3.0L Service Manual Revision - All Power Labs

[Pages:188]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

Section 0 General Information

General Information 0-1

Fastener Notice ........................................................ 0-2 General Information - 3.0L ..................................... 0-3 Conversion - English/Metric ..................................... 0-3 Equivalents - Decimal and Metric ............................ 0-3 Arrows and Symbols ................................................ 0-4 Engine ID Location ................................................... 0-5 Labels - How to Obtain Replacement ....................... 0-5 Fasteners ................................................................. 0-5 Metric Fasteners ....................................................... 0-5 Fastener Strength Identification ................................ 0-6 Prevailing Torque Fasteners ..................................... 0-7 Prevailing Torque Specifications (Metric) .................. 0-8 Prevailing Torque Specifications (English) ................ 0-8 Thread Inserts .......................................................... 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 .......................................... 0-15 Adding Engine Oil .................................................. 0-15 Engine Oil and Filter ............................................... 0-15 Engine Oil Quality ................................................... 0-15

Engine Oil Recommendation .................................. 0-15 Oil Filter .................................................................. 0-16 Engine Air Cleaner ................................................. 0-16 Safety Element ....................................................... 0-16 Cooling System Maintenance ............................. 0-16 Coolant Level ......................................................... 0-16 Radiator .................................................................. 0-17 Radiator Hoses ...................................................... 0-17 Fan Belts ................................................................ 0-17 Serpentine Belt ....................................................... 0-17 V-Type Belt ............................................................. 0-17 Fuel Delivery System Maintenance .................... 0-17 Fuel Filter Replacement ......................................... 0-17

Carbureted Engines ............................................ 0-17 TBI Engines .......................................................... 0-17 Zenith Z.E.E.M.S TBI Fuel Injection ..................... 0-17 Ignition Systems ..................................................... 0-18 Types of Ignition Systems ....................................... 0-18 Ignition Timing ........................................................ 0-18 Spark Plugs ............................................................ 0-18 Maintenance Schedule - 3.0L Engine ................ 0-19 Approximate Fluid Capacities ................................. 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 - 3.0L

Conversion - English/Metric

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General Information 0-3

Conversion - English/Metric (cont'd)

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Equivalents - Decimal and Metric

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0-4 General Information Equivalents - Decimal and Metric (cont'd)

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Industrial 3.0L Arrows and Symbols

This service manual uses various symbols in order to describe different service operations. You may find some or all of these symbols used in the manual.

196216

Industrial 3.0L

Engine ID Location

An identification label is affixed to the right side of the engine on the rocker cover when looking at the engine from the flywheel end.

General Information 0-5

In addition, the GM serial number is stamped on the right side of the cylinder block, just to the rear of the distributor.

79300001

The engine serial number is also stamped into the left side of the cylinder block near the engine flywheel. The 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 concerning the engine and/or ordering replacement service parts.

FASTENERS

79300003

Metric Fasteners

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 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

Fastener Strength Identification

Industrial 3.0L

Legend (1) English Bolt, Grade 2 (Strength Class) (2) English Bolt, Grade 5 (Strength Class) (3) English Bolt, Grade 7 (Strength Class)

(4) English Bolt, Grade 8 (Strength Class) (5) Metric Nut, Strength Class 9 (6) Metric Bolts, Strength Class Increases as Numbers Increase

171891

The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face.

The correct fasteners are available through the GM Service Parts Group Standard Parts Catalog. Many metric fasteners available in the aftermarket parts channels are designed to

metric standards of countries other than the United States, and may exhibit the following defects:

Lower strength No numbered head marking system Wrong thread pitch

The metric fasteners on PSI products are designed to new, international standards. Following are the common sizes and pitches, except for special applications:

M6.0 X 1 M8 X 1.25 M10 X 1.5 M12 X 1.75

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