2012 LANCIA THEMA Service and Repair Manual

2011-2015 CHRYSLER 300 & LANCIA THEMA SERVICE & REPAIR MANUAL

ENGINE 3.0L Turbo Diesel - Service Information - Chrysler 300 DESCRIPTION 3.0L COMMON RAIL DIESEL ENGINE The 3.0L (183 C.I.D.) six - cylinder "common rail" direct injection engine is a 60° overhead valve design. The engine utilize a cast iron cylinder block. 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  Turbocharger and intercooler  Oil Jet Cooled Pistons  Swirl Intake Ports  Water cooled exhaust gas recirculation, Compliance with EURO V emission regulations  Chain driven D.O.H.C. per bank of cylinders, with 4 valves per cylinder The engine identification stamp (3) for the 3.0L is located on the right side of the engine block, by the generator behind its mounting bracket. 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. 12. Loose directed piston cooling nozzle. 12. Tighten directed piston cooling nozzle. LUBRICATING OIL PRESSURE TOO HIGH 1. Pressure switch/gauge not operating properly. 1. Verify pressure switch is functioning correctly. If not, replace switch/gauge. 2. Engine running too cold. 2. Coolant Temperature Below Normal 3. Oil viscosity too thick. 3. Make sure the correct oil is being used. 4. Oil pressure relief valve stuck closed or binding 4. Check and replace valve. LUBRICATING OIL LOSS 1. External leaks. 1. Visually inspect for oil leaks. Repair as required. 2. Crankcase overfilled. 2. Verify that the correct dipstick is being used. 3. Incorrect oil specification or viscosity. 3. (a) Make sure the correct oil is being used. (b) Look for reduced viscosity from dilution with fuel. (c) Review/reduce oil change intervals. 4. Oil cooler leak 4. Check and replace the oil cooler. 5. High blow-by forcing oil out the breather. 5. Check the breather tube area for signs of oil loss. Perform the required repairs. 6. Turbocharger leaking oil to the air intake. 6. Inspect the air ducts for evidence of oil transfer. Repair as required (slight oil residue is normal). COMPRESSION KNOCKS 1. Air in the fuel system. 1. Identify location of air leak and

repair. Do not bleed high pressure fuel system. 2. Poor quality fuel or water/gasoline contaminated fuel. 2. Verify by operating from a temporary tank with good fuel. Clean and flush the fuel tank. Replace fuel/water separator filter. 3. Engine overloaded. 3. Verify the engine load rating is not being exceeded. 4. Improperly operating injectors. 4. Check and replace misfiring/inoperative injectors. EXCESSIVE VIBRATION 1. Loose or broken engine mounts. 1. Replace engine mounts. 2. Damaged fan or improperly operating accessories. 2. Check and replace the vibrating components. 3. Improperly operating vibration damper 3. Inspect/replace vibration damper. 4. Improperly operating balance shaft 4. Inspect/replace balance shaft. 5. Improperly operating electronically controlled viscous fan drive. 5. Inspect/replace fan drive. 6. Worn or damaged generator bearing. 6. Check/replace generator. 7. Flywheel housing misaligned. 7. Check/correct flywheel alignment. 8. Loose or broken power component. 8. Inspect the crankshaft and rods for damage that causes an unbalance condition. Repair/replace as required. 9. Worn or unbalanced driveline components. 9. Check/repair driveline components. EXCESSIVE ENGINE NOISES 1. Drive belt squeal, insufficient tension or abnormally high loading. 1. Check the automatic tensioner and inspect the drive belt. Make sure water pump, tensioner pulley, fan hub, generator and power steering pump turn freely. 2. Intake air or exhaust leaks. 2. Refer to Excessive Exhaust Smoke. Refer to SMOKE DIAGNOSIS CHARTS . 3. Excessive valve lash. 3. Adjust valves. Make sure the rocker arms are not bent. Replace bent or severely worn components. 4. Turbocharger noise. 4. Check turbocharger impeller and turbine wheel for housing contact.

SMOKE DIAGNOSIS CHARTS The following charts include possible causes and corrections for excess or abnormal exhaust smoke. Small amounts of exhaust smoke (at certain times) are to be considered normal for a diesel powered engine. Repair/replace as required. 5. Gear train noise. 5. Visually inspect and measure gear backlash. Replace gears as required. 6. Power function knock. 6. Check/replace rod and main bearings. EXCESSIVE BLACK SMOKE POSSIBLE CAUSE CORRECTION Air filter dirty or plugged. Check and replace the filter if necessary. Air intake system restricted. Check entire air intake system including all hoses and tubes for restrictions, collapsed parts or damage. Repair/replace as necessary. Air Leak in Intake System. Check entire air intake system including all hoses and tubes for collapse, cracks, loose clamps, or holes in rubber ducts. Also check intake manifold for loose mounting hardware. Diagnostic Trouble Codes (DTC's) active or multiple, intermittent DTC's. Refer to 3.0L DIESEL - DIAGNOSTIC CODE INDEX article. Engine Control Module (ECM) has incorrect calibration. Refer to 3.0L DIESEL - DIAGNOSTIC CODE INDEX article. Exhaust system restriction is above specifications. Check exhaust pipes for damage/restrictions. Repair as necessary. Fuel grade is not correct or fuel quality is poor. Temporarily change fuel brands and note condition. Change brand if necessary. Fuel injection pump malfunctioning. A DTC may have been set. If so refer to 3.0L DIESEL - DIAGNOSTIC CODE INDEX article. Fuel injector malfunctioning. A DTC may have been set. Perform "Injector Classification Programming" using scan tool. Also refer to 3.0L DIESEL - DIAGNOSTIC CODE INDEX article and Return Fuel Quantity Test. Fuel injector lower washer doubled or missing. Remove and inspect injector washer. Fuel return system restricted. Check fuel return lines for restriction. Intake manifold restricted. Remove restriction. Manifold Air Pressure (Boost) Sensor or sensor circuit malfunctioning. A DTC should have been set. Refer to 3.0L DIESEL - DIAGNOSTIC CODE INDEX article. Turbocharger air intake restriction. Remove restriction.

Turbocharger damaged. Refer to TURBOCHARGER, DIAGNOSIS AND TESTING . Turbocharger has excess build up on compressor wheel or diffuser vanes. Refer to TURBOCHARGER, DIAGNOSIS AND TESTING . Turbocharger wheel clearance out of specification. Refer to TURBOCHARGER, DIAGNOSIS AND TESTING . EXCESSIVE WHITE SMOKE POSSIBLE CAUSE CORRECTION Air in fuel supply: Possible leak in fuel supply side. Inspect fuel system Coolant leaking into combustion chamber. Perform pressure test of cooling system. Diagnostic Trouble Codes (DTC's) active or multiple, intermittent DTC's. Refer to 3.0L DIESEL - DIAGNOSTIC CODE INDEX article. In very cold ambient temperatures, engine block heater is malfunctioning (if equipped). Refer to HEATER, ENGINE BLOCK, DIAGNOSIS AND TESTING . Engine coolant temperature sensor malfunctioning. A DTC should have been set. Refer to 3.0L DIESEL - DIAGNOSTIC CODE INDEX article. Also check thermostat operation. Engine Control Module (ECM) has incorrect calibration. A DTC should have been set. Refer to 3.0L DIESEL - DIAGNOSTIC CODE INDEX article. Fuel filter plugged. Refer to DIAGNOSIS AND TESTING . Fuel grade not correct or fuel quality is poor. Temporarily change fuel brands and note condition. Change brand if necessary. Fuel injector malfunctioning. A DTC should have been set. Perform "Injector Identification Programming" or "Cylinder Cutout Test" using scan tool to isolate individual cylinders. Also refer to 3.0L DIESEL - DIAGNOSTIC CODE INDEX article. Fuel injector hold-down(s) loose. Replace the copper washer(s) (shim) and tighten to specifications. Fuel injector protrusion not correct. Check washer (shim) at bottom of fuel injector for correct thickness. Fuel injection pump malfunctioning. A DTC should have been set. Refer to 3.0L DIESEL - DIAGNOSTIC CODE INDEX article. Fuel supply side restriction. For fuel system testing. Refer to DIAGNOSIS AND TESTING . Intake manifold air temperature sensor malfunctioning. A DTC should have been set. Refer to 3.0L DIESEL - DIAGNOSTIC CODE INDEX article. Intake manifold heater circuit not functioning correctly in cold weather. A DTC should have been set. Refer to 3.0L DIESEL - DIAGNOSTIC CODE INDEX article. Also check heater elements for correct operation. Intake manifold heater elements not functioning A DTC should have been set if heater

STANDARD PROCEDURE COMPRESSION TEST correctly in cold weather. elements are malfunctioning. Refer to 3.0L DIESEL - DIAGNOSTIC CODE INDEX article. Internal engine damage (scuffed cylinder). Analyze engine oil and inspect oil filter to locate area of probable damage. Restriction in fuel supply side of fuel system. For fuel system testing. Refer to DIAGNOSIS AND TESTING . EXCESSIVE BLUE SMOKE POSSIBLE CAUSE CORRECTION Dirty air cleaner or restricted turbocharger intake duct. Check Air Cleaner Housing for debris and replace filter as necessary Air leak in boost system between turbocharger compressor outlet and intake manifold. Service charge air system. Obstruction in exhaust manifold. Remove exhaust manifold and inspect for blockage. Restricted turbocharger drain tube. Remove turbocharger drain tube and remove obstruction. Crankcase ventilation system plugged. Inspect oil separator system for function and clear drain back hole in cylinder head cover/intake manifold Valve seals are worn, brittle, or improperly installed. Replace valve stem oil seals Valve stems or guides are worn. Remove valves and inspect valves and guides. Broken or Improperly installed piston rings. Tear down engine and inspect piston rings. Excessive piston ring end gap. Remove pistons and measure piston ring end gap. Excessive cylinder liner wear and taper. Remove pistons and measure cylinder liner wear and taper. Cylinder damage. Remove pistons and inspect cylinder liner for cracks or porosity. Repair with new cylinder liner if necessary. Piston damage. Remove pistons and inspect for cracks, holes. Measure piston for out-of-round and taper. Turbocharger failure. Refer to TURBOCHARGER, DIAGNOSIS AND TESTING .

Fig. 1: Fuel Injector Clamp, Compression Test Adapter & Bolt Courtesy of CHRYSLER GROUP, LLC 1. Warm up engine to operating temperature (approximately 80 °C, 176 °F). 2. Shut off engine. 3. Disable the low pressure fuel pump. 4. Remove the fuel injector. Refer to INJECTOR(S), FUEL, REMOVAL . 5. Crank engine several times with the starter to eliminate combustion residues in the cylinders. 6. Insert the (special tool #VM.10357, Adapter, Compression Test) (3) into fuel injector hole of cylinder to be tested. Install fuel injector clamp (1), bolt (2) and securely tighten. 7. Test compression pressure by cranking engine with starter for at least 8 revolutions. 8. Carry out test procedure at the remaining cylinders in the same way. 9. Remove the (special tool #VM.10357, Adapter, Compression Test) from cylinder head. 10. Install the fuel injector. Refer to INJECTOR(S), FUEL, INSTALLATION . DUST COVERS AND CAPS Cylinder Compression Difference Between Cylinders 5 Bar (73 psi)

Fig. 2: Covers/Caps Courtesy of CHRYSLER GROUP, LLC Due to the high amounts of failures cased by dust, dirt, moisture and other foreign debris being introduced to the engine during service. Covers or caps are needed to reduce the possible damage that can be caused or created. Fig. 3: Opening Cover Courtesy of CHRYSLER GROUP, LLC Covers over openings will reduce any possibilities for foreign materials to enter the engine systems. Using miller tool (special tool #10368, Set, Universal Protective Cap), Select the appropriated cover needed to the procedure. ENGINE GASKET SURFACE PREPARATION

Fig. 4: Proper Tool Usage For Surface Preparation Courtesy of CHRYSLER GROUP, LLC To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of aluminum engine components and multi-layer steel cylinder head gaskets. Never use the following to clean gasket surfaces:  Metal scraper (1).  Abrasive pad or paper to clean cylinder block and head.  High speed power tool with an abrasive pad or a wire brush (2). Fig. 5: Proper Tool Usage For Surface Preparation Courtesy of CHRYSLER GROUP, LLC NOTE: Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface.

2012 LANCIA THEMA Service and Repair Manual

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