
General repair procedures 
Whenever scrvie,,,U. repair or overhaul work ,$ c;nric
Joinl mating ftlces ,7l1d gaskets Where 1'1 gasket IS lIsed tmlwl:CIl the ",,,,ill\1  [
Make SUfi) lh,,[ tnppcd holes nrc ciedncd WIth il pI pc clcilncr, and kcep thcm flcc 01 101l1llng compound If  tillS IS helll\) used unless 
speCIfIcally Instructed otherWIse Ensure that "II ollfrtes. (:hannels 0 1  pIpes ,lie Clt'ill ilnd blow thlough Ihelll. p,eleriluly llsing compressed ill( 
ai/ seal s 
Wheneve, nn od sCill is removed flom its wOlkll1\1  10Ciliion, eIther mdlvidu"lly or "s p"rt of iln assemhly, It should be lencwcd The very finc sc"lIng IIp of the sei'll IS e"slly dama\Jcd and WIll not seal  If the surface it COI11<1(:15 IS not completely c lean and free  frOlll 
SCHl\ches, nicks 0' grooves. If the o'iginal scaling surfi'lce of the COlnponern cannOI he restorCd, Ihe component shoul d he renewed, PrOlect lhe lips of the scal from any surlace which mi'lY damage them in  the course of fmlng. Usc wpe or a conical sleeve where POSSIble, LUb ricate the senl lips WIth 011 befole fruing and, on dual lipped se"ls, fill the space be twcen the hps With grease. Unless otherwise stated. all seills must be hlled with then sealing hps toward the lubricilrH to he seillcd Use iI\ubuli'l' <111ft 01 block 01 wood 01 the npploprime sIze to II1sta ll 
) I he  scal ilnd, lithe sCi,1 housing IS ~houldeleu. drive the seill down to the shoulue,. If the scal  hOUSIng is unshouldcred, the seal Should be fItted with its lace flush W ith the hou$lIlg top face, 
Screw IhrCiU/s and lasleoings Always cnsurc that a blind t"pped hole is completely free from orl.  U
reilSe, 
wilte, or  other flUId hcfore instatllng the hott a' stud. Fililu'e 10 do tillS could C,luse thc housm\) to c"lck due to the hydrilulic <1ction of the bolt or slud ilS It IS sc,ewed '" When tluhtenlllU ,1 cilswllilled nut to ilCCCpt iI spht pin, tIghten the nut to the speCIfIed torque, whele ilpphcilh le,  and then lIghten furthe, to the next split pin hole Ncver slilckenlhe nulla "lrgn a spirt pin hole unless ~t
SOllle Inswnces, where no a lterniltlve IS  poss ible. II  hilS been necessary 10 resort to the  use of a manufilclurer"S tool and thIS has been done for reilsons of safety as well as  Ihe eHlcien! completion of the repair 
operation. Unless you are highly Skilled  ilnd hilve a thorough unde,standlng of the procedure desc(lbed, neve, " tWlllpl to bypass the use of any specl,,1 tool when the procedure descrIbed specllies ils use, Not only IS I here  a ve,y great risk of pe,sonal Injury, but expensive dillllage could be causJd 10 Ihe components involved 
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 I. 
) 
24 
Cylinder block Bore d'iJrllCIC ' mm (.n). SI;'1ncli'll(t {j.,1CICS , 
2.3and4 .. OverSIze  UI,lcics. A ... Il and C 
Crankshaft Endfl0i1 1 mill (OIl) . 
Camshaft nUllS! plme Illtcknc~s 111111 (m). Red Blue Endflo;'1 illm (m) 
Pisto ns elc.uance III bo.e ""11 (Ill) Rm!J !J'~P mm (m) Top. CClille BUliom 
Connecting rods BO!I "lid IHJ.IIUI!IIUn'UHU  r, h: ;,. ;uu";C  m ... (m) 
V
E'h,"'~I 
Lubricatio n systmn e"p.1';' ly W,t h t,llc' W,thout  hll(:' 0,1 p,eS~I"e (111111111,,,11' 1ll 80 C) 750 'PIII 7000 .pm 
Torque w re nch sctlings Malll hea.",u CalIS B'g·cnd ClIPS C .,II.kshalt pulley boll C;.III sh;.lt Oem Call1shilit th'ust vlme Flywhcel 
TUlII"\) cove' To hlock To .1(111pt(II I)I;II C 0,1 pump 0,1 pUll',.  covel Rocke. ~hall Slimp 
Staue 1 SI:lge  2 0" dUlln pllill CyIUI(I,,;, heild bolb SI1I\Jf! 1 S I; 'UI , 2 
S Ing.., 3 (;dlCI 10 1020 nUllul(lS WilH) 
Chapter 1 Engine 
93.0 10 1093020 (3  6618 10 36(22) InCr(!mcnlS of I 0010 (e.ClO04 ) 
935201093530 (3 .68 19 10 3 (823) I ncrements 01 0010 (0.0004 ) 
0080100280(000311000110) 
3.960 10 3 985 (0  1559  10  0 15(9) 3986 to <1 011 (0 1569 to 0 1579) 002 to 0  10 (00008 (000039) 
0028100048 (00011 (000019) 
038 10058 (00150 to 0027.8) 038 !O 0 58 (001 50 100 0228) 038 to 1 110 (00150 10 00551 ) 
0006 10 0 064 (00002 10 0  0025) 
46" 
035 (0014) 
0 40(0016) 
24 -oroc 72 ' ABOC 
73 ' OBOC 
25 ' ATDe 
0023 10 a aGO co 0009  10 a 0024 ) 525 (2 06(9) 
a 
020 I n 0 063 (0 0008 to 0 0025) a  046 to 0 089 (0 0018 to 00035) 
1 25 h ilC (7 5 Pilot) 400 litre ("l0 IJIIlI) 
1 a kol/cm' ( 14 2 II>IIIIl' , 28 kul/clII' (398 Ihf:,n') 
Nfll 90 to 104 29 to 34 
4 2 to 50 42 to 50 17 to 21 65 to 7 1 
17 
t o 2 1 
1 3 to 1 7 141017 91013 59 10 67 
4  107 7 10 10 2 1 1028 
39 to 5 4 54 10 69 
Ihf It 6610 77 21 to 25 3 1 1037 31 10 37 13 to 15 48 1 0 52 
13 10 1 5 101013 10 to 13 71010 44 1049 
3105 5 10 7 15 to 21 
29 10 4 0 40 10 5 1 70 to 85 S I;'lle 4 (:,Itt"  '",,",nU enumc to , 15 .llIl)Ules ill 1000 fpm) 
Ror;kl1' cow:! ...... ..............•.. 
95 t o 1 15 Bilek 011 1/2 "to 7 IU'I)  and .elolQuc one bOlt al a l'I11C 10 Stagc 3 valu<] 310 5 
procarmanuals.com 

Chapter 1 Engine 
: Part B: 3.0 litre engine 
General 
) 
rr 
T ype  .. Bore Slroke 
Cubic capacoly .... Compression 111100 
cylinde r block Bo,e dlnmCler mrn (In): $wndMd urnelcs. A B.CllndD DverSilC {)Inel!} A 
Cranksh aft Endllonl  mrll (III) .. 
Camshaft ThruSI plate  tlllckness mm (III) EnclllO;1! 111m (In) . 
Piston s Clearances III bore mm (111) nlllg gap mm (tn) Top .. Cenue BOllom .. 
Connecting rods Blg·end hea,ony running clearance mm (In) 
Valves Seill :myle . V,llve  clearance (cold) mm (m) Inlel .. E~h

Chapter 1 Engine 45 
---------------------~--------------~ 
) 
33 7 ApplylllU se~lInu COIll I)(IUlld to the unnkshnlt pulley wash"r 
34 Cylinder hcads. rocker gCM and inlct manifold - rc lin ill(j 
Lubricate the valve tnppets wllh cleiln cnUlIle  otl ;md Ulse,1 th,,'" It! th o cylindcr block. Ensurc they ille fm"d in thei . OIlDlIlal tOGillrOIl~ 2 EnSIHe tha t the mnllng lilces of thc cylinder hlock ilnd 1he cyllndel h~,lds a.e  clean, 3 Position the new cylrnder hCild  \I,1skets over 1he  \Julde I>ushe~ on the cylinder block. Chec k thm they ilre correc 11y locilled The n!Jht ilod 1, ,11.hnnd  gilskets il,e different TIl(:  onskets ilrc rn,lrke d FRO NT  TOP (pIl Ol0S) 
! 
.' 
/ . .-,,~ .. ~ 
Fi(J 1.7 T iuiltening sequence fo r cylinder he
~4 3A TIl(: dlfferencc hClween the left nmt ','Ilht  head  gnskets The ""OW mdlcoltes 
. oot 3438 CyJrnder  head \1,1Skt:1 pOSrilon 
rnarkinos 
• 
r.
/ 1':' .j I 
,  I  • 1 ... , 345T.  h  ' , __ ..1 I!., u U  lco"I\I 1he cyhnder head bolts 34,7 Guidlfl~J 1he roc ke. ilrm il
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Chapter 1 Engin e 47 
--;; ble chec k ~II littings nnd elcct"cill connections. Ensu,e  thnt the 2 .,",or is correctly lilted ilnd Ihil t Ihe IUnil,on tlmmg StJtlC  Selllll\) 's distrlU 
I CI  , t II in doubt Ie el 10 1npler . eorr~~ ~10VO 1110 SPJlk plugs nnd the '- '  conneC lion from Ihe 1\)111110n 3 '1 Turn Ihe engine over on Ihe st~rler motor unlil Ihe 011 pres~!II{! co'· . light is e~til1gu,shed or unlIt 01' pres sure IS .ccorded on IIl{! 
warnu"lg . d I This  witt ensure Ihill Ihe  engme ,s no l Slarve  0 0,1 dU"I1!11he g~~ge,. I,w minules running alte. IflIlJ.1t SI.:lrl·Up. The l uel syslulll W Ill ,,,toea . I· • be p!"iOled dunng IllS ope.atlon. 
:  SOReconne<:llhe  '_ ' conneclion on the 'IIn'tlon co,1 and ,elll th e sp.:llk 
lugs  and loads . 
Stilrl .Ihe ~ngme .. ~ AS soon as Ihe  engme  Ilfes and .uns. keel)  ,t gOll1g ill il lilst \lckov(;. 
nl (no las te,) and bring it up 10  nOlll1nl  wo.kong  ICmpernturc ~ ~s the engine WilflllS up there  WIll lie (){I(I smelts nnd SOfll~ "mol Il 
hom  pariS getting hOI and uUI.l1Ing  olf all (leposIl5. The Signs  IU luok 
10' arc l eilks 01 w
exact  gos liUht position unlil lhe w:1I1l11h ;oml vlh!al'On  hiwU ;I(;t,," on Ihem,  and il is almos t CllrWU1 th.11 th(ly WIlt ncrHI I'Hhw1l1l1H hllth". Tills should be done.  of course. wllh Ihe  C"( ,,nc slopped 7  When nOrmal running lefllJ}Coallll e hilS hecn .cnch",
I' !.tilled as a new engine and run IIl.1t.1  .cducc(1  spcud tor Ih~ IUS I 1000 miles (1600 km). 
PART  B: 3.0 LITRE ENG INE 
39 Gener;!1 description 
ThC !lcne'il' conl,uu'illion 0 1 the  3 0 hue enuine is sil11l'nr 10 the 2 8 
( \:\.~ ,..d r •• -~~ ..  ; ~ 
389 Recloeck,,'u  Ihe Iluhlness 0 1  Ihe cyhnder head bolts afte. ,,,,,.loIlU lhe enu")e fOf 20 'I1In ul('"5 
hire nllu""1 d(:~c"hed III Sec(,on 1. Thc Slunillcan t dltferences  iI.e .1S follows 
(i') FI,'I •. yllll(/vr ht',1(/$ ",'III the combustion cl.,1mba,s itl lila I".~I()IIS (b) Imhvr(/",llly IIIOUlIlCd rOC~t'f ,Jrms illstead of a lockct sitaft (c) W"lvr pump 10C,11cd 011 Ihe ,i!llu of the allgine ((f) DiSlfllmto' ,WI/ orf ,,"1/11' (I,ivell f,om thc front of thc c,lrmllllft (e) ML'ch,mic.1llllcl,Jl/flfP ollcfMed by ,1f1 ccccntric on tllC frolll vllhc c,lmshMt (f) /rr.';" (Ill sC;llloCMCII '" ,1 S':l'olfall: c,ltric, (y) OJ! trltvr IOt';llvl/ on tlw "I}fI1 lef(-h,mrf sidc (If tlw clI{Jlln' 
Fig. 1.9 Sectional view o f tho  3.0 litre engine ( Sec 39) 
i 
" 
'j 
~ .... ------------------------------.. ~; 灲潣慲浡湵慬献捯m 

Chapter 1 Engine 49 
----------------~--~----------------= anuill  transmiSsIOn  models, remove foul clops 
Ir~nsler it to a WOrk lJench 
4 $ Engine disill1lotling -generill 
Refer \0 Sec t,on 7 
46 Engine illlcillilrics -removi\1 
.. 
1,',lh the engine sep,l rated from th" t r;IIl~:nHS~r()" remove Ihe ~.tcrnally mounted componelliS ;l~ lulluw~ 
C;J//)Ulello, i.lnd fllcl {lump (C"'1!,lt" 3) IlIlel ,wll exhiwsl tII,wi/a/ris (Chaf!/t't 3) Sp,>r/( plugs and drS/fllmlor (Chaplet 4) AllCllwlor (Chaplet /2) F.w  ,7I!d policy (CII,71I1C' 2) W.JICf pump ,wd Ihcffllos/.1I (Clmp/t't 2) C, ,1IIkc,lSC vcn/iliilion lubc 011 {,f/CI (Scc/ion 40) Ol/Icvl!! r/rpsllc/o; and {,/lCf C,?!, [II!1int' 1II01tn/ill.ll  h,.1r:kvls Ciulell (Ch,7/I/l'l 5) Powl'r S/Cl'l/IIN 1'(11111' (Ch;lll/Vf 10J 
<11 Cylind(Jr heads relllowti with engine in car 
I 
Q,scunnecllhe IJiltlery  le,lds ") ~cmove the splilsh  slucld. by renuJVIII
,onneCI  the  vac\JUnl h"e I
MId  I I If . CiI( 10 lie dlSl1i Julor Reillove aile h Xlng bolt 11 0
' I 
a Ihe dlst"I>[1I0r ilSsemlily. 
'Sconllect Ihe all II 51 halts' ,  ' ernillOr Cil) es. ilcken the ailelllntor 1110ul1l11lg un( 
Fi~,. 1 .10 Turn the rocker (HillS to olle side 10 relllove the pushrods (Sec 47) 
15 n,,,,,ove Iwelve lIolts ilnd delilch Ihe exh,lusl I1\,lrlllolds  frOI" Ihe cylrrlrtr:f he,lds. 16 Sinckell the cyhmter hend  boilS progressively in the revtnSe order to Ih"l shown ill FIll 1.19. IlcrllOVC  Ihe bolts nlld hit olt Ihe cylindOf  head. 
It lile (.Iilsket  has stuck and the cylrnder heJd cannot lJe lifted off. wp the cylinder heild wllh n  hide·f.1cert. or plnstic·headed hJmmer. 00 nOI try to pri se IlIelil off wllh a  screwdrivOf Of rtilillage WIll result. 
4 8 
Cylinder he,l(ls -rernovfli wilh engine O\lt o f car 
Follow Ihe sequence  (.I,,·elllll SectIon '17. 51;lItll1g.l1  PillillJl1lph  10. dl$lcoa,d,n!1 leil.!lellCeS to pa'is willch hJve alreildy bcen rcmuved 
49 Villve$ _. removal 
Rt:rllove the d('POSIlS /'0111 tire corllb\lsl,on chambers ~nd vnlve 
h eads by ScrilPIl1!l and W" ~ b'\Ishlll(.l  Tilke CJre  nOI 10 scratCh the cyllnde, he~d gaskel lilces 2 Lay the CylOl(ier hemt on ,IS sllll) .llld h t the lo,~ed cnd of .1 VJlve spllng compressor ove, the ~plln9 rctiluler ""d ti le head uf the complessor screw in Ihe cenl'e of Ihe v"lve head 3 Compress Ihe sprrng abolll " qUJller 01 an Ulc h 10 Iree Ihl} split colle l hom the top 0 1 the v,llve stelll. If Ihe sPltng ,eliHner "nd collel Slicks. do not screw the co",p,essor down lurlhc< . bec"use IIIIs lII.ly dJr11J\je the valve  Slem.  bUI lJp the sprong  reliluler sha,ply wllh a Ioghl 
hammer. 'I When the Iwo halves of Ihe collet h')ve been '(:nloved. onscrew the spllng compressor umrl Ihe spring IS no longe, compressed nnd 
remove Ihe compreSSOr . 5 f1Olllove the spltng retnlner.  the spflng and the oil seal from Ihe villve Slem. Ihen wrlhdrflw Ihe villve from I he cylinder head. 6 D iscard  the valve Slem all senls  and plflce Ihe Olher componenls to\jellrCt. identilying them so Ihal they arc refItted III the correC I plnce 
III Ihe cylinder  head. 7 Remove Ihe sp,11k plugs from Ihe cyhnder hend.  II nOI alrendy 
removed. 
50 Rocker arms -removal 
1 Remove the SIIfI nul from Ihe foch" .1'111 Illoullt,n\) stud 2 Lift off the  rocker 
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7 
Chapter  1 Engine 
Fig . 1.1 8 R ear oil sen I ilnd ildaptcr pliltc (Sec 84) 
84 Renr oil se;1i ,,,,(I lIywheel  - rc fitti"u 
1 I'll the ()n!J"I(~ .r,," ,,(1"1'10' pla1<:1 and s(:clIre ,I wllh 'I S IIv(: holls. 2 Smenr  en\J1ne  (ld OlltO  the CI,mkshah '''".  Smear 0,1 on the lip 01 the sea l tlnd pos(( lon tlon ';".11 on th e  cran hha ll. 3 Align the seil l c;""er holos wllh Ihose 011 the cylrnd(:, hlock . Insell the loul bolts and 11!lhlCll Ihem 10 the SpeCifIed 10lqUfl 4 F it the  flywher.:l . or dllveplalc on au lOlllallC  lwnsrnis sion Illodels. 
InSerll h e  six holl S ;",d u\llole rllhem 10  Ihe  10 lque w rench sell"'U  Uiven in lhe Speclllcm'olls 
8 5 Sump -rciiuill!) 
En~",,, lh;ol  Ill" ru,rI "'!)  ',u.l,u :e s  01 hoth IllI.! Slimp a"d t h e  c(,1nkcilsc ,lie cl ea" ,mol IIi,1I n", '.""I",!)  SlIrJ ,u;e 01 the Sli mp IS not d'S lo lte d. 2 Apply IO" ,I,,,!! c"'''pollnd 1 0  the  pOUltS wllel(~ Ihe l"llllll) cover ablilS  lhu ,;yir r"lr" 1,Io ck .lIId where Ihe rea' 001 $u,,1 carr.(:r "dIOIllS  II 3 Pln ce  tloo \J,,~k"l '" fJo~.t.on, lIt  tlo"  SlIm l} ,'Ild IIlS(). 1 lhe r0Io1111il1l) 
bolts ImUO I tl!lhl 4 PrO!lres~lvely 1I!llIt,," llw sump holt s 011 opposIte I'ilr ts lIllt,1 all 0 1 
t
hem ,H" il l tl", ~ 1"":lllI"d IOlllUU , 5 FII ,1 now w;,~h", 10 Ihe ~Ul1lp II"'UI pili!) , IIlscrl  lhe dl,lIll pllll) and 
t ,uhlen ,t 
8 6 Cylinder h e"ds re;rssernbly 
L~y the cylrnd" r h",.\! on .IS s Ide. luhrrcnt e cvcry valve Uu ide with eng;l1(! oil. ,lilt! ,"~,,"t the valves 11110 the \Ju, dc Irom whIch lh ey wele remov(:d 2 To ,WOld d
lhero.s dilnlJC'  oltl1<.: ~I""IU rcW""C' dillllil\)IIlU tllC villve SHlm 011 sen l 
G Ahcr "lsert")!J tit" ~pllt collets. r eleilSo  the spllny compressor (111(1 
rcmove II 7 C hcc k th"t lh..: ~pl'l cull":IS hilve seilled properly and t
Fi g.  1.1 9 Tightening sequenc e for cylinde r head bolts on the 3.0 litre enuine (Sec 8 7) 
a Repe"l liln pruccdwn orven III p;ua!Jrnphs 1 to 7 o n the (CmJlnlllU 
v,llv"s 
87 Cylinder heads - re fitt;nu 
11 the tappels w ere rcmoved.  luiJricnle  lhe  lilppets nnd I heu hores wnh enoine orl nnd insor t thOlll wilh lhc;, d Ished cnds uppermost Ensule lha l every tappet ,s rclltlcd Into lhe hore hom whIch II wns 
t nkcl1 
2 Mak e  sure  tha t Ihe rna t"'!1 surlaccs o f lhe cylinder block.  cyl lndor henrJs  ;Uld 1111,,1 Ill,lIlIlold ;lIe de;"l. then plnce new cyhndcr head \Ja~kets ove, the Wildes un thn cylrmh"  block. Tho cyirnder head \I,,~k ~IS beilr  thO malkln\! TOP f:nON T ilnd nced to h e  pOSII,oned 
cOII(:ct ly . 
3 Low ul  Ille cyl ""lcr he,1ds ov"r the" posl tlonrngst u(!s, Although t he cyhlld\~r headS ,"0 Id entlc;,I,  they should h,lVe  been Illtlrke d when remuved ilnd should be lehllUd III  thcrr ()IIUinal positions t1 Inse rt  the cyirndcf 11I)"d boilS f"'!I(:r t.!Jh l then tIghten  lhelll prUglC SSlv(: ty OIl the olde, shown III r,U I l!J and III llle  stnucs",s U iven 
m the SpcelirC;lt'OnS 
88 Rocker arms and cover
s -refiUing 
Ensure Ihm "II Ihe  puslllOlls ,lie ,nselwd I!ltO the" p'llpor placos ;II1
)olt S nntl lighten them t o  the spec ,f led torque. 
89 Valve clearnnees -checking nnd adjustment 
R eier 
to SeC!lon 3 5 
90 Engine ancillaries -refitting 
R eier 10 Sec tIon 46 and ref, t lhe  I. ste d componenlS w,th refercnce 
to th e Chaptels ind,cilte(f 
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Chapter 3 Fuel and exhaust systems 67 
Torque wrenc h setting s Fuel  P\JlllP Inlet n'
G ene ra l SyS1c'" Iype Idl e sp ce d CO "o,![ ull" Fu el p"mp rfelov(!ry (nHrHrl1lJlll) 
SyS1cn, P")~"'''U Fvcll,mk Co1P,lC '(y 
Torque wrenc h settings Fue l ,11,>1,,1.,,101 
W",m "p "'~11I1;,1O' 51<1,1 V,llvt: A\J~'h;"y i'" duvlC(! Air eh.""I>", Bal1)o I>ull~ Fuel d'SI"hu\or W",nl up '«!lul,l1or (MIO) W,llln·up rC(jul
Gener,,1 description 
TI", 1",,1 sy'>I<'1ll <;onSIS1$ of " reM moulI1ed fuel  wl1k. il {hilpluo1\Jn1 type 1",,1 1l"'''P d"v(JIl I,om the C,lIllSh
prc .. en ('''Uliat spots or mlsf""'\J  .... ·ho)lI the eng"'e h<1s re<1ched  liS norm;ll ope,mll1\J lemperJtllle Ihe PV S  I, open In tillS condltloll lhe C<1rbUle1l0' '5 connected 10 Ihe 
d ,s t"hu!Or  v.a lhe PVS. 
2 Rouline lll
Check condilion of fuel hoses 2 E>.n''''lle illl Ihc fuef hoses on the eng ine compartment and on the fu!:1 ""'k. for SIgns 01 leilkJge or eletellowt,on. 3 Che ck the secullty 01 
) 
s!:q uence  (jlvcn 
Renew the ilir filler element 5 D'$ coruWct lhe hauery. G Remove lhe twO nuts secullng the air cleaner lid nnd remov e tile 
N rn 16 to 20 
4 to 8 8!O 15 
'8 to 2 2 
1 8 to 2 2 20 to 27 38 to 45 20 to 2 4 
Ibl It 12 to 15 
3 to 6 6  to 11 13 to 16 
13 to 16 15w20 28 to 33 15 to 18 
1305<:h K ·JetfOnic COlltonnous inlCCllon !JOO .1. 25 rpm 1 25 I 0.2 930 a cc cvcry 30 scconds 5 f)5 I 0.25 kUI/crn' (789 I 36 11l1/on') 580 hlrc ( 12.7U