3.0L Service Manual Revision - All Power Labs

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

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 ..................................

Oil Filter ..................................................................

Engine Air Cleaner .................................................

Safety Element .......................................................

Cooling System Maintenance .............................

Coolant Level .........................................................

Radiator ..................................................................

Radiator Hoses ......................................................

Fan Belts ................................................................

Serpentine Belt .......................................................

V-Type Belt .............................................................

Fuel Delivery System Maintenance ....................

Fuel Filter Replacement .........................................

Carbureted Engines ............................................

TBI Engines ..........................................................

Zenith Z.E.E.M.S TBI Fuel Injection .....................

Ignition Systems .....................................................

Types of Ignition Systems .......................................

Ignition Timing ........................................................

Spark Plugs ............................................................

Maintenance Schedule - 3.0L Engine ................

Approximate Fluid Capacities .................................

Filter Chart - 3.0L Engine .......................................

0-15

0-16

0-16

0-16

0-16

0-16

0-17

0-17

0-17

0-17

0-17

0-17

0-17

0-17

0-17

0-17

0-18

0-18

0-18

0-18

0-19

0-19

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

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