage above the specified value 1 Inspect the battery Refer to Battery Not Operating Properly 2 Charge or replace the battery if necessary Is the battery OK Repair the loose connection or open circuit between the battery negative terminal and the generator housing Is the repair complete 1 Inspect the circuit between the generator output terminal and the battery positive terminal for a loose connection or open circuit condition 2 If a loose connection or open circuit was located repair it Is the circuit okay between the generator output terminal and the battery positive terminal Go to Step 6 Industrial 3 0L Engine Electrical 3 29 Generator Not Operating Properly cont d ep vmm vm no Disconnect the negative battery cable from the battery 12V Disconnect the battery white wire from the generator battery terminal Connect the red ammeter lead to the generator battery terminal and the black lead to the generator battery white wire terminal Re connect the negative battery cable to the battery Observing polarity connect the voltmeter leads to the positive and negative battery terminals Is t
146. o the starter motor s mechanical ground The combined magnetic force of the coil windings overcomes the force of the return spring to pull in and hold in the plunger The plunger moves the shift lever This causes the drive assembly to engage with the engine flywheel The plunger actuation also operates a contact within the starter solenoid which closes to apply battery voltage directly to the starter motor The starter motor now cranks the engine With battery voltage applied directly to the starter motor the pull in coil now has voltage applied to both ends of the coil and current ceases to flow The starter solenoid remains engaged due to the current flow through the hold in coil alone The starter motor continues to operate until the ignition switch is returned to the RUN position With the ignition switch in the RUN position voltage is removed from the starter solenoid S terminal Voltage is applied at the solenoid B terminal so both coils are still energized by battery voltage through the closed motor contacts However the forces from these coil windings now oppose one another and the plunger returns to the disengaged position through the opera tion of the return spring This opens the contact within the solenoid to remove battery voltage from the starter motor and the motor stops Both coils also de ener gize This plunger operation also retracts the starter drive assembly from the flywheel and the engine operates on its own power
147. o to este 38 Repair or replace the tester Is the action complete O Go to Step 1 39 A problem exists with the battery s built in hydrometer if applicable Replace the battery Refer to Battery Replacement System OK Is the action complete Battery Electrical Drain Parasitic Load Current Drain Test If the equipment exhibits a low or dead battery after an overnight period or discharges over a period of 2 or 3 days and no cause is evident the electrical system should be checked for an excessive electrical drain The cause of the excessive unintended current drain is referred to as a parasitic load One or more on board solid state control modules such as the ECU may at some time exhibit a failure mode that causes a high parasitic drain on the equipment s battery Another source of parasitic drain could be an unnoticed load which remains on at all times Testing for a parasitic drain requires a special tool because the excessive current drain may not occur after the battery is disconnected to install an ammeter Cycling the ignition key to the RUN and then to the OFF position may cause such a drain to recur but there may be drains that will not recur unless the equipment systems are reactivated in a use test The ignition switch must not be rotated to the START position with an ammeter installed between the battery terminal and the battery cable but the special tool enables the equipment to be run to assure that all equi
148. of many machined honed polished and lapped surfaces with tolerances that are measured in millimeters or thousandths of an inch These surfaces should be covered or protected to avoid component damage A liberal coating of clean engine oil should be applied to friction areas during assembly Proper lubrication will protect and lubricate friction surfaces during initial operation Replacing Engine Gaskets 1 Gasketreuse and applying sealants Do not reuse any gasket unless specified Gaskets that can be reused will be identified in the service procedure Do not apply sealant to any gasket or sealing surface unless specified in the service procedure 2 Separating components Use a rubber mallet to separate components Bump the part sideways to loosen the components Bumping should be done at bends or reinforced areas to prevent distortion of the parts 3 Cleaning gasket surfaces Remove all gasket and sealing material from the part using a plastic or wood scraper if required Care must taken to avoid gouging or scraping the aluminum sealing surfaces Do not use any other method or technique to remove sealant or gasket material from a part Do not use abrasive pads sand paper or power tools to clean gasket surfaces These methods of cleaning can cause damage to the component sealing surfaces Abrasive pads also produce a fine grit that the oil filter cannot remove from the oil This grit is abr
149. of the remover on the table of a press and press the camshaft out of the gear Important The retainer must be positioned so that the woodruff key in the camshaft does not damage it when the camshaft is pressed out of the gear Also support the hub of the gear or the gear will be seriously damaged Installation 1 Install the camshaft sprocket retainer and gear spacer ring to the camshaft as follows 1 1 Firmly support the camshaft at the back of the front journal in an arbor press 1 2 Place the gear spacer ring and retainer over the end of the camshaft and install the woodruff key in the camshaft keyway 1 3 Align the sprocket keyway with the woodruff key in the camshaft and press it onto the shaft until it bottoms against the gear spacer ring Industrial 3 0L Engine Mechanical 1 49 Camshaft Bearing Installation Tools Required J 6098 01 Camshaft Bearing Installer Important Aloose camshaft bearing may be caused by an J 6098 01 enlarged out of round or damaged engine block bearing bore The outer front and rear camshaft bearings must be installed first These bearings serve as guides for the tool pilot and help center the inner bearings during the installation process The camshaft bearing oil holes must align with the oil galleys in the engine block An improperly aligned camshaft bearing oil galley hole will restrict oil flow to the bearing and camshaft journal 1 Usethe J 6098 01 in order to install the fron
150. oil ignition with a General Motors High Energy Ignition HEI distributor that features Electronic Spark Timing or EST The ignition system consists of the battery the distributor the ignition coil the ignition switch the spark plugs and the primary and secondary ignition wiring Ignition Switch The ignition switch Is mounted directly to the instru ment panel and has three terminals The B bat tery terminal is connected directly to the battery and is hot at all times The I ignition terminal is hot when the switch is in the RUN or START positions This terminal provides current to the ignition system and the engine electrical components such as the gauges and the generator field circuit The S terminal is hot in START only It provides current to energize the starter solenoid allowing the starter motor to operate Ignition Coil The external ignition coil is mounted to the right hand side of the cylinder head Battery voltage is avail able at the primary ignition terminal of the coil anytime the ignition switch is in the RUN or START position The secondary circuit is connected to the rotor by a high tension wire It is controlled by pulses provided by the distributor The primary side of the coil has a tach output terminal This terminal is not used for most PSI applications Distributor The distributor connects the ignition secondary current from the ignition coil to the spark plugs th
151. ol solution at 12 C 10 F below the temperature indicated on the valve The valve will close when you submerge the valve and agitate the coolant Use the following procedure to check for engine overheating boiling or poor engine cooling 1 Relieve the pressure and carefully remove the radiator cap 2 Rub a 96 6 C 206 F temperature stick on the thermostat housing 3 Warm up the engine at a fast idle Watch for coolant flow before the mark begins to melt f the coolant does not flow install a new thermostat Recheck the system in order to ensure the system is operating properly If there is coolant flow the problem is caused by something other than a faulty thermostat Replace the glycol The recommended ethylene glycol mix 52 48 is normal up to a maximum of 60 glycol 40 water Is there still a loss of coolant Thermostat Diagnosis 2 6 Engine Cooling Industrial 3 0L Thermostat Diagnosis Cont d Use the following procedure in order to check for a cold engine slow warm up or the engine does not reach normal operating temperature of 86 6 C 188 F to 96 6 C 206 F 1 Relieve the pressure and carefully remove the radiator cap 2 Rub a 86 6 C 188 F temperature stick on the thermostat housing 3 Warm up the engine at a fast idle Watch for coolant flow before the mark begins to melt If the coolant flows before the mark begins to melt install a new thermostat Recheck the system in order to ensure the system
152. ole facing up with a suitable light plastic or rubber hammer VE127 3L Crankshaft Sprocket Installation Tools Required J 5590 Crankshaft Sprocket Installer 1 Install the keys into the crankshaft keyways 2 Use the J 5590 in order to install the crankshaft sprocket VE107 3L Camshaft Installation Important If camshaft replacement is required the valve lifters must also be replaced 1 Carefully rotate and install the camshaft into the engine 2 Install the two camshaft retainer bolts working through the holes in the camshaft sprocket Be sure to align the camshaft and the crankshaft sprocket alignment marks Tighten Tighten the camshaft retainer bolts to 9 Nem 80 Ib in TIMING Industrial 3 0L Engine Mechanical 1 65 Engine Front Cover and Oil Seal Installation Tools Required J 35468 Engine Front Cover Aligner and Oil Seal Installer 1 Usethe J 35468 in order to install the engine front cover oil seal VE109 3L 2 Install the engine front cover gasket 3 Install the engine front cover and bolts Tighten Tighten engine front cover bolts to 3 4 Nem 30 Ib in VE030 3L 1 66 Engine Mechanical Industrial 3 0L Oil Pump Installation Important Inspect the oil pump and engine block oil galley passages These surfaces must be clear and free of debris or restrictions 1 Install the oil pump 2 Install the bolts that attach the oil pump to the engine block Tighten Tighten the oil
153. ooseness If the pipe is loose or has been removed from the screen the oil pump screen must be replaced The gears for chipping galling and wear Important If the drive gear and driveshaft are worn replace the entire oil pump The drive gear and driveshaft for looseness and wear 1 52 Engine Mechanical Industrial 3 0L Oil Pump Assemble Tools Required J 21882 Oil Suction Pipe Installer Important Replace the pressure relief valve spring when you reuse the oil pump 1 Install the following items The pressure relief valve 2 The pressure relief valve spring 3 The retaining pin 1 VE085 3L 2 Coat the drive gear the driven gear and the housing gear surfaces with clean engine oil 3 Install the drive gear 2 and the driven gear 1 into the pump body Align the matchmarks on the gears Install the smooth side of the gear toward the pump cover VE084 3L 4 Install the pump cover 5 Install the cover bolts Tighten Tighten the bolts to 8 Nem 72 Ib in VE083 3L Industrial 3 0L Engine Mechanical 1 53 6 Inspect the pump for smoothness of operation by turning the oil pump driveshaft by hand 7 Install the oil pump screen 7 1 If removed replace the oil pump screen The oil pump screen must have a good press fit into the oil pump body 7 2 Mountthe oil pump in a soft jawed vise 7 3 Apply sealer to the end of the pipe 7 4 Usethe J 21882 and a soft faced hammer in order
154. or excessive wear 5 Inspect the camshaft retainer plate for wear VE075 3L Industrial 3 0L 6 8 Inspect the camshaft bearings for proper fit in the engine block Camshaft bearings have an interference fit to the engine block and should not be loose in their engine block bearing bores Inspect the camshaft bearings for excessive wear or scoring Bearings with excessive wear or scoring must be replaced Measure the camshaft for out of round taper or undersize with a micrometer Refer to Engine Mechanical Specifications Support the camshaft front and rear journals on V blocks Measure the camshaft run out at the intermediate journal with J 7872 Refer to Engine Mechanical Specifications Replace camshaft if measurements are not within specifications Engine Mechanical 1 47 VE076 3L VE077 3L VE078 3L 1 48 Engine Mechanical VE079 3L UIID VE080 3L UTD VE081 3L Industrial 3 0L Camshaft Sprocket and Retainer Removal and Installation Removal Tools Required J 791 Camshaft Sprocket Remover 1 If the inspection indicated that the camshaft gear and retainer were in good condition the camshaft end play should be checked Refer to Engine Mechanical Specifications 2 Ifthe inspection indicated that the camshaft gear or retainer should be replaced the gear must be removed from the camshaft as follows 2 1 Place the camshaft through the J 791 2 2 Place the end
155. or cap contains a blow off or pressure valve The cap also contains a vacuum or atmospheric valve The pressure valve is held against its seat by a spring of predetermined strength This valve protects the radiator by relieving internal pressure when the internal pressure exceeds the cooling system design limits The vacuum valve is held against its cap seat by a light spring The spring permits the valve to open in order to relieve vacuum created in the system when the system cools The radiator cap is designed to discourage inadvertent removal In order to safely remove the cap from the radiator rotate the cap slowly in a counterclockwise direction to the detent Do not press down Allow any pressure to release from the radiator Press down on the cap Continue to rotate the cap counterclockwise and lift the cap off the radiator A gasket is under the diaphragm spring at the top of the cap Embossed on the cap is a caution against opening the cap Arrows indicating the proper closed position are also embossed on the cap Radiator Cap Inspection Check the seal of the filler cap and the operation of the pressure valve with a conventional cooling system testing kit 2 20 Engine Cooling Industrial 3 0L Water Pump Description The die cast pump is a centrifugal vane impeller type The impeller turns on a steel shaft that rotates in a permanently lubricated ball bearing The pump inlet connects to the bottom of the radiator by a rub
156. or for the higher voltages of an HEI system The secondary wire connections are covered with rubber boots and form a tight seal to prevent arcing Notice Because the secondary wires are designed for a tight fit always remove the wires by pulling on the boot while exerting a gentle twisting action This will prevent damage to the wire connectors Pulling directly on the spark plug wires can damage them 12 1 2 i Lnd E TO COIL PRI SEC 7936021 7936022 Industrial 3 0L Engine Electrical 3 65 Special Tools and Equipment NOTE The diagnostic tools shown here are available from Kent Moore However equvalent tools supplied by other manufacturers are permissable for use Miustration Tool Number Description Tool Number Description J 21008 A Self Powered Test Light J 35590 Current Clamp J 38758 Parasitic Draw Test Switch J 39200 Digital Multimeter 404758 J 34142 B Unpowered Test Light P N 12303040 Battery Terminal Adapters J 36169 A Fused Jumper Wire J 42000 Battery Load Test Tool
157. ousing Gasket Camshaft Rear Bearing Hole Plug Engine Block Core Plug Engine Mechanical 1 13 1 14 Engine Mechanical Industrial 3 0L Cylinder Head and Components VE003 3L Legend Cylinder Head Valve Rocker Arm Stud Valve Stem Key Valve Spring Cap Intake Valve Stem Oil Shield Valve Spring Valve Stem Oil Seal Valve Spring Cap Exhaust Exhaust Valve Intake Valve Industrial 3 0L Engine Mechanical 1 15 Oil Pump and Components VE004 3L Legend Drive Gear Driven Gear Oil Pressure Relief Valve Oil Pressure Relief Valve Spring Oil Pump Screen Oil Pump Oil Pump Cover Gasket Oil Pump Cover Oil Pump Cover Washer Oil Pump Cover Bolt OOONOVPRPOD 1 16 Engine Mechanical Industrial 3 0L Repair Instructions Draining Fluids and Oil Filter Removal 1 Remove the oil pan drain plug and allow the oil to drain VE005 3L 2 Remove the oil filter 3 Remove right rear engine block coolant plug and allow the coolant to drain VE007 3L Industrial 3 0L 4 Remove the left rear engine block coolant plug and allow the coolant to drain Engine Flywheel Removal Important Note the position and direction of the engine flywheel before removal The flywheel center alignment hole is a tapered fit to the crankshaft The engine flywheel must be reinstalled to the original position and direction 1 Remove the engine flywheel bolts 2 Remove th
158. ove the pick up coil retainer PICKUP 10 Lift the pick up coil assembly straight up to remove from the distributor RETAINER Installation Procedure 1 Position the pick up coil assembly on the distributor 2 Install the pick up coil retainer 3 Connect the pick up coil electrical connector to the distributor module MODULE 7936017 Industrial 3 0L Installation Procedure Continued 1 2 3 Install the drive shaft into the distributor Install the drive gear onto the distributor shaft Align the marks made during disassembly on the gear and shaft then install a new roll pin Install the rotor Remove the distributer from the holding fixture Spin the distributor shaft to ensure that there is no tooth contact between the timer core and pole piece Install the distributor to the engine Refer to Distributor Replacement in this section Engine Electrical 3 57 7936019 3 58 Engine Electrical Industrial 3 0L Setting Ignition Timing Important PSI Timing Connector Part Number 33000036 MUST be used when checking and adjusting the engine timing 1 With the engine shut off plug the 33000036 Timing Connector into the distributor 4 pin connector Notice DO NOT connect the alligator clip to any positive or negative terminal Connecting this wire to any battery terminal prior to starting the engine will cause the distributor module to fail when starting the engine 2 Start the engine and
159. p 7 System OK System NUN Industrial 3 0L Engine Electrical 3 37 Voltmeter Gauge Voltmeter Gauge Inaccurate or Inoperative ves DEFINITION The voltmeter gauge in the instrument cluster does not read the correct battery or charging system voltage 1 Turn off any electrical loads 1V 2 Start the engine and let it idle briefly 3 Use a digital multimeter to measure the voltage from the battery positive terminal to the battery negative f Go to Voltmeter 4 Compare the digital multimeter voltage with a Gauge simultaneous reading of the Voltmeter Gauge in the Displaying Higher instrument cluster or Lower Than Is the difference in voltage more than the specified value Go to Step 2 Normal Voltage Using a digital multimeter check the fuse in the instrument Go to Step 3 Go to Step 4 panel for continuity Is the fuse blown Replace the fuse in the instrument panel Is the repair complete System OK Repair the high resistance or intermittent open circuit on fuse between the alternator S terminal and the power side of the fuse Is the repair complete System OK 1 Turn the ignition switch to the RUN position engine 12 V not running 2 Measure the voltage at the Voltmeter Gauge Is the voltage lower the specified value Go to Step 7 Go to Step 8 Repair the high resistance or intermittent open circuit between the voltmeter gauge and the fuse Is the repair complete Sys
160. pment systems are ready for testing Tools Required J 38758 Draw Test Switch J 39200 Digital Multimeter or equivalent Industrial 3 0L Notice Always turn the ignition switch OFF when 11 connecting or disconnecting batteries battery charg ers or jumper cables Failure to do so may damage the electronic control unit or other electrical components 1 2 5 6 Disconnect the negative battery cable Ensure that the ignition switch is OFF and that all electrical accessories are OFF 314656 Install the male end of the J 38758 to the negative battery terminal Turn the J 38758 test switch to the OFF position Connect the negative battery cable to the female end of the J 38758 test switch Turn the J 38758 test switch to the ON position Notice Do not turn the parasitic draw test switch to the OFF position with the engine running Damage will 13 occur to the equipment s electrical system 7 8 9 10 Test the electrical system by running the engine and operating the equipment Turn the ignition switch to the LOCK position and remove the key Turn all electrical accessories off In order to avoid a false reading wait 15 minutes for all components to power down before continu ing this test Before connecting the ammeter use the following procedure to determine whether or not the current drain is less than 10 amps 10 1 Connect a jumper wire with an in line 10 amp fuse or circuit b
161. poration may change the reading Reading the Tester 80 65 50 86 40 57 30 5595 20 aon 10 44 FAIR 5 1 6 88 8 400 10 30 5 2058 m 16 26 16 21 g i 8 20 10 g d 8 20 18 25 10 25 1055 ETHYLENE FROPCYLENE ALYSOL GLYCOL 829 10 329 00 FREEZE POINT GLYCOL BY VOLUME 13713 e Point the tester toward any light source and look into the eyepiece e antifreeze protection reading is at the point where the dividing line between the light and the dark edge of the shadow crosses the scale The antifreeze protection is the right scale and the battery charge is on the left 2 8 Engine Cooling Industrial 3 0L On Equipment Pressure Testin e tester temperature scale is reversed from 9 the standard thermometer scale that below Tools Required zero readings are on the upper half ofthe J 24460 01 Radiator Pressure Tester scale Readings on the lower half of the scale which are the above zero readings indicate solutions without enough antifreeze concentration to provide adequate rust protection e Tilt the tester toward the light source in order to obtain the best results If the edge of the shadow is not defined the measuring surfaces are not clean or dry Wipe the tester dry and retest the coolant Cooling System Leak Testing Notice Pressure above 139 kPa 20psi should not be used whe
162. portant The insert should be flush to one turn below the surface 5 Lubricate the insert with light engine oil except when installing in aluminum and install the insert 6 If the tang of the insert does not break off when backing out the installer break the tang off with a drift Abbreviations and Their Meanings Am per Alemathg Curent Anabg REFUI RAD 0 10 General Information Industrial 3 0L Abbreviations and Their Meanings cont d Assem bly Accebratorand Servo ContolM odut Am exban im Gage 57 m N B B BR BTDC Before Top Dead Center BTM Battery Them alM odub Calbaton C Degrees Cebus Caloma ArResoumes Board Cubr Centmeters Convenience Charge oduk Chasss ContiolM odukb Cycling C litch Tube CCP ate ContolPanel Con pactD isc Abbreviations and Their Meanings cont d cg CenterofG raviy cs Charging System ee QUEEN dB Dee DC D iectC unent Duty Dem Industrial 3 0L Abbreviations and Their Meanings cont d Abbmvintbn ulin eter DOHC Dualo verhead Cam shafts Ekctrcall enter Engine Contol Engme CoohbntLevel ECM Engine ContolM oduk Ekctionr Contio1M oduk Em 5spn Contols ystem Engine CoohbntTem perature EEPROM bctrraly Exasabk Program m Read O n em ory E arly FuelEvaporaton ExhaustG as R ecicubtbn EGR TVV ExhaustG a
163. pump screen has a press fit in to the pump cover Do not remove the screen from the pipe The pipe and screen are serviced as a complete assembly VE082 3L 2 Remove the cover bolts 3 Remove the pump cover VE083 3L 4 Remove the drive gear 2 and the driven gear 1 Matchmark the gear teeth for assembly VE084 3L Industrial 3 0L Engine Mechanical 1 51 5 Remove the following items The retaining pin 1 The pressure relief valve spring 3 The pressure relief valve 2 VE085 3L Oil Pump Clean and Inspect Important The internal parts of the oil pump are not serviced separately If the oil pump components are worn or damaged replace the oil pump as an assembly The oil pump pipe and screen are to be serviced as an assembly Do not attempt to repair the wire mesh portion of the pipe and screen assembly 1 Clean all of the parts in cleaning solvent Caution Wear safety glasses in order to avoid eye damage 2 Dry the parts with compressed air 3 Inspect the following areas The oil pump housing and cover for cracks scoring casting imperfections and damaged threads The drive gear shaft If the shaft is loose in the oil pump housing replace the oil pump The pressure relief valve for scoring and sticking Burrs may be removed with a fine oil stone The pressure relief valve spring for loss of tension VE086 3L The oil pump screen for broken wire mesh or l
164. pushrod cover 3 Install the pushrod cover bolts Tighten Tighten the pushrod bolts to 4 5 Nem 40 Ib in VE118 3L Valve Rocker Arm Cover Installation 1 Install the valve rocker arm cover gasket 2 Install the valve rocker arm cover 3 Install the valve rocker arm bolts Tighten Tighten the valve rocker arm cover bolts to 4 5 N m 40 Ib in VE119 3L Industrial 3 0L Oil Level Indicator and Tube Installation 1 Install the oil level indicator tube into the engine block 2 Usealight plastic or rubber hammer in order to tap the tube until it seats in the engine block 3 Install the oil level indicator into the tube Water Pump Installation 1 Position the water pump and gasket to the engine block 2 Install the water pump bolts Tighten Tighten the water pump bolts to 20 Nem 15 Ib ft Coolant Inlet and Coolant Thermostat Installation 1 Position the coolant inlet housing 5 and NEW gasket 7 to the engine block 2 Install the coolant inlet housing bolts 6 Tighten Tighten the coolant inlet housing bolts to 34 40 25 30 Ib ft 3 Install the coolant thermostat 3 and NEW gasket 4 on the coolant inlet housing 4 Install the coolant thermostat housing 2 5 Install the coolant thermostat housing bolts 1 Tighten Tighten the coolant thermostat housing bolts to 24 31 Nem 18 23 Ib ft Engine Mechanical 1 71 VE017 3L 79362005 1 72 Engine Mechanical Industrial 3 0L
165. rade 2 to grade 8 Radial lines are embossed on the head of e Lower strength No numbered head marking system each bolt in order to identify the strength class The Wrong thread pitch number of lines on the head of the bolt is 2 lines less The metric fasteners on PSI products are designed to than the actual grade For example a grade 8 bolt will new international standards Following are the com have 6 radial lines on the bolt head Some metric nuts mon sizes and pitches except for special applications are marked with a single digit strength identification e M60X1 m nn x ilable th h the GM correct fasteners are available through the e 10 15 Service Parts Group Standard Parts Catalog Many metric fasteners available in the aftermarket parts e M12 X 1 75 channels are designed to Industrial 3 0L General Information 0 7 Prevailing Torque Fasteners 88808 1 2 5 171892 A prevailing torque nut is designed in order to develop an interface between the nut and bolt threads Distor tion of the top of the metal nut or using a nylon patch on the threads in the middle of the hex flat causes that interface A prevailing torque bolt nut that is clean and free of rust may be reused If there is any doubt replace the fastener 1 Clean away all dirt or foreign material 2 Inspect the fastener for signs of overtightening 3 4 Inspect the fastener for torque development Hand start the fastener at the ori
166. radiator and the coolant thermostat housing Notice Refer to Fastener Notice 3 Install the radiator hose clamps Tighten Tighten the radiator hose clamps to 2 5 Nem 22 Ib in 4 Add the coolant to the proper level Refer to Draining and Filling Cooling System 5 Start the engine and check for leaks Industrial 3 0L Engine Cooling 2 11 Drive Belt Replacement Removal Procedure 1 Remove the fan guard Refer to Fan Guard Replacement 2 Loosen the generator mounting bolts 3 Move the generator inward to loosen the tension on the drive belt Slide the belt off of the pulleys and over the fan blades 5 Inspect the drive belt for Cracks Glazing Tears or cuts Hardening Excessive wear 79362001 Installation Procedure Tools Required 6 Steel Rule 1 Slide the belt over the fan blades and route it over the pulleys 2 Move the generator outward until the fan belt measures approximately 1 2 inch 13 mm deflection Notice Refer to Fastener Notice 3 While maintaining tension on the drive belt tighten the generator mounting bolts Tighten Tighten the lower generator mounting bolt to 50 37 Ib ft Tighten the upper generator mounting bolt to 25 N m 18 Ib ft 4 Verify that the belt tension is correct with the ruler 5 Install the fan guard Refer to Fan Guard Replacement 79362001 Cooling Fan Replacement Removal Procedure 1 Remove the fan guard Refer to Fan Guard Replacement 2 R
167. rder to prevent entry of foreign material The part number is stamped on a label attached to the field frame The shift lever mechanism and the solenoid plunger are enclosed in the drive housing in order to protect them from exposure to dirt icing conditions and splash The solenoid windings energize when the ignition switch is in the START position The resulting plunger and the shift lever movement causes the pinion to mesh with the engine flywheel ring gear the solenoid main contacts close and the engine cranking takes place When the engine starts the pinion overrunning clutch protects the armature from excessive speed until the ignition switch is released at which time the plunger return spring causes the pinion to disengage In order to prevent excessive overrunning release the ignition switch immediately when the engine starts Starting System Circuit Description Battery voltage is applied at all times to the starter solenoid B battery terminal through the positive battery cable When the ignition switch is turned to the START position battery voltage is applied from the closed contacts of the ignition switch to S terminal of the starter solenoid through the BLUE wire Engine Electrical 3 59 185425 With voltage applied to the starter solenoid S terminal current flows through the hold in coil to the mechanical ground at the solenoid At the same time current flows through the pull in coil and the starter motor t
168. reaker to the termi nals of the J 38758 test switch 10 2 Turn the J 38758 test switch to the OFF position 10 3 Wait 10 seconds Engine Electrical 3 25 If the fuse in the jumper wire does not blow turn the J 38758 test switch ON set the J 39200 to the 10 amp scale and connect the digital multimeter to the J 38758 test switch and then remove the jumper wire If current is greater than 10 amps use a test lamp instead of an ammeter Important Always turn the J 38758 test switch to the ON position between tests The ON position allows current to flow through the battery cable If the test switch is left in the OFF position between tests the ammeter could be damaged due to accidental over loading 12 Remove the fuses one at a time and install each one after it is tested Perform the following steps each time a fuse is removed 12 1 Turn the test switch to the OFF position which forces all current to flow through the meter Wait at least 60 seconds Check the current reading If the reading is at or below 2 amps turn the test switch to the ON position in order to maintain continuity in the electrical system while switching to the 2 amp scale for a more accurate reading Turn the test switch to the ON position between tests The parasitic draw is typically under 60 milliamperes If the ammeter drops to an acceptable reading after a fuse is re moved the circuit causing the drain has been identified Install
169. requires correct connections to the battery terminals A failure to obtain the correct connections during the test may result in replacing the battery unnecessarily Adhere to the following instructions in order to avoid an incorrect diagnosis due to poor connections When testing the equipment with the battery cables still connected rock the J 42000 clips back and forth on the terminal bolt in order to cut through any coating or oxidation that may be present on the bolt Even new bolts contain a protective coating that may insulate or cause a resistance in the test circuit If it is uncertain that correct connections can be made to the battery terminal bolts in the equipment perform the following steps 1 Disconnect the battery cables 2 Install the test adapters on the terminals 3 Follow the instructions for testing the battery outside of the equipment If a REPLACE BATTERY result is obtained for a battery tested in the equipment with the battery cables connected perform the following steps 1 Disconnect the battery cables 2 Install the approved battery terminal adapters 3 Follow the instructions for testing the battery outside of the equipment 4 Replace the battery only if the second test shows a REPLACE BATTERY result For warranty purposes use the test code from the second test On side post batteries use the approved terminal adapters Do not use any common bolts or a combina
170. res Charging System Check Stp Actin Normal Result s Abnormal Result Action 1 Check the generator pulley drive The drive belt is correctly Refer to Drive Belt Tensioner belt tension tensioned Diagnosis in Engine Mechanical 2 Visually inspect the battery for The battery case is not cracked or Battery damaged Replace Battery physical damage broken Inspect the battery terminal The battery terminals are clean and Refer to Fastener Tightening connections tight Specifications Clean or Replace Battery Cable 4 Visually inspect the built in battery The battery hydrometer displays a Battery Hydrometer Displays Dark hydrometer if equipped green dot if equipped or Yellow Dot if equipped 5 Inspect the generator output The generator output terminal is Refer to Fastener Tightening terminal for a loose connection clean and tight Specifications Inspect the generator connector for Generator connector terminals are Connector Repairs looseness or damaged terminals not loose or damaged Battery Not Operating Properl The battery passes the load test Replace Battery Generator Not Operating Properly The generator passes the electrical Refer to Generator Replacement test Start the engine and allow it to idle The volts gauge in the instrument Voltmeter Displaying High or Low cluster is in the normal range 10 Increase the engine speed to 2500 The volts gauge in the instrument Voltmeter Displaying High or Low RPM cluster is in the
171. roblems do not require disassembly of the cooling system Large obstructions block the radiator Ice mud or snow obstructs the radiator engine oil is overfilled Incorrect ignition timing The following problems do require disassembly of the cooling system An incorrect or damaged fan Incorrect radiator for the application Incorrect or faulty radiator pressure cap Check the specifications for the correct part numbers Pressure check the cooling system while the pressure cap is installed This shows if the pressure cap leaks due to radiator filler neck damage Worn or damaged water pump The impeller vanes are eroded or broken The bearing or the seal is worn or damaged Check the shaft for bearing play Plugged radiator tubes Perform a flow check Internal system leaks The cylinder head gasket The cracked block The timing chain cover The intake manifold gasket Plugged coolant passages in the cylinder heads Do a visual check Radiator Assembly Description The radiator assembly is a downflow tube type utilizing an aluminum core with brass upper and lower tanks It is fitted with a shroud designed to assist the cooling fan in directing airflow through the radiator cores and also serves as a fan guard An additional fan guard is also installed to protect person nel from injury Pressure is maintained in the system by a pressure cap The pressure cap has two valves on
172. rough the rotor distributor cap and secondary ignition wires There is a magnetic pick up assembly inside the distributor which consists of a permanent magnet a pole piece with internal teeth and a pick up coil This assembly sends a signal to the distributor control module to trigger the primary circuit in order to induce a voltage in the secondary circuit to fire the spark plugs Dwell and spark timing are both controlled by the distributor control module 3 64 Engine Electrical Industrial 3 0L Spark Plugs The 3 0 liter engine uses resistor type spark plugs The plugs used in this engine have a tapered seat so a gasket is not required A spark plug must operate within certain temperature limits to provide the performance and service life expected The plug selected for this engine is based on the normal service for which the engine was designed Depending on operating conditions the spark plug heat range may have to be adjusted upward or downward one range in order to match the specific engine requirements Secondary Wiring The secondary wires often referred to as spark plug wires carry voltage between the ignition coil the distributor and the spark plugs The secondary wiring used with the 3 0 liter engine is a carbon impregnated cord conductor encased in an 8 mm 5 16 inch diameter silicone rubber jacket The silicone wiring will withstand very high tempera tures and also provides an excellent insulat
173. rple wire and a good ground Turn the ignition switch OFF after test Was the voltage above the specified value Go to Step 18 3 40 Engine Electrical Industrial 3 0L switch Engine Cranks But Fails to Start Continued in this section 3 Reconnect the gray ignition coil electrical connector 1 Remove the distributor cap 2 Disconnect the pick up coil electrical connector 3 Testthe pick up coil Refer to Testing Pick up Coil in this section Were the ohmmeter reading as specified in the tests Go to Step 21 Go to Step 22 Replace the pole piece and shaft assembly Are repairs complete an Wes e M 2 Locate and repair the open circuit between terminal B of Are repairs complete System OK Check the pole piece to see if it is still magnetized Is the pole piece still magnetized Go to Step 24 Go to Step 23 24 If a distributor module tester J 24642 is available test the distributor module and 2 if necessary When a module tester is not available replace the ignition coil and check for spark If still no spark reinstall original coil 3 Check the distributor ground connection if OK replace System OK System OK B 1 Refer to the applicable Schematic and Routing Diagram the ignition coil connector and terminal of the ignition 19 1 Connect a test light from the distributor connector terminal B white wire to ground 2 Crankthe engine while observing the test light 3 Turn the ignition switch OFF after
174. s Refer to the appropriate symptom diagnostic table for the applicable abnormal result Battery Check The battery case the battery tray and the surrounding area are dry The battery is not cracked broken or damaged The ratings of the vehicle battery meet or exceed the CCA and the RC of the original equipment specification The battery hydrometer displays a green dot The engine cranks normally and starts The battery is firmly held in place in the tray and the hold down bolt is properly tightened The battery terminals are clean and tight Ain o Normal Result s Abnormal Result s Replace battery Replace battery If the battery hydrometer has a dark dot no green dot visible test the condition of the battery Refer to Battery Not Operating Properly If the battery hydrometer has a yellow dot check the battery for low electrolyte Refer to Battery Hydrometer Displays Dark or Yellow Dot Engine does not crank or cranks slowly refer to Battery Not Operating Properly Engine cranks normally but does not start refer to Engine Cranks But Does Not Run in Engine Controls Engine starts but does not start overnight or after a couple of days refer to Charging System Check and Battery Electrical Drain Parasitic Load Install the battery in the battery tray correctly Refer to Battery Terminal Check Industrial 3 0L Engine Electrical 3 19 Battery Terminal Check sep
175. s Recicuhtbn Them al Vacuum Vale EPROM E rasabE Programm abb Read On Memory E bc pstat D charge Bctonr SeralNumber ETC EEctonr Conto E Tem perature Contol Ekctonr Tin ng Contol General Information 0 11 Abbreviations and Their Meanings cont d Abbieviatbn Degrees Fahrenheit Fan Control FuelData Center Federal ALU nied States except Cal oma FuelEnabE Data Steam FExbk Fuel Federal U S MotorVehib Safety Standards GeneralM otrs Servie Parts O peratons G albns perM nute hj H GM SPO H MPR H gh Com pression 0 12 General Information Industrial 3 0L Abbreviations and Their Meanings cont d Hz ac DI 5 1 Ng Abbreviations and Their Meanings cont d 5 kPa Kibpascak FourCylinderEngne hnine Pound Pound Feet Tomue Pound mch Torque Lipi rystalD sphy LightEm iting D ide LeftHand M Absolite Pressure anioH Absolite Tem perature M xture Contol M ani H D ifferentalPressure M ultportFuelm cton M alfncton hdratorLamp M nium M illilter M ilm eter M illsecond MST Surface Tem perature Industrial 3 0L Abbreviations and Their Meanings cont d Abbreviation M ean ing Nom aly C bsed Negative 2 N rkelM ealHyd de NatonalLubrratng Base hstiute Newtonm eter Torque 8 2 24 NomalyOpen xiles ofN ihogen NatonalP pe Thread Coarse
176. shaft bearing caps are in place Tighten the bearing caps to the proper torque in order to avoid distortion of the bores in the final assembly The crankshaft must be clear of the boring cutter when you bore each cylinder Cover or tape the crankshaft bearings and other internal parts to protect during the boring or honing process 10 Honing Procedure 1 When honing the cylinders follow the 11 manufacturer s recommendations for use cleaning and lubrication Use only clean sharp stones of the proper grade for the amount of material you remove Dull dirty stones cut unevenly and generate excessive heat When using coarse or medium grade stones leave sufficient metal so that all stone marks may be removed with the fine stones you use for finishing in order to provide for proper clearance During the honing process thoroughly clean the cylinder bore Check for a correct fit of the piston you select for the individual cylinder When honing to eliminate taper in the cylinder make full strokes of the hone in the cylinder Repeatedly check the measurement at the top the middle and the bottom of the bore Notice Handle the pistons with care Do not force the pistons through the cylinder until you hone the cylinder to the correct size The piston can be distorted through careless handling 4 When finished honing a cylinder bore to fit a piston move the hone up and down at a sufficient speed to obtain very fine unifor
177. sket Pushrod Cover Removal 1 Remove the pushrod cover bolts 2 Remove the pushrod cover 3 Remove the gasket VE020 3L 1 22 Engine Mechanical Industrial 3 0L 5 E MUN u Ct Ww V WE 5 T CW C m 0 A L S EZ 3 4 5 6 VEO22 3L 2 3 Valve Rocker Arm Pushrod Removal 1 Remove the following components from the cylinder head 1 1 The valve rocker arm nuts 1 1 2 The valve rocker arm balls 2 1 3 The valve rocker arms 3 Measuring Camshaft Lobe Lift Tools Required J 8520 Camshaft Lobe Lift Indicator Position the J 8520 with the ball socket adapter on the valve pushrod Be sure that the valve pushrod is in the valve lifter socket Slowly rotate the crankshaft until the valve lifter roller is on the heel of the cam lobe The valve pushrod will be in its lowest position Set the J 8520 on zero Slowly rotate the crankshaft until the valve pushrod is raised fully Compare the total lift shown on the J 8520 with the specifications Refer to Engine Mechanical Specifications Remove the J 8520 Remove the valve pushrods Place the following parts in a rack so that they can be reinstalled in their original locations The valve rocker arms The valve rocker arm balls The valve pushrods Industrial 3 0L Engine Mechanical 1 23 Valve Train Components Inspect Cylinder Head Inspect the following areas The valve roc
178. spectthe fluid level pressure for being too high 2 Checkthe crankcase ventilation system for restrictions or malfunctioning components 3 Inspect for improperly tightened fasteners or dirty damaged threads 4 Lookfor warped flanges or sealing surfaces 5 Check for scratches burrs or other damage to the sealing surface 6 Lookfor a damaged or worn gasket 7 Checkfor cracking or porosity of the component 8 Checkfor use of an improper sealant used where applicable 1 10 Engine Mechanical Industrial 3 0L Component Locator Disassembled Views Upper Engine Block and Components VEOO1 3L Industrial 3 0L Legend Valve Rocker Arm Cover Bolt Valve Rocker Arm Cover Reinforcement Valve Rocker Arm Cover Oil Filler Cap Valve Rocker Arm Cover Gasket EFE Valve Thermostat Intake Manifold Intake Manifold Nut Intake Exhaust Manifold Clamp Intake Exhaust Manifold Washer Intake Exhaust Manifold Bolt Intake Exhaust Manifold Gasket EFE Valve Spring EFE Valve Bushing Exhaust Manifold Intake Exhaust Manifold Bolt Exhaust Manifold Stud Intake Exhaust Manifold Gasket Cylinder Head Bolt Cylinder Head Cylinder Head Gasket Lift Bracket Lift Bracket Bolt Engine Block Water Pump Gasket Water Pump Water Pump Bolt Water Pump Bolt Pushrod Cover Gasket Pushrod Cover Pushrod Cover Bolt Valve Lifter Engine Block Coolant Plug Distributor Gasket Distributor Distributor Hold Down
179. stall the oil control ring spacer in the groove 2 2 Install the lower oil control ring The oil control rings do not have a dimple or orientation mark and may be installed in either direction 2 3 Install the upper oil control ring 2 4 Stagger the three oil control ring end gaps a minimum of 90 degrees 2 5 Using piston ring pliers install the lower compression VE123 3L ring The lower compression ring has a dimple or FAN END OF ENGINE orientation mark This mark must face the top of the piston The lower compression ring also has a bevel on the edge that faces the bottom of the piston 2 6 Using piston ring pliers install the upper compression ring The upper compression ring has a dimple or orientation mark This mark must face the top of the piston The upper compression ring has a B molybdenum filling and no bevelled edge A POSITION OF THE GAP FOR THE SPACER OF THE OIL RING B POSITION OF THE GAP FOR THE OIL RING C POSITION OF THE GAP FOR THE LOWER COMPRESSION RING D POSITION OF THE GAP FOR THE UPPER COMPRESSION RING VE074 3L Camshaft and Bearings Clean and Inspect Tools Required e J 7872 Magnetic Base Indicator Set Caution Wear safety glasses in order to avoid eye damage 1 Clean the camshaft in solvent 2 Dry the camshaft with compressed air 3 Inspect the camshaft bearing journals for scoring or excessive wear 4 Inspect the camshaft valve lifter lobes for scoring
180. stem OK 13 16 V Go to Battery Not Operating Properly System OK Go to Step 2 System OK Go to Step 5 Go to Step 3 Go to Step 6 System OK OV OV Go to Step 8 Industrial 3 0L Engine Electrical 3 27 Engine Cranks Cranks Slowly But Does Not Start ves No Use a digital multimeter to measure the voltage of the 12V battery Is the voltage greater than or equal to the specified value Go to Step 5 Go to Step 2 1 Ensure the battery terminals and terminal bolts are free from corrosion 2 Charge the battery Refer to Battery Charging 3 Disconnect the engine shutoff solenoid 4 Attempt to crank the engine Does the engine crank normally Go to Step 3 Go to Step 5 1 Connect the engine shutoff solenoid 2 Verify that the charging system is operating correctly Refer to Charging System Check System OK Go to Step 4 Does the voltage drop below the specified value while the starter is cranking the engine Go to Step 6 Go to Step 9 Is the charging system OK Load test the battery Refer to Battery Not Operating Properly Is the battery OK Go to Step 8 Go to Step 7 connect the engine shutoff solenoid until all cranking tests are completed Turn the ignition switch to the START position Use a J 39200 DMM to measure the voltage between the battery terminals while cranking the engine for 15 fifteen seconds Notice Never operate the starter motor for more than 15 seconds at a time
181. t On engines equipped to run on LPG the in line fuel filter must be changed every 800 hours 0 18 General Information Industrial 3 0L Fuel Delivery System Maintenance Continued CAUTION Failure to change the fuel system filters as recommended can result in premature failure of the TBI fuel system components NOTE Some original equipment manufacturers install their own fuel systems Please refer to the manufacturers manual if the gasoline fuel system is different than described here WARNING Use extreme care when changing the fuel filters on gasoline engines Gasoline is highly flam mable and should not be exposed to open flame sparks or hot engine components Allow the engine to cool to ambient temperatures prior to changing fuel filters Ignition Systems Types of Ignition Systems Three types of ignition systems are used on PSI GM Powertrain engines Solid state electronic distributor solid state electronic distributor with ECU Electronic Control Unit and distributor less electronic ignition with ECU Please refer to the Section 2 Engine Electrical to determine the ignition system used on your particular engine Ignition Timing Proper adjustment of the ignition timing must be obtained to provide the optimum engine power output and economy To properly adjust ignition timing refer to Section 2 Engine Electrical Spark Plugs Spark plugs should be replaced at the recommended intervals described in the Maintenance Schedule
182. t and rear camshaft bearings VE055 3L 1 1 Assemble the bearing tool to the driver handle 1 2 Align the oil holes 1 3 Drive the front and the rear camshaft bearings inward toward the center of the engine block 2 Use the J 6098 01 in order to install the inner camshaft bearings Repeat the following steps for each of the inner camshaft bearings 2 1 With the nut 4 and the thrust washer 3 installed to the end of the puller screw threads index the pilot in the camshaft front bearing and install the puller screw through the pilot 2 J 6098 01 2 2 Index the camshaft bearing in the bore Make sure you align the oil galley holes 1 2 3 Install the puller screw through the bearing bore and ZA bearing to be installed and assemble bearing tool 1 Tol o el to the puller screw with the shoulder toward the E n NO m zn bearing Make sure that enough threads are engaged 2 4 Using two wrenches hold the puller screw 5 while you turn the nut in order to draw the bearing into the bore When the bearing has been pulled into the bore remove the bearing tool and the puller screw and check the alignment of the bearing oil hole to the bore VE054 3L oil hole 3 Install anew camshaft rear bearing hole plug Coat the plug outside diameter with GM P N 1052080 sealant or the equivalent 1 50 Engine Mechanical Industrial 3 0L Oil Pump Disassemble 1 Ifnecessary remove the oil pump screen The oil
183. tem OK Replace the voltmeter gauge Is the repair complete System OK 4 1 Turn the ignition switch to the RUN position engine 12V not running 2 Measure the voltage at the power side of the fuse in the instrument panel Is the voltage lower the specified value Go to Step 5 Go to Step 6 3 38 Engine Electrical Industrial 3 0L Engine Cranks But Fails to Start Sie Important n order to properly perform this test the battery must be fully charged cranking speed must be sufficient and there must be an adequate supply of fuel in the tank Check the wires for open circuits cracks or improper seating of terminals at the spark plugs ignition coil and distributor Check the spark at the 1 spark plug with a spark tester J 26792 or equivalent while cranking the engine If there is no spark on the 1 spark plug wire check a second wire A few sparks then nothing is considered no spark Is adequate spark present while cranking Go to Step 2 Go to Step 3 Check the spark plugs fuel etc replace as necessary Refer to Engine Wont Start Did replacement of the fuel or spark plugs resolve the Section 4 Engine problem System OK Controls 1 Remove the coil wire from the distributor Go to Step 4 Go to Step 9 2 Check the spark at the coil wire with a spark tester J 26792 or equivalent while cranking the engine Is adequate spark present while cranking 5 Clean or replace the distributor cap
184. ten Anaerobic Sealer Anaerobic gasket eliminator hardens in the absence of air This type sealer is used where two rigid parts such as castings are assembled and no sealer or gasket is readily noticeable the parts were probably assembled using a gasket eliminator Follow all safety recommendations and directions that are on the container Toremove the sealant or the gasket material Refer to Replacing Engine Gaskets Apply a continuous bead of gasket eliminator to one flange Surfaces to be resealed must be clean and dry Spread the sealer evenly with your finger to get a uniform coating on the sealing surface Do not allow the sealer to enter any blind threaded holes as it may prevent the bolt from clamping properly or cause damage when the bolt is tightened Tighten the bolts to specifications Do not overtighten After properly tightening the fasteners remove the excess sealer from the outside of the joint Engine Mechanical 1 79 Separating Parts Important Many internal engine components will develop specific wear patterns on their friction surfaces When assembling the engine internal components MUST be separated marked or organized in a way to ensure reinstallation to original location and position Mark or identify the following components Piston and the piston pin Piston assembly to the specific cylinder bore Piston rings to the specific piston assembly and cylinder bore
185. the battery Refer to Battery Not Operating Properly Battery Replacement Removal Procedure Caution Refer to Battery Cautions on page 3 17 Notice Always turn the ignition OFF when connecting or disconnecting battery cables battery chargers or jumper cables Failing to do so may damage the Electronic Control Module ECU or other electronic components 1 Disconnect the negative cable from the negative battery terminal 2 Disconnect the positive cable from the positive battery terminal 3 Remove the battery hold down retainers 4 Remove the battery 5 Inspect the battery for damage 6 7 Inspect the battery cables and the connections Inspect the carrier for damage or foreign objects If damage is found correct the cause 3 48 Engine Electrical Industrial 3 0L Battery Replacement Continued Installation Procedure 1 Install the battery into the carrier Notice Refer to Fastener Notice onpage 3 2 2 Install the battery hold down retainers or the top bars Tighten Tighten the retainer bolt to 18 Nem 13 Ib ft Tighten the top bar nut to 10 Nem 89 Ib in 3 Install the positive battery cable to the battery Tighten Tighten the battery side terminal bolts if applicable to 12 Nem 106 Ib in Tighten the top terminal nuts if applicable to 18 Nem 13 lb ft 4 Install the negative battery cable to the battery Tighten Tighten the battery side terminal bolts if applicable to 12 Nem 106 Ib in Tighten the top t
186. the oil be checked just before the engine is started for the first time for that day The oil level should be between the Add and the Full marks on the dipstick CAUTION Do not operate the engine with the oil level below the bottom or Add mark on the dipstick or above the top or Full mark on the dipstick Adding Engine Oil It is normal to add some oil in the period of time between oil changes The amount will vary with the severity of operation When adding or replacing engine oil be sure the oil meets or exceeds the recommended specification Engine Oil and Filter The engine oil and filter must be changed every 200 hours or every 3 months whichever occurs first Under normal operating conditions you do not need to change them more often if you use oil and filters of the recommended quality The oil and filter should be changed more often if the engine is operating in dusty or extremely dirty areas or during cold weather No oil additives or break in oil change is required Engine Oil Quality To achieve proper engine performance and durability it is important that you use only engine lubricating oils of the correct quality in your engine Proper quality oils also provide maximum efficiency for crankcase ventilation systems which reduces pollution Important use only engine oils displaying the American Petroleum Institute API Starburst Certification Mark FOR GASOLINE ENGINES on the container Gasoline engines that ar
187. the radiator cap while the engine is hot and the pressure is high will cause the solution to boil instantaneously and possibly with explosive force spewing the solu tion over the engine body and person removing the cap Under some conditions the engine coolant is combustible Use the following procedure in order to drain the cooling system 1 Place a drain pan under the radiator drain cock 2 Install a tube on the drain cock 3 Place the end of the tube in the drain pan 4 Ensure the cooling system is cool Remove the radiator cap Open the drain cock completely Allow the cooling system to drain until the flow stops 7 Place a drain pan under the engine Remove the drain plug from the engine block 9 Allow the engine block to drain until the flow stops There may be some more drainage from the radiator at this time 10 Replace the engine block drain plug 11 Close the radiator drain cock ow Refilling Procedure Use the following procedure in order to refill the cooling system 1 Check the radiator drain cock in order to ensure that the drain cock is closed 2 Check the engine drain plug in order to ensure that the drain plug is closed 3 Place a large funnel in the radiator fill hole 4 Fill the system with ethylene glycol based coolant to the radiator Do not pre mix the coolant and water Fill the remainder of the radiator with clean drinkable water in order to equal a 52 48 mix Refer to Engine Coolin
188. the terminal adapters to both of the battery terminals Refer to P N 12303040 Are the battery terminal adapters installed Go to Step 6 Ensure that the battery terminals are clean tight and in good condition Go to Battery Are the terminal connections OK Go to Step 5 Terminal Check 1 Turn the ignition switch to the OFF position 2 Turn the electrical loads and all accessory lights to the OFF position Are all of the electrical loads and accessory lights OFF Go to Step 6 Does a CHECK CONNECTION message appear on the J 42000 tester display Go to Step 8 Go to Step 9 Important When testing the battery on the equipment connect the tester directly to the cable bolts Do not connect either of the tester clamps to a remote terminal such as a junction block or a jump start terminal The use of a remote terminal will cause invalid test results 1 Connect the red clamp on the J 42000 to the adapter or the cable bolt on the battery positive terminal 2 Connect the black clamp on the tester to the adapter or cable bolt on the battery negative 7 terminal 3 Rock both of the tester clamps back and forth in order to cut through to the bare metal The message GM MICRO 410 should appear for a short time on the tester display and then change to SELECT TEST Does the display read SELECT TEST Go to Step 10 Go to Step 7 Inspect the tester connections to the battery terminal adapters or cable bolts for the following conditions Both sides of
189. ther electronic components Important Tighten the adapters against the lead terminals of the battery in order to keep the resistance between the adapters and the battery terminals to a minimum 1 Make sure all connections to the charger are clean and tight When charging side terminal batteries out of the equipment install a pair of GM P N 12303040 adapters Important Do not use the charger settings for jump starting equipment in order to charge the battery 2 Set the charger for 12 volt batteries that gives the highest charge rate NOTE On batteries with a built in hydrometer charge the battery until the green dot 1 appears e Check the battery periodically while charging e Lightly tap the hydrometer on top in order to dislodge any air bubbles that may prevent a correct indication 3 Discontinue charging or reduce the charging rate if the following apply battery feels hot above 52 C 125 F Violent gassing or spewing of electrolyte through the vent holes After charging test the battery Refer to Battery Not Operating Properly and Battery Electrical Drain Parasitic Load Engine Electrical 3 45 181056 42433 3 46 Engine Electrical Industrial 3 0L Charging Time Required The time required to charge a battery will vary The time depends on the following factors e Size of the battery A completely discharged heavy duty battery requires more than twice the recharging time as a complet
190. tion of bolts nut and washers as adapters when testing the battery Use the test adapters that are provided with the J 42000 tester or GM part number 12303040 terminal adapters If the adapters that are provided with the J 42000 tester require replacement only use adapters with the GM part number 12303040 Any other adapters may not contact the correct areas of the battery terminal causing resistance that may result in an invalid battery test result In order test the top terminal threaded stud batteries outside of the equipment use GM part number 12303040 adapters Do not connect the tester to the plain threaded terminals Important For warranty purposes always place the test code displayed by the tester on the repair order The number is a unique identifier that describes the test data for a particular battery at a particular time While the test code may occasionally repeat when retesting the same battery it is more likely that a different code will result each time the battery is tested Industrial 3 0L Engine Electrical 3 21 Tools Required J 42000 Battery Tester J 39200 Digital Multimeter DMM P N 12303040 Battery Terminal Adapters Side Post Batteries Only B Has the Battery Check been performed Go to Battery Go to pum 2 Is the battery in the vehicle with the battery cables connected Go to 4 Go to 3 Lightly wire brush the lead faces of both battery terminals 2 Install
191. to tap the oil pump screen into the pump body The Screen must align parallel with the bottom of the oil pan when it is installed J 21882 VE087 3L Cylinder Head Disassemble Tools Required J 8062 Valve Spring Compressor Important Mark organize or sort the cylinder head components for assembly Return the components to their original location during assembly 1 Measure the valve spring installed height using a ruler Measure from the machined surface of the cylinder head to the top of the valve spring cap Refer to Engine Mechanical Specifications VE088 3L 2 Usethe J 8062 in order to compress the valve springs VE089 3L 1 54 Engine Mechanical VEO9O 3L VE092 3L NO aK 8 Important Place the valves in a rack in the proper sequence so that you can install them in the same order Industrial 3 0L Remove the valve stem keys 1 Remove the cap from the valve spring 28 Remove the valve stem oil shield 8 Remove the valve spring 4 Remove the valve stem oil seal 5 Remove the valve 7 Cylinder Head Clean and Inspect Tools Required J 8089 Carbon Remover Brush J 9666 Valve Spring Tester J 8001 Dial Indicator Caution Wear safety glasses in order to avoid eye damage 1 Use the J 8089 in order to clean the carbon from the combustion chambers and the valve ports Be careful not to scuff the chamber Clean the following areas 2 1 carbon and the slu
192. to S S 3 60 Generator Noise 3 28 Built In Hydrometer If Equipped 3 60 Generator Not Operating Properly 3 28 Charging System Description 3 61 Generator Assembly Bench Check 3 31 SI Series Generators 3 61 Starter Motor Noise 3 31 Voltage Regulator 3 62 High Pitched Whine During Cranking 3 29 Charging System Circuit Description 3 62 High Pitched Whine after the Engine Fires 3 29 Ignition System Description 3 63 Loud Whoop Sound after the Engine Fires 3 30 Ignition 8 3 63 Rumble Growl or 3 30 Ignition Coll u 3 63 Starter No Load 3 30 eM 3 63 Starter Solenoid Does Not Click 3 31 Spark ad U o EL 3 64 Starter Solenoid Clicks Engine Does Not Crank or Secondary 3 64 Cranks 3 34 Special Tools and Equipment 3 65 Voltmeter Gauge Displaying Higher or Lower Than Normal
193. ton alignment mark MUST face the front of the engine block 1 Lubricate the following components with clean engine oil The piston The piston rings The cylinder bore VE124 3L The bearing surfaces 2 Install the connecting rod bearing into the connecting rod and bearing cap 3 Install the J 5239 onto the connecting rod 4 Install the J 8037 or equivalent onto the piston and compress the piston rings 5 Install the piston assembly into its matched bore with the stamped arrow facing forward 6 Use the J 8037 andthe J 5239 and lightly tap the top of the piston with a wooden hammer handle Hold the J 8037 firmly against the engine block until all of the piston rings enter the cylinder bore Use the J 5239 in order to guide the connecting rod onto the crankshaft journal VE105 3L Industrial 3 0L Engine Mechanical 1 63 7 Remove the J 5239 VE038 3L 8 Install the connecting rod cap and nuts Tighten Tighten the nuts evenly to 61 Nem 45 Ib ft 9 When all of the connecting rod bearings are installed tap each connecting rod assembly lightly parallel to the crankpin in order to make sure that they have clearance 10 Use a feeler gauge or a dial indicator in order to measure the side clearance between the connecting rod caps Refer to Engine Mechanical Specifications VE106 3L 1 64 Engine Mechanical Industrial 3 0L Timing Gear Oil Nozzle Installation 1 Drive the new nozzle in place oil h
194. ton on the J 42000 2 For warranty purposes write the displayed code on the repair order 3 Charge the battery Refer to Battery Charging Is the green dot if applicable visible in the battery Go to Step 2 hydrometer Important Surface charge removal is only necessary when the tester detects that a surface charge may affect the results of the test The tester will not complete the testing sequence until the surface charge is removed Follow the tester prompts in order to remove the surface charge by turning the vehicle s headlights ON and OFF If the sequence is followed properly the tester will automatically complete the test If the sequence is not followed properly the tester will display the message DISCONNECT AND RETEST Does the DISCONNECT AND RETEST message appear Go to Step 31 Go to Step 32 31 Disconnect the J 42000 from the battery terminals Is the action complete Go to Step 2 32 The tester will display the word RETESTING and show the CCA rating that was selected for the test If the test is successfully completed the test results will be displayed Do the test results appear on the display Go to Step 14 Go to Step 36 3 24 Engine Electrical Industrial 3 0L Battery Not Operating Properly cont d affect the results of the test Use the scroll keys to indicate whether the internal temperature of the battery is above or below 0_C Important Temperature compensation is only necessary when the tester d
195. trolled and increases above 16 volts the rotor field is shorted the regulator is not working properly or both A shorted rotor field coil can cause repeat regulator failure 4 Ifthe voltage is below 16 volts increase speed and turn on and adjust the carbon pile to obtain maximum amperage output Maintain the voltage above 13 volts 5 Ifthe output is within 15 amperes of the rated output the generator is good If the output is not within 15 amperes of the rated output replace the generator Output Terminal STARTER MOTOR NOISE DIAGNOSIS High Pitched Whine During Cranking Ct DEFINITION A high pitched whine during i ine fi i i The distance is too great between the starter Remove the shims at the starter mount Refer to Starter Pinion Clearance pinion and the flywheel Check High Pitched Whine After the Engine Fires DEFINITION high pitched whine after the engine fires as the key is being released engine cranks fires normally This complaint is often diagnosed as starter hang in or solenoid weak The distance is too small between the starter Add shims at the starter mount Refer to Starter Pinion Clearance Check pinion and the flywheel flywheel runout contributes to the intermittent nature of the problem 3 32 Engine Electrical Industrial 3 0L Loud Whoop Sound after the Engine Fires DEFINITION loud whoop sound after the engine fires but while the
196. ttachments the flywheel 2 Tighten or adjust as necessary Does the engine continue to knock Go to Step 5 System OK Remove the pushrod cover Refer to Pushrod Cover Removal Rotate the engine and measure the lifter movement in the bore Compare the measurement with the specifications in Engine Mechanical Specifications Is the camshaft within specifications Go to Step7 Go to Step 6 Replace the camshaft Refer to Camshaft Removal and Installation Does the engine continue to knock Go to Step 7 System OK 1 Remove the rocker arms the pushrods and the lifters Inspect the parts for excessive wear or damage 3 Replace the parts as necessary Are the repairs complete 1 8 Engine Mechanical Industrial 3 0L Engine Compression Test Perform the following steps in order to conduct a compression test 1 Conduct the following steps in order to check cylinder compression 1 1 Engine should be at room temperature 1 2 Disconnect the two electrical connectors from the distributor 1 3 Remove the spark plugs 1 4 Throttle plates should be wide open 1 5 Battery should be at or near full charge 2 For each cylinder crank engine through four compression strokes 3 The lowest cylinder reading should not be less than 70 of the highest 4 Nooylinder reading should be less than 689 kPa 100 psi Important The results of a compression test will fall into the following categories 1 Normal
197. uction 0 00762 0 01651 mm 0 0003 0 00065 in Clearance in Piston Service Limit 0 0254 mm Maximum 0 001 in Maximum Fit in Connecting Rod 0 02032 0 050292 mm 0 0008 0 00198 in Interference Interference Piston Compression Ring Gap Top Service Limit 0 88 mm Maximum 0 035 In Maximum Measured in cylinder bore 1 6 Engine Mechanical Industrial 3 0L Engine Mechanical Specifications cont d 58 3666 58 4047 mm 2 2979 2 2994 0 005 mm Maximum 0 0002 in Maximum 0 0254 mm Maximum 0 001 in Maximum 0 005 mm Maximum 0 0002 in Maximum 0 0254 mm Maximum 0 001 in Maximum 0 0254 0 06096 mm 0 001 0 0024 in 0 0406 0 0889 mm 0 0016 0 0035 in 0 0254 0 0635 mm 0 001 0 0025 in 0 0381 0 0889 mm 0 05 0 1524 mm 0 002 0 006 in 0 07 mm Maximum 0 003 in Maximum Connecting Rod Journal Diameter 53 2892 53 3273 mm 2 0980 2 0995 in 0 00762 mm Maximum 0 0003 in Maximum 0 0254 mm Maximum 0 001 in Maximum 0 005 mm Maximum 0 0002 in Maximum 2 WE imi 0 001 in Maximum 0 0015 0 0035 in 0 0254 mm Maximum 0 04318 0 06858 mm 0 0017 0 0027 in 0 0762 mm Maximum 0 003 in Maximum 0 1524 0 4318 mm 0 006 0 017 in 47 440 47 490 mm 1 8677 1 8697 in 0 0762 0 2032 mm 0 003 0 008 in 0 1 mm Maximum 0 004 in Maximum 0 10 0 15 mm 0 004 0 006 in 6 4247 mm 0 25294 6 4247 mm 0 25294 0 0254 mm 0 001 in Hydraulic 1751 Half to One Turn Down From Zero Lash 45 Degrees 46 Degrees 0 05 mm Maximum 1 27
198. urrent high enough to cause burns Therefore in order to reduce the risk of personal injury while working near a battery observe the following guidelines e e e Always shield your eyes Avoid leaning over the battery whenever possible Do not expose the battery to open flames or sparks Do not allow battery acid to contact the eyes or the skin Flush any contacted areas with water immediately and thoroughly Get medical help Important Battery Diagnosis Information PSI does not supply batteries to equipment manufacturers However on the following pages you will find some generic methods used to diagnosis common battery problems You may need to contact the equipment manufacturer for specific procedures for the battery you are working with 3 18 Engine Electrical Industrial 3 0L Inspect the following areas for battery acid The battery case The battery tray The area around and underneath the battery tray Inspect the battery for a cracked broken or damaged case Compare the Cold Cranking Amperage CCA and the Reserve Capacity RC of the battery or the Equipment Manufacturer s specification Inspect the battery hydrometer for a green dot if equipped Turn the ignition key to START and check to see if the engine cranks normally and starts 1 Inspect the battery for proper installation and retention in the battery tray 2 Inspect the battery terminals for clean and tight connection
199. valve seat 5 6 Use light pressure and move the valve stem from side to side in order to obtain a clearance reading VE094 3L 5 7 If the valve stem to guide clearance is excessive the valve must be replaced and or the guide must be repaired to obtain the proper clearances Refer to Engine Mechanical Specifications MM u TO 1 56 Engine Mechanical VEO95 3L VE096 3L VE097 3L Industrial 3 0L 6 Inspect the valve springs for squareness 7 Measure the valve seat runout Use the J 8001 in order to check the valve seat runout The valve seats should be concentric to within 0 0508 mm 0 002 in 8 Measure the cylinder head for warpage with a straight edge and a feeler gauge A cylinder head with excessive warpage must be repaired or replaced Refer to Engine Mechanical Specifications Industrial 3 0L Valve Guide Reaming Valve and Seat Grinding 1 Ream the valve guides for oversize valves ifthe clearance exceeds the specifications Service valves are available in the standard and 0 038 mm 0 015 in Ream the valve guide bores for the service valves as necessary Reconditioning the valve seats is very important Recondition the valve seat after reaming the valve guide bores or installing the new valve guides The valves must seat perfectly for the engine to deliver optimum power and performance Cooling the valve heads is another important factor Good
200. ver J 3049 A Valve Lifter Remover J 3936 03 Piston Ring Groove Cleaner J 4822 Valve Guide Reamer J 5239 Connecting Rod Bolt Guide Set Industrial 3 0L J 5590 Crankshaft Sprocket Installer J 5715 or J 6036 Rocker Stud Hole Reamer J 5802 01 Rocker Arm Stud Remover J 6098 01 Camshaft Bearing Remover Installer J 6585 Slide Hammer Industrial 3 0L J 6880 Rocker Arm Stud Remover J 6978 E Crankshaft Sprocket Puller J 7872 Magnetic Base Dial Indicator J 8001 Dial Indicator J 8037 Piston Ring Compressor Engine Mechanical 1 81 J 8062 Valve Spring Compressor J 8087 Cylinder Bore Gauge J 8089 Carbon Remover Brush J 8520 Camshaft Lobe Lift Indicator J 8792 Crankshaft Pulley Installer 1 82 Engine Mechanical J 9290 01 Valve Lifter Remover Slide Hammer Type J 9534 Distributor Lower Bushing Remover J 9535 Distributor Lower Bushing Installer J 9666 Valve Spring Tester J 21882 Oil Suction Pipe Installer Industrial 3 0L J 24086 C Piston Pin Remover Installer Set J 24270 Ridge Reamer J 24420 C Universal Crankshaft Pulley Remover J 35468 Engine Front Cover Aligner and Oil Seal Installer J 35621 Crankshaft Rear Oil Seal Installer Industrial 3 0L Engine Cooling 2 1 Section 2 Engine Cooling Fastener Notice 2 2 Specifications 42 4
201. y Av aa C sb N NOS HOWL XY e bid a a 3 a ER LIOA 214 NOES ND S 3 EB S UO1O3NNOO 3LIHM NMOQ HS LANI XNY SE E x AYTSAHBMOG 1109 OLUMO NI JOZI f AOR N INS E j DaN IUIS JOZ Ct boi ang P 000215 1620030 05246 HH ae E STIENE DONI 18 088 18 me d ud i ST iil d 81 SA YOLOSNNO N yn BEN 28 i 1717772 V Thu TC NTOEVD gt bd I SURANROHE EM na gd INI odd d B i rd 5 0 HOLDENNOI LOLOAN 941 c MALO OW P BE i mE 3001941 U EE ds do me n mc DD ARENIS e _ FEE 8 1 N S i m V 8 eo p eee inis 19 S mS WOOT 3051198001 5 m l TIME 1 i p E 5 xe Zen f mai 3 WOLANNOO WBNS 102 2 HOSNS P pri 1 J Je 4 YOLOINNOS X914 TW HOLS TONOS HOWL e Hi NI TEE att 1 an seen 389853810 Wow A ANO i SHALOO U03 389336 MOPIGINSTYS 3 380 CHINI S3tOdaifld DI NENOISSINHIG di Y04038 38 AVH NOILONAgdEH A

3.0L Service Manual Revision

Contents

Download Pdf Manuals

Related Search

Related Contents