Operation CHARM: Car repair manuals for everyone.

General

Displacement 3.0L
Number of cylinders 6
Bore 3.50 inch
Stroke 3.14 inch
Firing order 1-4-2-5-3-6
Oil pressure (Hot 2500 rpm) 40-60 psi
Cylinder head and valve train Combustion chamber volume 2.874 cu in.
Valve guide bore diameter Intake and Exhaust 0.2772 - 0.2763 inch
Valve seats Width-Intake 0.06-0.08 inch
Width-Exhaust 0.08-0.10 in.
Angle 45°
Runout (T.I.R.) 0.003-0.004 in.
Bore diameter insert counterbore diameter Intake 1.8542 in. MAX
1.8532 in. MIN
Exhaust 1.5645 in. MAX
Gasket surface flatness 0.003 in.
over 6.00 in.
Valve stem to guide clearance Intake 0.001-0.0028 inch
Exhaust 0.0015-0.0033 inch
Valve head diameter Intake 1.57 inch
Exhaust 1.30 inch
Valve face runout limit 0.002 in.
Valve face angle 45°
Valve stem diameter (STD) Intake 0.2744-0.2752 inch
Exhaust 0.2740-0.2748 in.
Over size Intake 0.289-0.290 inch
Exhaust 0.289-0.290 inch
Intake 0.304-0.305 inch
Exhaust 0.304-0.305 inch
Valve springs compression pressure Valve open to maximum lift 193-217 lb @ 1.17 inch
Valve closed 64-72 lb 1.60 inch
Free length (approximate) 1.83 inch
Installed spring height 1.650-1.736 inch
Service limit 10% Force Loss @
Specified Height
Rocker Arm Ratio 1:61
Valve tappet, hydraulic Diameter (Std) 0.874 inch
Clearance to bore 0.0007-0.0027 inch
Service limit 0.005 inch
Leakdown rate 20-200 seconds
to leakdown 0.125 inch @50 lbs load and tappet filled with leak-down fluid.
Collapsed tappet gap (nominal) Intake 0.088-0.189 inch
Exhaust 0.088-0.189 inch
Camshaft position sensor shaft bearing bore diameter Tappet bore diameter 0.8752-0.08767 inch
Camshaft bore inside diameter No. 1 2.1531-2.1541 inch
No. 2 2.1334-2.1344 inch
No. 3 2.1334-2.1344 inch
No. 4 2.1531-2.1541 inch
Camshaft Lobe lift Intake 0.251 inch
Exhaust 0.264 inch
Allowable lobe lift loss 0.005 inch
Theoretical valve lift @ zero lash Intake 0.404 inch
Exhaust 0.424 inch
End play Service limit 0.007 inch
Journal to bearing clearance Clearance 0.001-0.003 inch
Journal diameter All 2.0074 - 2.0084 inch
Cam bearing I.D. 2.0094-2.0104 inch
Runout limit 0.002 inch
Runout of #2 or #3 relative to #1 and #4
Out-of-round limit 0.001 inch
Cylinder block Head gasket surface flatness 0.003 inch @ 6.00 inch
Head gasket surface finish 1.0-3.3 Micrometers (RMS)
Cylinder bore Diameter 3.504 inch
Surface finish (RMS) 0.45-0.96 micrometers
Out-of-round limit 0.001 inch
Out-of-round service 0.002 inch limit
Taper service limit 0.002 inch
Main bearing bore diameter 2.713 inch @ 2.712 in.
Crankshaft and flywheel Main bearing journal diameter 2.5190-2.5198 in.
Out-of-round limit 0.0003 in.
Taper limit 0.006 in @0.003 in per 1 in.
Journal runout limit 0.002 in.
Surface finish (RMS) 10.0 micro in.
Thrust bearing journal Length 1.0148-1.067 inch
Connecting rod journal Diameter 2.1253-2.1261 inch
Out-of-round limit 0.0003 inch MAX @ 0.0006 in Total
Taper limit 0.0003 in per inch
Surface limit (RMS) 0.25 micrometers
Main bearing thrust face Surface finish (RMS) 0.4 micrometers
Runout limit 0.001 inch
Flywheel ring gear lateral turnout (T.I.R.) Automatic transmission 0.07 inch
Crankshaft end play 0.004-0.008 inch
Connecting rod bearings Clearance to crankshaft Desired 0.001-0.0014 inch
Allowable 0.00086-0.0027 inch
Bearing wall thickness (Std) 0.0612-0.0618 inch
Main bearings Clearance to crankshaft Desired 0.001-0.0014 inch
Allowable 0.0005-0.0023 inch
Bearing wall thickness 0.0962-0.0976 inch
1st and 2nd 0.0980-0.0955 inch 3rd and Rear
Connecting rod, piston and rings Connecting rod Piston pin bore diameter 0.9096-0.9112 inch
Crankshaft bearing bore diameter 2.250-2.251 inch
Length (center-to-center) 5.530-5.533 inch
Alignment (bore-to-bore max. diff.) Twist 0.003 per inch
Bend 0.0016 per inch
Side clearance (assembled to crank) Standard 0.006-0.014 inch
Service limit 0.014 in MAX
Piston Diameter Coded red 3.5024-3.5031 inch
Coded blue 3.5035-3.5041 inch
Coded yellow 3.5045-3.5051 inch
Piston-to-bore clearance 0.0012-0.0022 inch
Service limit 0.031 inch Max
Service piston selection
When replacing pistons, measure the cylinder bore. Install the indicated service piston.
Piston bore diameter Service piston grade required
Red 3.5043-3.5053 inch
Blue 3.5053-3.5063 inch
Yellow 3.5063-3.5073 inch
Ring groove width Compression (top) 0.0602-0.0612 inch
Compression (bottom) 0.0602-0.0612 inch
Oil 0.1587-0.1596 inch
Piston pin Length 2.248-2.278 inch
Diameter 0.9119-0.9124 inch
Pin to piston clearance 0.002-0.0005 inch
Pin to rod clearance Press Fit 4 Kilonewtons 900 lbs.
Piston rings - ring width Compression (top) 0.0575-0.0587 inch
Compression (bottom) 0.0575-0.0587 inch
Oil ring Side Seal-Snug Fit
Service limit Side Clearance 0.0006 in MAX
Ring gap Compression (top) (in gauge) 0.01-0.02 inch
Compression (bottom) 0.01-0.02 in
Oil ring (steel rail) (in gauge) 0.010-0.049 in.
Side clearance 1st ring 0.0016-0.0037 inch
2nd ring 0.0016-0.0037 inch
Lubrication system Oil pump Relief valve spring tension
force @ length
10.1-9.1 lb @ 1.11 in.
Relief valve to bore clearance 0.0029-0.0017 inch
Oil pump gear backlash 0.008-0.012 inch
Oil pump gear radial clearance Idler and driver 0.0055-0.002 inch
Oil pump gear height clearance 0.0027-0.0015 inch
Idler shaft to idler gear clearance 0.0027-0.0015 inch
Driver shaft to housing clearance 0.0019-0.0005 inch
Oil capacity with filter change 4.5 Quarts
Drive belt tension Vee-ribbed drive belts 6 rib (non-serpentine)
New belt installation tension
New belt installed and tensioned; engine not rotated.
34-23 ft.lbs.
Used belt reset tension
Used belt is any belt that has been rotated on an engine.
31-36 ft.lbs.
Cold belt audit check
Cold belt i.e., 3-hour soak ; 0 warm uo.
Allowable limits 20 ft.lbs.