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MODEL SELECTION INDEX
MY 2006 WL Series - Service Information
Section 6A1 Engine Mechanical – V6 Engine
1 General Information
1.1 Engine Components
Major Component Assemblies
Intake Manifold Assembly
Engine Front Cover
Camshaft Timing Components
Camshaft Cover Assembly
Cylinder Head Assembly
Oil Pump
Engine Block Assembly
Pistons, Rings, Bearing and Connecting Rod
Oil Pan Assembly
Oil Filter Assembly
1.2 Engine Serial Number
1.3 Engine Construction
Cylinder Block
Cylinder Heads
Crankshaft
Pistons, Pins and Connecting Rods
Camshaft Drive System
Camshaft Position Actuator Control System
Intake Manifold
1.4 Engine Lubrication System
Lubrication Description
1.5 Service Notes
Cleanliness and Care
Replacing Engine Gaskets
Re-Using Gaskets and Applying Sealants
Separating Components
Cleaning Gasket Surfaces
Assembling Components
Use of Room Temperature Vulcanising and Anaerobic Sealer
Room Temperature Vulcanising Sealer
Anaerobic Sealer
Pipe Joint Compound
Separating Parts
Tools and Equipment
Fasteners
Clamp Load
Torque Angle and Torque to Yield Fasteners
2 Diagnosis
2.1 Engine Diagnosis
2.2 Symptoms
Strategy Based Diagnosis
Visual / Physical Inspection
Intermittent
2.3 Engine Misfire without Internal Engine Noises
2.4 Engine Misfire with Abnormal Internal Lower Engine Noise
2.5 Engine Misfire with Abnormal Valve Train Noise
2.6 Engine Misfire with Coolant Consumption
2.7 Engine Misfire with Excessive Oil Consumption
2.8 Engine Noise on Start-up, but only Lasting a Few Seconds
2.9 Upper Engine Noise, Regardless of Engine Speed
2.10 Lower Engine Noise, Regardless of Engine Speed
2.11 Engine Noise Under Load
2.12 Engine Will Not Crank – Crankshaft Will Not Rotate
2.13 Coolant in Combustion Chamber
Definition
2.14 Coolant in Engine Oil
Definition
2.15 Engine Compression Test
Preliminary Steps
Engine Cylinder Compression Test
Test Result Evaluation
2.16 Cylinder Leakage Test
2.17 Engine Oil Consumption Diagnosis
Definition
2.18 Engine Oil Leak Diagnosis
Introduction
Locating and Identifying the Leak
Visual Inspection
Powder Method
Black Light and Dye Method
Possible Causes for Engine Oil Leaks
2.19 Engine Oil Pressure Diagnosis
2.20 Accessory Drive Belt Diagnosis
Tension Check
Inspect
Drive Belt Chirp
Definition
Diagnostic Aids
Test Description
Diagnostic Table
Drive Belt Squeal
Definition
Diagnostic Aids
Test Description
Diagnostic Table
Drive Belt Whine
Definition
Diagnostic Aids
Test Description
Diagnostic Table
Drive Belt Rumble
Definition
Diagnostic Aids
Test Description
Diagnostic Table
Drive Belt Vibration
Definition
Diagnostic Aids
Test Description
Diagnostic Table
Drive Belt Falls Off
Definition
Diagnostic Aids
Test Description
Diagnostic Table
Drive Belt Excessive Wear
Definition
Diagnostic Aids
Test Description
Diagnostic Table
Accessory Drive Belt Tensioner Diagnosis
Diagnostic Table
3 Minor Service Operations
3.1 Engine Dress Cover
Remove
Reinstall
3.2 Engine Oil
Check
Replace
Pressure Check
3.3 Oil Filter Cartridge
Replace
3.4 Oil Filter Adaptor
Remove
Reinstall
3.5 Oil Level Indicator Tube
Remove
Reinstall
3.6 Accessory Drive Belt
Remove
Reinstall
3.7 Accessory Drive Belt Idler Pulley
Remove
Reinstall
3.8 Accessory Drive Belt Tensioner Assembly
Remove
Reinstall
3.9 Power Steering Reservoir and Pump Brackets
Remove
Reinstall
3.10 Upper Intake Manifold
Remove
Disassemble
Clean
Inspect
Reassemble
Reinstall
3.11 Intake Manifold Assembly – Complete
Remove
Disassemble
Clean
Inspect
Reassemble
Reinstall
3.12 Exhaust Manifold Assembly
Remove
Disassemble
Clean
Inspect
Reinstall
3.13 Camshaft Cover
Remove
Clean and Inspect
Reinstall
3.14 Crankshaft Balancer Assembly
Remove
Clean and Inspect
Reinstall
3.15 Crankshaft Front Seal
Replace
3.16 Front Cover Assembly
Remove
Disassemble
Clean
Inspect
Reassemble
Reinstall
3.17 Timing Chains, Tensioners, Shoes and Guides
Primary and Left-hand Secondary Timing Chain Installation
Right-hand Secondary Timing Chain Installation
Remove
Right-hand Secondary Timing Chain
Primary Timing Chain
Left-hand Secondary Timing Chain
Clean
Inspect
Timing Chains
Camshaft Intermediate Driveshaft Sprockets
Inlet and Exhaust Camshaft Position Actuator
Crankshaft Sprocket
Primary Timing Chain Upper Guide
Primary Timing Chain Lower Guide
Primary Timing Chain Tensioner
Left-hand Secondary Timing Chain Guide
Left-hand Secondary Timing Chain Shoe
Left-hand Secondary Timing Chain Tensioner
Right-hand Secondary Timing Chain Guide
Right-hand Secondary Timing Chain Shoe
Right-hand Secondary Timing Chain Tensioner
Reinstall
Left-hand Secondary Timing Chain Components
Primary Timing chain Components
Right-hand Secondary Timing Chain Components
3.18 Oil Pump Assembly
Remove
Disassemble
Clean
Inspect
Reassemble
Reinstall
3.19 Camshaft Position Actuator Assembly
Remove
Right-hand Side
Left-hand Side
Clean
Inspect
Reinstall
3.20 Camshaft
Remove
Right-hand Side
Left-hand Side
Clean
Inspect
Camshaft Visual Inspection
Camshaft Measurement
Reinstall
Right-hand Side
Left-hand Side (Bank 2)
3.21 Rocker Arm
Remove
Clean and Inspect
Reinstall
3.22 Stationary Hydraulic Lash Adjuster
Remove
Clean and Inspect
Reinstall
3.23 Cylinder Head Assembly
Remove
Right-hand Side (Bank 1) Cylinder Head
Left-hand Side (Bank 2) Cylinder Head
Disassemble
Clean
Inspect
Visual Inspection
Cylinder Head Measurement
Valve Spring Inspection and Measurement
Valve and Seat Grinding
Assemble
Reinstall
Right-hand Side (Bank 1) Cylinder Head
Left-hand Side (Bank 2) Cylinder Head
3.24 Engine Mounts and Brackets
Remove
Inspect
Reinstall
4 Major Service Operations
4.1 Engine Assembly
Remove
Disassemble
Reassemble
Reinstall
4.2 Oil Pan and Oil Pump Suction Pipe Assembly
Remove
Disassemble
Clean
Inspect
Reassemble
Reinstall
4.3 Flexplate Assembly
Remove
Clean
Inspect
Reinstall
4.4 Crankshaft Rear Seal and Plate Assembly
Remove
Reinstall
4.5 Pistons, Pins, Rings, Connecting Rods and Big-end Bearin
Remove
Disassemble
Clean and Inspect
Piston Cleaning Procedure
Piston Inspection Procedure
Piston Measurement
Piston Ring Measurement
Connecting Rod Cleaning Procedure
Connecting Rod Visual Inspection Procedure
Connecting Rod Measurement Procedure
Reassemble
Piston and Piston Pin
Piston Ring
Connecting Rod Bearing
Reinstall
Piston Connecting Rod and Connecting Rod Bearing Installatio
Connecting Rod Bearing Clearance Measurement Procedure
Connecting Rod Final Assembly Procedure
4.6 Crankshaft and Main Bearings
Crankshaft End Play Measurement
Remove
Crankshaft Bearing
Clean and Inspect
Crankshaft and Main Bearing Cleaning
Crankshaft and Main Bearing Visual Inspection
Crankshaft Main Bearing Inspection
Crankshaft Measurement
Reinstall
Crankshaft Bearing Installation Procedure
Crankshaft Main Bearing Clearance Measurement
Crankshaft Final Installation Procedure
4.7 Cylinder Block
Disassemble
Clean
Inspect
Visual Inspection
Measuring Cylinder Bore Diameter
Measuring Cylinder Bore Taper
Measuring Cylinder Bore Out-of-Round
Deck Flatness Inspection
Reassemble
4.8 Thread Repairs
General Information
General Thread Repair
Main Bearing Cap Bolt Hole Thread Repair
Cylinder Head Bolt Hole Thread Repair
4.9 Thread Repair Specifications
Left-hand Cylinder Head Camshaft Cover Face
Left-hand Cylinder Head Front Face
Left-hand Cylinder Head Intake Face
Left-hand Cylinder Head Exhaust Face
Left-hand Cylinder Head Rear Face
Right-hand Cylinder Head Camshaft Cover Face
Right-hand Cylinder Head Front Face
Right-hand Cylinder Head Intake Face
Right-hand Cylinder Head Exhaust Face
Right-hand Cylinder Head Rear Face
Engine Block Front
Engine Block Left-hand Side
Engine Block Right-hand Side
Engine Block Rear
Engine Block Bottom
Engine Block Left-hand Deck Face
Engine Block Right-hand Deck Face
Engine Front Cover
Upper Intake Manifold Top
Upper Intake Manifold Front
Upper Intake Manifold Rear
Lower Intake Manifold Top
Oil Pan Front
Oil Pan Rear
Oil Pan Bottom
5 Specifications
6 Torque Wrench Specifications
7 Special Tools
