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3.0L Service Manual Revision

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3.0L Service Manual Revision Original Issue Dated June 2002 Publication number 36100010 3.0L INDUSTRIAL ENGINE SERVICE MANUAL 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 Engine Oil Recommendation.................................. 0-15 General Information - 3.0L ..................................... 0-3 Oil Filter .................................................................. 0-16 Conversion - English/Metric ..................................... 0-3 Engine Air Cleaner ................................................. 0-16 Equivalents - Decimal and Metric ............................ 0-3 Safety Element ....................................................... 0-16 Arrows and Symbols ................................................ 0-4 Cooling System Maintenance ............................. 0-16 Engine ID Location ................................................... 0-5 Coolant Level.........................................................0-16 Labels - How to Obtain Replacement ....................... 0-5 Radiator.................................................................. 0-17 Fasteners ................................................................. 0-5 Radiator Hoses ...................................................... 0-17 Metric Fasteners....................................................... 0-5 Fan Belts ................................................................ 0-17 Fastener Strength Identification................................ 0-6 Serpentine Belt....................................................... 0-17 Prevailing Torque Fasteners ..................................... 0-7 V-Type Belt ............................................................. 0-17 Prevailing Torque Specifications (Metric).................. 0-8 Fuel Delivery System Maintenance .................... 0-17 Prevailing Torque Specifications (English) ................ 0-8 Fuel Filter Replacement ......................................... 0-17 Thread Inserts .......................................................... 0-9 Carbureted Engines ............................................ 0-17 Abbreviations and Their Meanings ........................... 0-9 TBI Engines .......................................................... 0-17 Maintenance and Lubrication .............................. 0-15 Zenith Z.E.E.M.S TBI Fuel Injection ..................... 0-17 Initial Start Up Maintenance ................................... 0-15 Ignition Systems ..................................................... 0-18 Routine Maintenance ............................................. 0-15 Types of Ignition Systems....................................... 0-18 Scheduled Preventive Maintenance ....................... 0-15 Ignition Timing ........................................................ 0-18 Engine Oil Level Check .......................................... 0-15 Spark Plugs ............................................................ 0-18 Adding Engine Oil .................................................. 0-15 Maintenance Schedule - 3.0L Engine ................ 0-19 Engine Oil and Filter ............................................... 0-15 Approximate Fluid Capacities ................................. 0-19 Engine Oil Quality................................................... 0-15 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) c«¦©¨®§ k°©¯¨­©´>M k¤¯¨¢ c«¦©¨®§ k°©¯¨­©´>M k¤¯¨¢ b¨±¨£¤>¡´ b¨±¨£¤>¡´ j¤«¦¯§ t¤©¬¢¨¯´ ¨« PSLR ªª ª­§ OLTNWQ ªM§ ¥¯ NLQNRV ª r¤ª­¤ ¯°¤ FdKQPG>M>OLV [ a ´£ NLWORR ª d [ Fa>v>OLVG>I>QP ª¨ OLTNW ª d°¤©>n¤¥¬ª «¢¤ _¤ PQPLPOSMª­¦ [ jMONN>ª ® >¨« TRSLP ® >ªª ® >¨« TLRS ® >¢ª ® >¥¯ NLNWPW ® >ª Equivalents - Decimal and Metric ® >´£ NLVQTO ® >ª d ¢¯¨¬«>F¨«G b¤¢¨ª ©>F¨«G k¤¯¨¢>FªªG t¬©°ª¤ OMTR NLNOSTPS NLQWTVV ¢°>¨« OTJQVULN ¢°>ªª OMQP NLNQOPS NLUWQUS ¢°>¨« OTLQWU ¢°>¢ª QMTR NLNRTVUS OLOWNTP ¢°>¨« NLNOTR j OMOT NLNTS OLSVUS ¯ NLWRTR j SMTR NLNUVOPS OLWVRQU ¦ © QLUVSR j QMQP NLNWQUS PLQVOPS ¢°>´£ NLURT ¢°>ª UMTR NLONWQUS PLUUVOP k ®® OMV NLOPS QLOUS ©¡ NLRSQT ¦ WMTR NLORNTPS QLSUOVU ¯¬« WNULOV ¦ SMQP NLOSTPS QLWTVUS ¯¬« NLWNU ¯¬««¤>F¯G OOMTR NLOUOVUS RLQTSTP d¬¢¤ QMOT NLOVUS RLUTPS ¦ WLVNU «¤²¯¬«®>FlG OQMTR NLPNQOPS SLOSWQU ¬µ NLPUVN «¤²¯¬«®>FlG UMQP NLPOVUS SLSSTPS ©¡ RLRRV «¤²¯¬«®>FlG OSMTR NLPQRQUS SLWSQOP _¢¢¤©¤ ¯¨¬« OMR NLPS TLQS P P ¥¯M® NLQNRV ªM® OUMTR NLPTSTPS TLURTVU P P ¨«M® NLNPSR ªM® WMQP NLPVOPS ULORQUS r¬ °¤ OWMTR NLPWTVUS ULSRNTP ©¡>¨« NLOOPWT lGª SMOT NLQOPS ULWQUS ©¡>¥¯ OLQSSV lGª POMTR >NLQPVOPS VLQQRQU n¬²¤ OOMQP NLQRQUS VLUQOPS §­ NLURS u PQMTR NLQSWQUS WLOPVOP n¤®®°¤>Fq¯¤®®G QMV NLQUS >WLSPS ¨«¢§¤®>¬¥>fPmNLPRWOn PSMTR NLQWNTPS WLWPOVU ©¡M® >¨« TLVWS n OQMQP >NLRNTPS ONLQOVUS c«¤¦´>Fu¬G PUMTR NLRPOVUS ONLUOSTP `¯° ONSSLN h>Fh[>¬«¤>u®G UMOT NLRQUS OOLOOPS ©¡>¥¯ OLQSSV h>Fh[>¬«¤>u®G PWMTR NLRSQOPS OOLSNWQU u>§¬° QJTNNJNNNLN h>Fh[>¬«¤>u®G OSMQP NLRTVUS OOLWNTPS j¨¦§¯ QOMTR NLRVRQUS OPLQNQOP P d¬¬¯>a «£©¤ ONLUTR ©ªMª OMP NLS OPLU 0-4 General Information Industrial 3.0L Equivalents - Decimal and Metric (cont’d) Arrows and Symbols This service manual uses various symbols in order to d ¢¯¨¬«>F¨«G b¤¢¨ª ©>F¨«G k¤¯¨¢>FªªG describe different service operations. You may find QQMTR NLSOSTPS OQLNWTVU some or all of these symbols used in the manual. OUMQP NLSQOPS OQLRWQUS QSMTR NLSRTVUS OQLVWNTP WMOT NLSTPS ORLPVUS QUMTR NLSUVOPS ORLTVRQU OWMQP NLSWQUS OSLNVOPS QWMTR NLTNWQUS OSLRUVOP SMV NLTPS OSLVUS ROMTR NLTRNTPS OTLPUOVU POMQP NLTSTPS OTLTTVUS RQMTR NLTUOVUS OULNTSTP OOMOT NLTVUS OULRTPS RSMTR NLUNQOPS OULVSWQU PQMQP NLUOVUS OVLPSTPS RUMTR NLUQRQUS OVLTSQOP QMR NLUS OWLNS RWMTR NLUTSTPS OWLRRTVU PSMQP NLUVOPS OWLVRQUS SOMTR NLUWTVUS PNLPRNTP QMOT NLVOPS PNLTQUS SQMTR NLVPVOPS POLNQRQU PUMQP NLVRQUS POLRQOPS SSMTR NLVSWQUS POLVPVOP UMV NLVUS PPLPPS SUMTR NLVWNTPS PPLTPOVU PWMQP NLWNTPS PQLNOVUS SWMTR NLWPOVUS PQLROSTP OSMOT NLWQUS PQLVOPS TOMTR NLWSQOPS PRLPNWQU QOMQP NLWTVUS PRLTNTPS TQMTR NLWVRQUS PSLNNQOP OOLNPSLR 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, The 3.0L engine is dimensioned in the metric system. 4.3L, 5.7L, etc.) and a serial number which identifies Most metric fasteners are very close in diameter to the engine from other GM Powertrain engines provided well known fasteners in the English, inch system. by Power Solutions, Inc. The engine model and serial Replace fasteners with those of the same nominal number are required when seeking information con- diameter, thread pitch, and strength. cerning the engine and/or ordering replacement service parts. A number marking identifies 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
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