ENGINE - 3.0L TD SERVICE INFORMATION
TABLE OF CONTENTS
page page
ENGINE - 3.0L TD SERVICE INFORMATION
DESCRIPTION
3.0L COMMON RAIL DIESEL ENGINE ...... 2550
ENGINE COVER .......................... 2552
DIAGNOSIS AND TESTING
ENGINE DIAGNOSIS - MECHANICAL ....... 2552
SMOKE DIAGNOSIS CHARTS ............. 2554
STANDARD PROCEDURE
FORM-IN-PLACE GASKETS AND SEALERS . 2556
REPAIR DAMAGED OR WORN THREADS . . 2557
HYDROSTATIC LOCK ..................... 2557
REMOVAL
3.0L COMMON RAIL DIESEL ENGINE ...... 2558
ENGINE COVER .......................... 2562
INSTALLATION
3.0L COMMON RAIL DIESEL ENGINE ...... 2563
ENGINE COVER .......................... 2568
SPECIFICATIONS
ENGINE SPECIFICATIONS ................ 2568
TORQUE ................................. 2575
SPECIAL TOOLS - 3.0L TURBODIESEL ....... 2577
ELEMENT-AIR CLEANER
REMOVAL ................................. 2581
INSTALLATION ............................. 2582
HOUSING-AIR CLEANER
REMOVAL ................................. 2583
INSTALLATION ............................. 2583
CHAMBER-MIXING
DESCRIPTION ............................. 2584
REMOVAL ................................. 2584
INSTALLATION ............................. 2586
HEAD-CYLINDER
DESCRIPTION ............................. 2588
STANDARD PROCEDURE
CYLINDER HEAD BOLT INSPECTION ...... 2588
VALVE SEALS - IN VEHICLE ............... 2588
VALVE SERVICE .......................... 2590
REMOVAL
LEFT .................................... 2592
RIGHT ................................... 2599
CLEANING ................................. 2606
INSPECTION ............................... 2606
INSTALLATION
LEFT .................................... 2606
RIGHT ................................... 2617
SEAL(S)-CAMSHAFT OIL
REMOVAL
LEFT .................................... 2627
RIGHT ................................... 2630
INSTALLATION
LEFT .................................... 2633
RIGHT ................................... 2636
CAMSHAFT(S)
DESCRIPTION ............................. 2640
OPERATION ............................... 2640
REMOVAL
LEFT .................................... 2640
RIGHT ................................... 2643
INSTALLATION
LEFT .................................... 2645
RIGHT ................................... 2650
CYLINDER HEAD COVER
DESCRIPTION ............................. 2655
REMOVAL
RIGHT ................................... 2655
INSTALLATION
RIGHT ................................... 2656
ARMS-ROCKER
DESCRIPTION ............................. 2658
OPERATION ............................... 2658
REMOVAL ................................. 2658
INSTALLATION ............................. 2659
LIFTERS-HYDRAULIC
DESCRIPTION ............................. 2660
REMOVAL ................................. 2660
INSPECTION ............................... 2661
INSTALLATION ............................. 2661
BLOCK-ENGINE
DESCRIPTION ............................. 2662
CRANKSHAFT
DESCRIPTION ............................. 2664
OPERATION ............................... 2664
STANDARD PROCEDURE
MEASURE CRANKSHAFT AND BLOCK
JOURNALS ............................. 2664
CHECKING CRANKSHAFT END PLAY ...... 2665
BEARINGS-CRANKSHAFT MAIN
DESCRIPTION ............................. 2666
SEAL - CRANKSHAFT OIL - FRONT
REMOVAL ................................. 2667
INSTALLATION ............................. 2669
SEAL-CRANKSHAFT OIL - REAR
DESCRIPTION ............................. 2671
REMOVAL ................................. 2671
INSTALLATION ............................. 2672
FLEXPLATE
DESCRIPTION ............................. 2673
REMOVAL ................................. 2673
INSTALLATION ............................. 2674
LINERS-CYLINDER
DESCRIPTION ............................. 2675
INSPECTION ............................... 2675
9 - 2548 ENGINE - 3.0L TD SERVICE INFORMATION WK
ROD-PISTON AND CONNECTING
DESCRIPTION ............................. 2676
STANDARD PROCEDURE
PISTON RING FITTING .................... 2676
REMOVAL ................................. 2677
INSPECTION ............................... 2678
DAMPER-VIBRATION
REMOVAL ................................. 2679
INSTALLATION ............................. 2681
PUMP-VACUUM
DESCRIPTION ............................. 2683
OPERATION ............................... 2683
REMOVAL ................................. 2684
INSTALLATION ............................. 2684
MOUNT-LEFT
REMOVAL ................................. 2685
INSTALLATION ............................. 2685
MOUNT-RIGHT
REMOVAL ................................. 2686
INSTALLATION ............................. 2686
LUBRICATION
DESCRIPTION ............................. 2687
OIL
DESCRIPTION ............................. 2688
FILTER-OIL
REMOVAL ................................. 2689
INSTALLATION ............................. 2689
PAN-OIL
REMOVAL
OIL PAN ................................. 2690
INSTALLATION
OIL PAN ................................. 2691
VALVE-OIL PRESSURE RELIEF
DESCRIPTION ............................. 2693
OIL PRESSURE SENDING UNIT
DESCRIPTION ............................. 2694
OPERATION ............................... 2694
REMOVAL ................................. 2694
INSTALLATION ............................. 2695
PUMP-OIL
REMOVAL
OIL PUMP PICKUP TUBE ................. 2696
REMOVAL ............................... 2696
INSTALLATION
OIL PUMP PICKUP TUBE ................. 2697
INSTALLATION ........................... 2698
JET-OIL
DESCRIPTION ............................. 2699
REMOVAL ................................. 2699
INSTALLATION ............................. 2700
PCV
DESCRIPTION ............................. 2701
REMOVAL ................................. 2701
INSTALLATION ............................. 2702
COOLER-OIL
DESCRIPTION ............................. 2703
REMOVAL ................................. 2703
INSTALLATION ............................. 2704
MANIFOLD-INTAKE
DESCRIPTION ............................. 2705
REMOVAL ................................. 2705
INSTALLATION ............................. 2707
MANIFOLD-EXHAUST
REMOVAL
RIGHT ................................... 2709
LEFT .................................... 2710
INSTALLATION
RIGHT ................................... 2711
LEFT .................................... 2712
ACTUATOR-SWIRL VALVE
DESCRIPTION ............................. 2713
REMOVAL ................................. 2714
INSTALLATION ............................. 2715
LINKAGE-SWIRL VALVE
DESCRIPTION ............................. 2717
REMOVAL ................................. 2717
INSTALLATION ............................. 2719
COVER-TIMING CHAIN
REMOVAL ................................. 2721
INSTALLATION ............................. 2723
SPROCKETS-TIMING CHAIN AND
REMOVAL
TIMING CHAIN GUIDE - UPPER ........... 2726
TIMING CHAIN TENSIONING RAIL ......... 2728
TIMING CHAIN ........................... 2729
INSTALLATION
TENSIONING AND SLIDE RAIL ............ 2730
TIMING CHAIN TENSIONING RAIL ......... 2732
INSTALLATION - TIMING CHAIN ........... 2733
TENSIONER-TIMING CHAIN
DESCRIPTION ............................. 2738
REMOVAL ................................. 2738
INSTALLATION ............................. 2739
BALANCE SHAFT
DESCRIPTION - BALANCE SHAFT ........... 2740
REMOVAL - BALANCE SHAFT ............... 2740
INSTALLATION — BALANCE SHAFT ......... 2743
WK ENGINE - 3.0L TD SERVICE INFORMATION 9 - 2549
ENGINE - 3.0L TD SERVICE INFORMATION
DESCRIPTION
3.0L COMMON RAIL DIESEL ENGINE
The 3.0L (183 C.I.D.) six - cylinder “common rail” direct injection engine is a 72°, overhead valve design. The engine
utilize a cast aluminum cylinder block molded around cast iron piston sleeves. The engine has aluminum cross flow
cylinder heads, four valves per cylinder, central injectors and dual overhead camshafts. The 3.0L is turbocharged,
intercooled, and also equipped with a EGR cooler.
Additional features are:
• Finger Follower Actuated Valves with Hydraulic Adjusters
• Counter Rotating Balance Shaft
• Oil Jet Cooled Pistons
• Swirl Intake Ports
• Chain driven D.O.H.C. per bank of cylinders, with 4 valves per cylinder
9 - 2550 ENGINE - 3.0L TD SERVICE INFORMATION WK
The engine identification stamp (3) for the 3.0L is
located on the left side of the engine block, below the
high pressure pump along with the 4 digit main bear-
ing identifying stamp (2) and the 6 digit cylinder bore
identifying stamp (1).
The engine identification number encompasses the
production number, engine plant code, engine type
and engine model.
WK ENGINE - 3.0L TD SERVICE INFORMATION 9 - 2551
ENGINE COVER
The insulated engine cover (1) is made of composite
material and used cosmetically to cover the top of the
engine and greatly reduce engine noise. Three brack-
ets secure the cover to the engine.
DIAGNOSIS AND TESTING
ENGINE DIAGNOSIS - MECHANICAL
CONDITION POSSIBLE CAUSES CORRECTION
LUBRICATING OIL
PRESSURE LOW
1. Low oil level. 1. (a) Check and fill with clean engine oil.
(b) Check for a severe oil leak, worn rings
(burning oil), oil leaking from the
turbocharger to the intake, or other root
causes for low oil level.
2. Oil viscosity thin, diluted or wrong
specification.
2. (a) Verify the correct engine oil is being
used.
(b) Look for reduced viscosity from fuel
dilution.
3. Improperly operating pressure
switch/gauge.
3. Verify the pressure switch is functioning
correctly. If not, replace switch/gauge.
4. Relief valve stuck open. 4. Check/replace valve.
5. If cooler was replaced, shipping
plugs may have been left in cooler
5. Check/remove shipping plugs.
6. Worn oil pump. 6. Check and replace oil pump.
7. Suction tube loose or seal leaking. 7. Check and replace seal.
8. Loose main bearing cap. 8. Check and install new bearing. Tighten
cap to proper torque.
9. Worn bearings or wrong bearings
installed.
9. Inspect and replace connecting rod or
main bearings. Check and replace directed
piston cooling nozzles.
10. Directed piston cooling nozzles
under piston, bad fit into main
carrier.
10. Check directed piston cooling nozzles
position.
9 - 2552 ENGINE - 3.0L TD SERVICE INFORMATION WK
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Description
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