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GM 3L Service Manual

1. N gt 38 VE028 3L Oil Pump Removal 1 Remove the bolts that attach the oil pump to the engine block 2 Remove the oil pump and gasket 3 Discard the gasket Engine 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 Remove the engine 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 7 Inspect the engine front cover for damage to the gasket surface or the oil seal surface Industrial Marine 3 0L 7A 12B 25 VE128 3L VE031 3L 7A 12B 26 Industrial Marine 3 0L Engine 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 If the sprocket runout exceeds specifications clean and remove any burrs from the shaft or replace the sprocket Measuring Timing Sprocket Teeth Backlash Tools Required e 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 J 6978 E Crankshaft Sprocket Puller 1 Usethe J 6978
2. 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 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 Gasket reuse and applying sealants 1 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 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 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 us
3. 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 e The valve rocker arms The valve rocker arm balls The valve pushrods Engine Industrial Marine 3 0L 7A 12B 23 Valve Train Components Inspect Cylinder Head Inspect the following areas The valve rocker 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 J 3049 Valve Lifter Remover Plier Type e J 9290 01 Valve Lifter Remover Slide Hammer Type 1 Use the 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 VE025 3L 7A 12B 24 Industrial Marine 3 0L Engine Cylinder Head Removal 1 Remove the cylinder head bolts 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 Oil Pan Removal 1 Remove the oil pan bolts 2 Remove the oil pan 3 Remove the gasket 4 Discard the gasket
4. Assemble mnnennennnanananaananaa 52 Cylinder Head Disassemble 0 1 53 Cylinder Head Clean and Inspect 54 Valve Guide Reaming Valve and Seat Grinding 57 Rocker Arm Stud Removal and Installation 58 Cylinder Head Assemble ssssssessss 59 Service Prior to Assembly n e 60 Crankshaft Bearings and Bearing Cap Installation 60 Crankshaft Rear Oil Seal and Housing Installation 61 Piston Connecting Rod and Bearing Installation 62 Timing Gear Oil Nozzle Installation 64 Crankshaft Sprocket Installation 64 Camshaft Installation essesssseeeeeeee 64 Engine Front Cover and Oil Seal Installation 65 Oil Pump Installation eeeeeenee 66 Oil Pan Installation ennenennnannnanannae 66 Crankshaft Pulley Installation nn 67 Cylinder Head Installation sesesesss 67 Valve Lifter Installation rnrr 68 Valve Rocker Arm and Pushrod Installation 68 Pushrod Cover Installation 40444440 nn 70 Valve Rocker Arm Cover Installation 71 Oil Level Indicator and Tube Installation 71 Water Pump Installa
5. E in order to remove the crankshaft sprocket J 6978 E 2 f necessary remove the crankshaft keys VE034 3L Engine Industrial Marine 3 0L 7A 12B 27 Camshaft Removal 1 Remove the two camshaft retainer bolts working through the holes in the camshaft sprocket VE035 3L 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 bearings VE125 3L 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 VE126 3L 7A 12B 28 Industrial Marine 3 0L Engine Timing Gear Oil Nozzle Removal 1 Remove the oil nozzle with pliers VE127 3L Piston Connecting Rod and Bearing Removal Tools Required e 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 a cloth on top of the piston 1 3 Usethe J 24270 to remove the cylinder ring ridge 1 4 Turn 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 th
6. 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 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 7 If the tang of the insert does not break off when backing out the installer break the tang off with a drift VE121 3L 7A 12B 78 Industrial Marine 3 0L Engine Cleanliness and Care Throughout this section it should be understood that proper cleaning and protection of machined surfaces and friction areas is part of the 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
7. 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 crankshaft bearings for dirt or debris imbedded into the bearing material Industrial Marine 3 0L 7A 12B 33 VE047 3L 4 VE039 3L n VE040 3L 77 7A 12B 34 Industrial Marine 3 0L Engine 8 Inspect the crankshaft bearings for improper seating indicated by bright polished sections of the bearing e 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 Engine Industrial Marine 3 0L 7A 12B 35 Crankshaft and Bearings Clean and Inspect Main Bearing Clearance Important Cranksha
8. in order to make sure that they have clearance 9 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 7A 12B 64 Industrial Marine 3 0L Engine Timing Gear Oil Nozzle Installation 1 Drive the new nozzle in place oil hole facing up with a suitable light plastic or rubber hammer VE127 3L Crankshaft Sprocket Installation Tools Required e J 5590 Crankshaft Sprocket Installer 1 Install the keys into the crankshaft keyways 2 Usethe 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 Engine Industrial Marine 3 0L 7A 12B 65 Engine Front Cover and Oil Seal Installation Tools Reguired e J 35468 Engine Front Cover Aligner and Oil Seal Installer 1 Use the 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
9. 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 Use the J 6098 01 in order to install the front and rear camshaft bearings VEO55 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 Usethe 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 2 3 Install the puller screw through the bearing bore and gt eo WC sr bearing to be installed and assemble bearing tool 1 a to the puller screw with the shoulder toward the To bearing Make sure that enough threads are engaged 10 mus i ao 2 4 Using two wrenches hold the puller screw 5 while Ol yn s Y you turn the nut in order to draw the bearing into the M bore When the bearing has been pulled into the bore remove the bearing tool and the puller screw and check the alignment of the b
10. 0 Valve rocker arm stud threads 1052080 Sealant Oil level indicator tube Engine Industrial Marine 3 0L 7A 12B 5 Engine Mechanical Specifications 1 of 2 Application SCS Mere Sid SSC gis id m Oil Pressure Minimum Hot 41 4 kPa 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 Oil Capacity With Oil Filter Change 4 00 ats Oil Pump Type Cylinder Block Bore Diameter 3 9995 4 0025 in Bore Out of Round Production 0 001 in Maximum Bore Out of Round Service Limit 0 002 in Maximum Bore Taper Thrust Side Production 0 0005 in Maximum Bore Taper Thrust Side Service Limit 0 001 in Maximum Bore Taper Relief Side Production 0 0005 in Maximum Bore Taper Relief Side Service Limit 0 001 in Maximum Runout Rear Face of Block to Crankshaft Center Line 0 002 in Maximum Piston To Bore Clearance Production 0 0635 0 0889 mm 0 0025 0 0035 in Piston To Bore Clearance Service Limit 0 0889 mm 0 0035 in Maximum 6 Piston Rings Piston Compression Ring Groove Clearance Production Top 0 03048 0 07366 mm 0 0012 0 0029 in Piston Compression Ring Groove Clearance Production 2nd 0 0012 0 0029 in Piston Compression Ring Groove Clearance Service Limit 0 0039 in Maximum Piston Compression Ring Gap Top Production 0 01 0 02 in Piston Compression Ring Gap 2nd Production 0 017 0 025 in Piston Compre
11. 0002 in Maximum 0 0254 mm Maximum 0 001 in Maximum 0 04318 0 06858 mm 0 0017 0 0027 in 0 0762 mm Maximum 0 003 in Maximum 0 1524 04318 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 Half to One Turn Down From Zero Lash 45 Degrees 46 Degrees 0 05 mm Maximum 0 002 in Maximum 1 27 1 778 mm 0 050 0 070 in 1 524 2 082 mm 0 060 0 080 in 0 0254 0 06858 mm 0 001 0 0027 in 0 01778 0 06858 mm 0 0007 0 0027 in 0 09398 mm Maximum 0 0037 in Maximum 0 1193 mm Maximum 0 0047 in Maximum 52 824 mm 2 06 in 444 490 N at 40 89 mm 100 110 Ib at 1 61 in 925 987 N at 30 99 mm 208 222 Ib at 1 22 in 41 91 mm 1 65 in 41 91 mm 1 65 in 11 25 mm 0 443 in 11 25 mm 0 443 in Cylinder Head Deck measured within a 152 4 mm 6 0 in area 0 0762 mm 0 1778 mm N 91 imd Engine Industrial Marine 3 0L 7A 12B 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 Go to Step 2 Go to Step 3 Remove the rod bearings and inspect the bearings and the journals for wear If the parts are OK remove the c
12. 30 Ib in VE030 3L 7A 12B 66 Industrial Marine 3 0L Engine 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 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 Ib in Tighten the oil pan bolts to the crankcase to 9 Nem 80 Ib in vE111 aL 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 Engine Crankshaft Pulley Installation Tools Required J 8792 Crankshaft Pulley Installer 1 Coat the front cover oil seal contact area of the crankshaft pulley with clean engine oil 2 Assemble the J 8792 as shown 3 Install the J 8792 o
13. AFT 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 HOUSING GASKET CAMSHAFT REAR BEARING HOLE PLUG ENGINE BLOCK CORE PLUG Industrial Marine 3 0L 7A 12B 13 Engine Industrial Marine 3 0L 7A 12B 14 VE003 3L Head Explode Disassembled View 3 of 4 CYLINDER HEAD VALVE SPRING CAP EXHAUST EXHAUST VALVE VALVE SPRING CAP INTAKE INTAKE VALVE VALVE STEM OIL SHIELD VALVE ROCKER ARM STUD VALVE SPRING VALVE STEM KEY VALVE STEM OIL SEAL Engine Industrial Marine 3 0L 7A 12B 15 Oil Pump Explode VE004 3L Disassembled View 4 of 4 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 OOONOVUIPWOD 7A 12B 16 Industrial Marine 3 0L Engine 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 co
14. Industrial Marine 3 0L 7A 12B 1 Table of Contents Engine Specifications sssssssseseeeeee 4 Fastener Tightening Specifications 4 Sealers Adhesives and Lubricants 4 Engine Mechanical Specifications 1 of 2 5 Engine Mechanical Specifications 2 of 2 6 Diagnostic Information and Procedures 7 Base Engine Noise Diagnosis 7 Engine Compression Test sseeesseeesss 8 Engine Noise Diagnosis eeeeeeeeese 8 Knocks Cold and Continues for 2 to 3 Minutes 8 Knocks on Start Up but Only Lasts a Few Seconds 8 Knocks at Idle Hot ese 8 Valve Train Diagnosis eese 8 Oil Consumption Diagnosis seeseesees 8 Low or No Oil Pressure Diagnosis and Testing 9 Oil Leak Diagnosis ssseeeeenme 9 Block Explode 1 Disassembled View 1 of 4 10 Block Explode 2 Disassembled View 2 of 4 12 Head Explode Disassembled View 3 of 4 14 Oil Pump Explode Disassembled View 4 of 4 15 Draining Fluids and Oil Filter Removal 16 Engine Flywheel Removal seeen 17 Distributor Removal sseeeeeenee 18 Ignition Coil Removal see
15. Oil Nozzle Removal 28 Piston Connecting Rod and Bearing Removal 28 Crankshaft and Bearings Clean and Inspect Connecting Rod Bearing Clearance nennen 29 Crankshaft Rear Oil Seal and Housing Removal 31 Crankshaft Bearings and Bearing Cap Removal 32 Crankshaft and Bearings Clean and Inspect 33 Crankshaft and Bearings Clean and Inspect Main Bearing Clearance ssssse 35 Camshaft Bearing Removal seessssess 37 Distributor Lower Bushing and Thrust Washer Removal nn 38 Oil Filter Bypass Valve Removal and Installation 38 Cylinder Block Clean and Inspect 39 Cylinder Bore Measurements nenn 39 Cylinder Boring and Honing seesssssss 40 Distributor Lower Bushing and Thrust Washer Installation 41 Piston and Connecting Rod Disassemble 41 Piston and Connecting Rod Clean and Inspect 42 Piston Selection sessseseeesseeeeeee 44 Piston and Connecting Rod Assemble 45 Camshaft and Bearings Clean and Inspect 46 Camshaft Sprocket and Retainer Removal and Installation ee 48 Camshaft Bearing Installation 49 Oil Pump Disassemble sese 50 Oil Pump Clean and Inspect 44 nenn 51 Oil Pump
16. 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 Industrial Marine 3 0L 7A 12B 37 J 6098 01 4 ELA o To as jeu AMD uu jas De ae A gt J 6098 01 VE054 3L VE055 3L 7A 12B 38 Industrial Marine 3 0L Engine Distributor Lower Bushing and Thrust Washer Removal Tools Required e J 9534 Distributor Lower Bushing Remover J 6585 Slide Hammer 1 Install the J 9534 into the distributor lower bushing 2 Usethe J 6585 in order to remove the bushing 3 Use a drift 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 Engine 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 gas
17. VER BOLT 32 VALVE LIFTER 33 ENGINE BLOCK COOLANT PLUG 34 DISTRIBUTOR GASKET 35 DISTRIBUTOR 36 DISTRIBUTOR HOLD DOWN 37 DISTRIBUTOR HOLD DOWN BOLT 38 OIL LEVEL INDICATOR TUBE 39 OIL LEVEL INDICATOR 40 PRIMARY IGNITION HARNESS 41 IGNITION COIL BOLT 42 IGNITION COIL WASHER 43 IGNITION COIL 44 IGNITION COIL WIRE 45 SPARK PLUG WIRE RETAINER 46 SPARK PLUG WIRE HARNESS 47 SPARK PLUG 48 VALVE PUSHROD 49 VALVE ROCKER ARM 50 VALVE ROCKER ARM BALL 51 VALVE ROCKER ARM NUT VALVE ROCKER ARM COVER BOLT VALVE ROCKER ARM COVER REINFORCEMENT VALVE ROCKER ARM COVER VALVE ROCKER ARM COVER GASKET INTAKE EXHAUST MANIFOLD CLAMP 10 INTAKE EXHAUST MANIFOLD WASHER 11 INTAKE EXHAUST MANIFOLD BOLT 12 INTAKE EXHAUST MANIFOLD GASKET Industrial Marine 3 0L 7A 12B 11 7A 12B 12 Industrial Marine 3 0L Engine VE002 3L Block Explode 2 Engine OOSOD OU KON Disassembled View 2 of 4 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 CRANKSH
18. and Bearing Installation Tools Required FACING FRONT OF e J 5239 Guide Set nen e 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 piston alignment mark MUST face the front of the engine block 1 Lubricate the following components with clean engine oil e 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 Usethe J 8037 and the 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 e Use the J 5239 in order to guide the connecting rod onto the crankshaft journal VE105 3L Engine Industrial Marine 3 0L 7A 12B 63 7 Remove the J 5239 Pl VE038 3L 8 Install the connecting rod cap and nuts Tighten Tighten the nuts evenly to 61 Nem 45 Ib ft 8 When all of the connecting rod bearings are installed tap each connecting rod assembly lightly parallel to the crankpin
19. ao by adding tie ee el he centerline Refer to Piston Selection Select the clearance specication yon can determine hefinish smallest piston for the piston fitting Slightly varied ae eke d pistons in a set may provide correction in case the Pe Ce SENSE ee ene first piston is too loosely fitted the piston at normal room temperature 2 Before you use any type of boring bar file the top of A ss v the en 2 z a the cylinder block in order to remove any dirt or Lond aed Arta pado BOHRER eg burrs If you do not check the cylinder block the final hone each bore in order to remove all stone or boring bar may be tilted this could result in the ad Maen Ein OCTO TO POS Sn rebored cylinder wall being at incorrect right angles Pee T from the crankshaft For piston to bore tolerance specifications Refer to 3 Carefully follow the instructions furnished by the Engine Mechanical Sp oeaks manufacturer regarding the use ofthe eguipment 9 After final honing and before the piston is checked 4 When you rebore cylinders make sure all for fit clean the bores with hot water and detergent i MEE bearing caps Hie in place Tighten the Scrub the bores with a stiff bristle brush and rinse A g cap pasa the bores thoroughly with hot water Do not allow bearing caps to the proper torque in order to avoid brasi terial t remaiiinthe cvlirider distortion of the bores in the final assembly The au a AE one anne ill w a u crankshaft must be clear of the boring c
20. arts and fasteners organized e An adequate set of hand tools e Approved engine repair stand e Anapproved engine lifting device that will adequately support the weight of the components 7A 12B 80 Industrial Marine 3 0L Special Tools and Equipment J 791 Camshaft Sprocket Remover 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 Engine 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 Engine 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 Industrial Marine 3 0L 7A 12B 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 7A 12B 82 Industrial Marine 3 0L 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 Engine J 24086 C Piston Pin Remover Installer Set J 24270 Ridge Reamer J 24420 C Universal Crankshaft Pulley Remover J 35468 Engine Front C
21. 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 Inspectthe 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 Checkfor 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 7A 12B 10 Industrial Marine 3 0L Engine VE001 3L Block Explode 1 Engine Disassembled View 1 of 4 OIL FILLER CAP EFE VALVE THERMOSTAT INTAKE MANIFOLD INTAKE MANIFOLD NUT oOONOVUIPWD 13 EFE VALVE SPRING 14 EFE VALVE BUSHING 15 EXHAUST MANIFOLD 16 INTAKE EXHAUST MANIFOLD BOLT 17 EXHAUST MANIFOLD STUD 18 INTAKE EXHAUST MANIFOLD GASKET 19 CYLINDER HEAD BOLT 20 CYLINDER HEAD 21 CYLINDER HEAD GASKET 22 LIFT BRACKET 23 LIFT BRACKET BOLT 24 ENGINE BLOCK 25 WATER PUMP GASKET 26 WATER PUMP 27 WATER PUMP BOLT 28 WATER PUMP BOLT 29 PUSHROD COVER GASKET 30 PUSHROD COVER 31 PUSHROD CO
22. cylinder bore to fit a piston move the hone up and down at a sufficient speed to obtain very fine uniform surface finish marks in a cross hatch pattern at 45 65 degrees prevent rusting Engine Industrial Marine 3 0L 7A 12B 41 Distributor Lower Bushing and Thrust Washer Installation Tools Required e J 9535 Distributor Lower Bushing Installer 1 Use the J 9535 in order to drive the thrust washer if removed into the cylinder block 2 Use the J 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 J 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 VE063 3L 7A 12B 42 Industrial Marine 3 0L Engine 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 VEDO 3 Clean the varnish from the piston skirts and the pins with cleaning solvent 4 Drythe components with compressed air 5 Donotuse a wire brush in ord
23. e 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 abrasive 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 com
24. e 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 e Wipe the oil from the bearings e Wipe the oil from the crankpins VE037 3L Engine 5 Use the J 5239 in order to remove the connecting rod and the 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 Inspect the crankshaft bearings for craters or pockets Flattened sections on the bearing halves also indicate fatigue J SS Industrial Marine 3 0L 7A 12B 29 VE038 3L A e VE039 3L 7A 12B 30 Industrial Marine 3 0L Engine 4 Inspect the crankshaft bearings for excessive scorin
25. ear safety glasses in order to avoid eye damage 1 Clean the camshaft in solvent 2 Drythe camshaft with compressed air 3 Inspect the camshaft bearing journals for scoring or excessive wear 4 nspect the camshaft valve lifter lobes for scoring or excessive wear 5 Inspect the camshaft retainer plate for wear VE075 3L Engine Industrial Marine 3 0L 7A 12B 47 6 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 7 Inspect the camshaft bearings for excessive wear or scoring Bearings with excessive wear or scoring must be replaced VE076 3L 8 Measure the camshaft for out of round taper or undersize with a micrometer Refer to Engine Mechanical Specifications VE077 3L 9 Support the camshaft front and rear journals on V blocks 10 Measure the camshaft run out at the intermediate journal with J 7872 Refer to Engine Mechanical Specifications 11 Replace camshaft if measurements are not within specifications VE078 3L 7A 12B 48 Industrial Marine 3 0L VE079 3L Ex ii CO VE080 3L CO VE081 3L Engine Camshaft Sprocket and Retainer Removal and Installation Removal Tools Required e J 791 Camshaft Sprocket Remover 1 Ifthe inspection indicated that the camshaft gear and retainer were in good condition the camshaft end play sho
26. earance with gauging plastic e 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 Engine Mechanical Specifications Engine Camshaft Bearing Removal Tools Required J 6098 01 Camshaft Bearing Remover Installer 1 Remove the camshaft rear bearing hole plug 2 Use the J 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
27. earing oil hole to the bore VE054 3L oil hole 3 Install a new camshaft rear bearing hole plug Coat the plug outside diameter with GM P N 1052080 sealant or the equivalent 7A 12B 50 Industrial Marine 3 0L Engine Oil Pump Disassemble 1 Ifnecessary remove the oil pump screen The oil pump screen has a press fit in to the pump cover Donot 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 Engine Industrial Marine 3 0L 7A 12B 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 safely glasses in order to avoid eye damage 2 Drythe parts with compressed air 3 Inspectthe following areas e The oil pump housing and cover for cracks scoring casting imperfections and damaged threads The drive gea
28. emove 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 Industrial Marine 3 0L 7A 12B 19 VE012 3L VE014 3L 7A 12B 20 Industrial Marine 3 0L Engine Intake Exhaust Manifold Disassemble and Assemble If necessary to replace either the intake or exhaust manifold separate them as follows 1 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 lb ft VE015 3L Intake Exhaust Manifold Clean and Inspect Clean and inspect the following areas e The manifold bolts and studs All manifold sealing surfaces e Any old RTV from the manifold VE016 3L Water Pump Removal Make sure the coolant is drained 1 Remove the water pump bolts 2 Remove the water pump and gasket 3 Discard the water pump gasket 4 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 en
29. er at a right angle to the piston measure the piston 11 mm 0 433 in from the bottom of the skirt 6 Subtract the piston diameter from the cylinder bore diameter in order to determine piston to bore clearance 7 For proper piston to bore clearance Refer to Engine Mechanical Specifications 8 Ifthe 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 9 When the piston to cylinder bore clearance is within specifications permanently mark the top of the piston for installation to the proper cylinder VE073 3L Piston and Connecting Rod Assemble Tools Required J 24086 C 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 Pressthe 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 VE064 3L 7A 12B 46 Industrial Marine 3 0L Engine Important When installing the piston rings onto the piston use a ring expanding plier type tool Do not ro
30. er 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 conditions e Cracked ring lands skirts or pin bosses Nicks or spurs in the grooves that may cause binding e Warped or worn ring lands Scuffed or damaged skirts e Eroded areas at the top of the piston e Worn piston bores and piston pins 9 Replace pistons that are damaged or show signs of excessive wear VE066 3L Engine 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 i
31. escription 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 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 four full round sleeve type bearings These bearings are a press fit into the engine block The camshaft timing sprocket is mounted to the front of the camshaft and is driven the crankshaft sprocket 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
32. f the end gap exceeds specifications Industrial Marine 3 0L 7A 12B 43 VE067 3L VE069 3L 7A 12B 44 Industrial Marine 3 0L Engine 12 Measure the piston ring side clearance 12 1 Roll the piston ring entirely around its ring groove on the piston 12 2 Dress the groove with a fine cut file if the 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 VE071 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 Engine Industrial Marine 3 0L 7A 12B 45 4 Measure the bore gauge with a micrometer and record the reading VE072 3L 5 With a micrometer or calip
33. 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 circuit 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 e Detonation or spark knock Check operation of ignition controls or knock sensor circuit e Loose flywheel bolts e Exhaust leak at manifold Tighten the exhaust manifold bolts and or replace the gasket e Excessive connecting rod bearing clearance Replace the bearings as necessary Excessive piston pin clearance Excessive crankshaft thrust bearing clearance e Bent connecting 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 brin
34. ft 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 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 e 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 Use the J 8062 in order to compress the valve springs VE089 3L 7A 12B 54 Industrial Marine 3 0L Engine Remove the valve stem keys 1 Remove the cap from the valve spring 2 amp 6 Remove the valve stem oil shield 3 Remove the valve spring 4 Remove the valve stem oil seal 5 8 Remove the valve 7 amp 8 Important Place the valves in a rack in the proper sequence so that you can install them in the same order np a Pr w VE090 3L Cylinder Head Clean and Inspect Tools Reguired J 8089 Carbon Remover Brush J 9666 Valve Sprin
35. ft 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 crankshaft 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 7A 12B 36 Industrial Marine 3 0L VE053 3L 5 Engine Remove the crankshaft bearing cap bolts 6 Remove the crankshaft bearing caps 10 Measure the gauging plastic at its widest area using the scale supplied with the plastic gauging kit Compare the measurements to Engine Mechanical Specifications e 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 e If the clearance is greater than Engine Mechanical Specifications select and install an undersized bearing set Measure the cl
36. g 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 e Worn valve rocker arm and or pushrod Broken valve spring e Sticking valves e Lifters worn dirty or faulty e Camshaft lobes worn e Worn valve guides e Worn or damaged valve keys e Bent pushrods 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 Engine 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 e Improper oil viscosity Use a recommended SAE viscosity for the prevailing temperatures Continuous high speed operation and or severe usage e Crankcase ventilation system restrictions or malfunctioning components Possible improper PCV valve e 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
37. g Tester J 8001 Dial Indicator Caution Wear safety glasses in order to avoid eye damage 1 Usethe J 8089 in order to clean the carbon from the combustion chambers and the valve ports Be careful not to scuff the chamber 2 Cleanthe following areas 2 1 The carbon and the sludge from the valve pushrods and the valve rocker arms 2 2 The valve stems and heads on a buffing wheel 2 3 The cylinder head and engine block gasket surfaces 2 4 The bolt holes and threads in the cylinder head and the engine block 3 Inspectthe 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 VE092 3L Engine Industrial Marine 3 0L 7A 12B 55 4 Usethe J 9666 and a flex bar torque wrench in order to measure the valve spring pressure e 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 a 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 indicato
38. g or discoloration 5 Inspect the crankshaft bearings for dirt or debris imbedded into the bearing material J 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 cap and bearing Tighten Tighten the nuts evenly to 61 Nem 45 lb ft VE037 3L Engine 8 Remove 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 Industrial Marine 3 0L 7A 12B 31 VE043 3L 7A 12B 32 Industrial Marine 3 0L Engine 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 Engine Crankshaft and Bearings Clean and Inspect Tools Required e J 7872 Magnetic Base Indicator Set Caution Wear safety
39. gine running and the cooling system pressurized replace the pump VE017 3L Engine Industrial Marine 3 0L 7A 12B 21 Crankshaft Pulley Removal Tools Required J 24420 C Universal Crankshaft Pulley Remover 1 Use the 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 gasket Pushrod Cover Removal 1 Remove the pushrod cover bolts 2 Remove the pushrod cover 3 Remove the gasket VE020 3L 7A 12B 22 Industrial Marine 3 0L Engine CP ES KON m En tee Wy V WE 5 T 4 0 C m A L S EZ 3 4 5 6 VE022 3L 2 3 Valve Rocker Arm and 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 8 The valve rocker arms 3 Measuring Camshaft Lobe Lift Tools Required e 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
40. hrod 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 j l aN AN s N N N A f Pushrod Cover Installation 1 Install the pushrod cover gasket 2 Install the 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 Nem 40 Ib in VE119 3L Engine Industrial Marine 3 0L 7A 12B 71 Oil Level Indicator and Tube Installation 1 Install the oil level indicator tube into the engine block 2 Use alight 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 VE017 3L Coolant Inlet and Coolant Thermostat Installation 1 Position the coolant inlet housing b 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 Nem 25 30 Ib ft 3 Install the coo
41. ket 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 Tools 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 Setthe gauge so that the thrust pin must be forced in about 1 4 in to enter the gauge in the cylinder bore 1 2 Center the gauge in the cylinder and turn the dial to 0 1 3 Work the gauge up and down to determine the taper 1 4 Turn the gauge to different point around the cylinder to determine the out of round condition Refer to Engine Mechanical Specifications Industrial Marine 3 0L 7A 12B 39 VE059 3L VE060 3L 7A 12B 40 Industrial Marine 3 0L Engine Cylinder Boring and Honing 5 The finish marks should be clean but not sharp The Borina Procedure finish marks should be free from imbedded particles i a i ae bori and torn or folded metal i al ah siet Boe t m M 6 By measuring the piston to be installed at the sizing contacting at points exactly 90 from the piston pin point specified
42. lant 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 7A 12B 72 Industrial Marine 3 0L Engine 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 Nem 22 Ib ft M gt m Lift Bracket Installation 1 Install the lift bracket 2 Install the lift bracket bolts Tighten Tighten the lift bracket bolts to 54 Nem 40 lb ft VE012 3L Engine Ignition Coil Installation 1 Install the ignition coil 2 Install the ignition coil bracket attaching bolts Tighten Tighten the attaching bolts to 22 Nem 16 lb ft 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 distribu
43. ll 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 Install 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 a gt 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 J 7872 Magnetic Base Indicator Set Caution W
44. 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 1 3 The intake valves 1 2 4 3 4 Adjust the correct valves as follows 3 4 1 Back off the valve rocker arm nut until the lash is felt in the valve pushrod 3 4 2 Tighten the valve rocker arm nut until all the lash is removed 3 4 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 4 4 When all the free play is gone tighten the valve rocker arm nut 1 additional turn 360 degrees Industrial Marine 3 0L 7A 12B 69 N V l Z oa SS ip f M I Ne ON 7A 12B 70 Industrial Marine 3 0L i j i Wi Engine 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 pus
45. n 18 Lift Bracket Removal sse 19 Spark Plug Removal eseseeseenee 19 Intake Exhaust Manifold Removal 19 Intake Exhaust Manifold Disassemble and Assemble sess 20 Intake Exhaust Manifold Clean and Inspect 20 Water Pump Removal eseese 20 Crankshaft Pulley Removal u 240u nennen 21 Valve Rocker Arm Cover Removal 21 Pushrod Cover Removal u 224uunssnennnnnnnennnnnnnnnnnnn 21 Valve Rocker Arm and Pushrod Removal 22 Measuring Camshaft Lobe Lift en 22 Valve Train Components Inspect Cylinder Head 23 Valve Lifter Removal 1 imeennennennnnnnnana 23 Cylinder Head Removal cccceseeeeeeeeeeeeeteeeeseees 24 Oil Pan Removal nnennnanannnannanannnannae 24 Oil Pump Removal inennnanannnannnnannnannae 24 Oil Level Indicator and Tube Removal 25 Engine Front Cover Removal ssssesesss 25 Measuring Crankshaft and Camshaft Sprocket Uu 1411154 ee 26 Measuring Timing Sprocket Teeth Backlash 26 Crankshaft Sprocket Removal susss 26 Camshaft Removal nennnaneenennenanannnnae 27 Crankshaft and Camshaft Sprocket Inspect 27 Timing Gear
46. 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 No cylinder reading should be less than 689 kPa 100 psi Important The results of a compression test will fall into the following categories 1 Normal 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 Type of 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
47. nto 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 Industrial Marine 3 0L 7A 12B 67 VE112 3L VE113 3L VE114 3L 7A 12B 68 Industrial Marine 3 0L Engine 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 Coat the bottom of the valve lifters with prelube GM P N 1052365 or equivalent 2 f reusing 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 Engine 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
48. olant to drain VE007 3L Engine 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 2 Remove the engine flywheel bolts Remove the engine flywheel Coolant Inlet and Coolant Thermostat Removal 1 NO a fF WO ND 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 Industrial Marine 3 0L 7A 12B 17 VE008 3L 7A 12B 18 Industrial Marine 3 0L Engine 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 Engine Lift Bracket Removal 1 R
49. oles as it may prevent the bolt from clamping properly or cause damage when the bolt is tightened e Assemble components while RTV is still wet within three minutes Do not wait for RTV to skin over e Tighten the bolts to specifications Do not overtighten Anaerobic Sealer e 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 e Follow all safety recommendations and directions that are on the container e To remove 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 e 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 e Tighten the bolts to specifications Do not overtighten e After properly tightening the fasteners remove the excess sealer from the outside of the joint Industrial Marine 3 0L 7A 12B 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
50. 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 Connecting rod to the crankshaft journal Connecting rod to bearing cap e Crankshaft main and connecting rod bearings e Camshaft and valve lifters Valve lifters guides pushrods pivot supports and rocker arms e Valve to the valve guide e 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 e A suitable parts cleaning tank Acompressed air supply e Trays or storage containers to keep p
51. orrect fastener in the proper location When you replace a fastener use ONLY the exact part number of that application General Motors will call out those fasteners that require a replacement after removal General Motors will also call out the fasteners that require thread lockers or thread sealant 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 7A 12B 4 Industrial Marine 3 0L Engine Engine Mechanical 3 0L Specifications Fastener Tightening Specifications Application Nem LbFt ibn _Camshaft Retainer Bolts Crankshaft Rear Oil Seal Housing Retainer Nuts 15 f 122 og FrontCover Bolts Intake Exhaust Manifold to Head outer Oil Pan Nuts rear pt Oil Pan Bolts to crankcase ooo o 9 Oil Pan Bolts tofrontcover 8 OilPan Studs to Oil Seal Retainer or Crankcase 2 Oil Pump Cover Bolts 8 N OilPumptoBlockBots oo a jJ Oil Pump Pickup Bot o Poo 07 Jo PushtodCoverBolts o Jo Rocker Arm Cover Bolts 8 Jo Sealers Adhesives and Lubricants 1052365 Valve train component prelube 105208
52. over Aligner and Oil Seal Installer J 35621 Crankshaft Rear Oil Seal Installer
53. pound 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 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 Engine 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 e 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 e To remove 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 h
54. 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 pressure gauge mproper oil viscosity for the expected temperature e Oil pump worn or dirty e Malfunctioning oil pump pressure regulator valve e 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 Oil galley plugs missing or incorrectly installed Install the plugs or repair as necessary e Oildiluted 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
55. r 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 The oil pump screen for broken wire mesh or looseness 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 VE086 3L 7A 12B 52 Industrial Marine 3 0L Engine 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 Theretaining 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 Engine Industrial Marine 3 0L 7A 12B 53 6 Inspect the pump for smoothness of operation by turning the oil pump drivesha
56. r 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 Dropthe valve head about 1 6 mm 0 0064 in off the 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 S KA u TC 7A 12B 56 Industrial Marine 3 0L Engine 6 Inspect the valve springs for squareness VE095 3L 7 Measure the valve seat runout e UsetheJ 8001 in order to check the valve seat runout The valve seats should be concentric to within 0 0508 mm 0 002 in VE096 3L 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 VE097 3L Engine Valve Guide Reaming Valve and Seat Grinding 1 Ream the valve guides for oversize valves if the 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
57. rankshaft and inspect the main bearings and journals for wear Replace the parts as necessary Does the engine continue to knock Go to 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 1 Inspect for loose accessory attachments the flywheel 2 Tighten or adjust as necessary Does the engine continue to knock Go to Step 5 System OK Remove the pushrod cover e 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 Step 7 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 Remove the rocker arms the pushrods and the lifters 2 Inspect the parts for excessive wear or damage 3 Replace the parts as necessary Are the repairs complete System OK 7A 12B 8 Industrial Marine 3 0L Engine 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 8 Remove the spark plugs 1 4 Throttle plates should be wide open 1 5 Battery should be at or
58. 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 valve adjustment Engine Industrial Marine 3 0L 7A 12B 77 Lubrication Caution Wear safety glasses in order to avoid eye The oil pump is gear driven from the camshaft Oil is drawn damage from the oil pan 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 outthe 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
59. rt 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 are 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 haft 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 nkshaft bearing caps 2 Coatthe crankshaft bearings with clean engine oil 3 Install the crankshaft Engine 4 Install the crankshaft bearing caps with the crankshaft bearings 5 Be sure that the cap directional arrows point toward the front of the engine block and the cap is in its original po
60. sition 6 Install the crankshaft bearing cap bolts 7 Thrust the 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 Nem 65 Ib ft Crankshaft Rear Oil Seal and Housing Installation Tools Required e 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 on the J 35621 until the oil seal bottoms 7 Remove the J 35621 from the crankshaft rear oil seal housing gt Industrial Marine 3 0L 7A 12B 61 J 35621 VE104 3L 7A 12B 62 Industrial Marine 3 0L Engine Piston Connecting Rod
61. ssion Ring Gap Top Service Limit 0 035 In Maximum Piston Compression Ring Gap 2nd Service Limit 0 035 in Maximum Piston Oil Ring Groove Clearance Production 0 001 0 006 in Piston Oil Ring Groove Clearance Service Limit 0 007 in Maximum Piston Oil Ring Gap Production 0 01 0 03 in Piston Oil Ring Gap Service Limit 0 04 in Maximum Diameter 23 545 23 548 mm 0 9270 0 927 in Clearance in Piston Production 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 Measured in cylinder bore 7A 12B 6 Industrial Marine 3 0L Engine Engine Mechanical Specifications 2 of 2 58 3666 58 4047 mm 2 2979 2 2994 in 0 005 mm Maximum 0 0002 in Maximum 0 0254 mm Maximum 0 001 in Maximum Crankshaft Journal Out of Round Production 0 005 mm Maximum 0 0002 in Maximum Crankshaft Journal Out of Round Service Limit 0 0254 mm Maximum Crankshaft Bearing Clearance Production 1 0 0254 0 06096 mm Crankshaft Bearing Clearance Production 5 0 0406 0 0889 mm 0 001 in Maximum 0 001 0 0024 in 0 0016 0 0035 in 0 001 0 0025 in 4 0 0254 0 0635 mm 0 0381 0 0889 mm 0 0015 0 0035 in 0 05 0 1524 mm 0 002 0 006 in 0 07 mm Maximum 0 003 in Maximum 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
62. the paper Industrial Marine 3 0L 7A 12B 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 solvent 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
63. 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 not attempt to install an oversize stud without reaming the stud hole VE101 3L Engine Industrial Marine 3 0L 7A 12B 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 7 amp 8 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 8 Install the cap on the valve spring 2 amp 6 oar WN gt VE090 3L 7A 12B 60 Industrial Marine 3 0L Caution 8 1 VE089 3L 8 2 8 3 Engine Wear safety glasses in order to avoid eye damage 7 Usethe 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 Cranks cra Di
64. tion esee 71 Intake Exhaust Manifold Installation 72 Spark Plug Installation eese 72 Lift Bracket Installation nena 72 Ignition Coil Installation sseeeeeees 73 Distributor Installation 44444He nennen 73 Engine Flywheel Installation 74 Engine Block Coolant Plug Oil Filter Installation 74 7A 12B 2 Industrial Marine 3 0L Description and Operation 4 76 Engine Component Description 76 Engine Block eeene 76 Cylinder Head ssssseesseeeeeeeenennne 76 Granksh ft u 2 Ri 76 Camshafts cede ee er 76 Pistons and Connecting Rods sssss 76 Valve Train BEER 76 Engine L brication u eea aah aa Me Aaa 77 Thread Repair mennmennenanenarennenanenaannaa 77 Cleanliness and Care 244usnsnnennnnnnnnnnnnennnnnnnnn 78 Replacing Engine Gaskets ssussss 78 Use of RTV and Anaerobic Sealer 78 Separating Parts mtnannennennenanannnnee 79 Tools and Equipment mnrnemennnnn 79 Special Tools and Equipment s s s 80 Engine Industrial Marine 3 0L 7A 12B 3 3 0L NOTICE Always use the c
65. tor 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 Nem 20 Ib ft 3 Connectthe primary ignition harness 4 to the ignition coil 4 Connectthe secondary ignition wires 1 to the spark plugs and the ignition coil Industrial Marine 3 0L 7A 12B 73 VE011 3L VE010 3L 7A 12B 74 Industrial Marine 3 0L Engine 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 Nem 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 Engine Industrial Marine 3 0L 7A 12B 75 3 Install the oil filter 4 Install the oil pan drain plug Tighten Tighten the oil pan drain plug to 25 Nem 18 Ib ft VE005 3L 7A 12B 76 Industrial Marine 3 0L Engine D
66. uld be checked Refer to Engine Mechanical Specifications 2 If the 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 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 Engine Industrial Marine 3 0L 7A 12B 49 Camshaft Bearing Installation Tools Required e J 6098 01 Camshaft Bearing Installer Important e A loose 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
67. utter when Se d d ub ma A d b Bet a b fad you bore each cylinder Cover or tape the crankshaft DOR Sr See APO RL He i by the contaminated oil After you wash the bore bearings and other internal parts to protect during A A the boring or honing process brush the dry bore clean with a power driven fiber brush 10 Permanently mark the piston for the cylinder to Honing Procedure which the piston has been fitted 1 When honing the cylinders follow the 11 Apply clean engine oil to each bore in order to 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
68. 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 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 e 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 e Several different types of equipment are available for reconditioning valves and valve seats Use the manufacturers recommendations of equipment to obtain the proper results Industrial Marine 3 0L 7A 12B 57 VE098 3L VE096 3L t T VE099 3L 7A 12B 58 Industrial Marine 3 0L Engine Rocker Arm Stud Removal and Installation Tools Required J 5802 01 Rocker Arm Stud Remover e J 6880 Rocker Arm Stud Installer Rocker arm studs with damaged

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