3.0D Build guide

This is the build guide for the 3.0D i6 engine,

base model engine (non turbo) will be built but the upgrade guide will be at the botom.

step 1. parts (long block)

a list of all the parts needed to build a "long block" which includes the timing set and the head, does not include "extra" parts like alternator, intake manifold, ect

1. crank shaft
2. crankshaft sprocket
3. cam shaft
4. camshaft sprocket
5. engine block
6. head gasket
7. head
8. pistons (6)
9. timing chain
10. fuel pump

(picture of all parts listed)

step 2. assembly

1. put crank into block use wrench to tighten 8 nuts (picture)
2. put pistons (6) on crank, use wrench to tighten 2 cap bolts on each rod end
3. place head gasket on top of engine block
4. put head on top of block making sure head gasket is in place, tighten 6 head bolts
5. put cam in head, tighten 14 bolts
6. put fuel pump on side of engine block, mounts to the front side of the engine block on the right side, 2 bolts
7. place timing chain in front of engine
8. put crank shaft and cam shaft sprockets on their respective shafts 1 bolt for the cam sprocket

that is the short block complete

step 3, the rest of the head assembly.

theres many more parts to put into the head still,

parts to buy

1. cylinder head cover (valve cover)
2. exhaust manifold
3. fuel filter
4. fuel hoses
5. glow plug (6)
6. injector (6)
7. intake manifold

(pic of parts)

assembly:

1. put head cover (valve cover) on top of head, held with 5 bolts
2. put exhaust manifold on left side of head, 7 bolts.
3. injectors (6) uses spark plug wrench to tighten
4. glow plugs (6) also uses spark plug wrench to tighten
5. put on intake manifold, 12 bolts
6. injector hose, tighten 6 nuts on injector pump
7. fuel filter, bolt is on top of housing, right side of engine in front of fuel pump

accesories

last segment

1. water pump
2. air filter
3. air filter housing
4. air filter lid
5. alternator belt
6. alternator
7. alternator bracket
8. crank shaft pulley
9. glow plug relay
10. oil filter housing
11. oil filter
12. oil filter lid
13. oil pan
14. steering pump
15. timing cover
16. engine fan
17. belt tensioner
18. starter

(picture of all parts)

assembly

1. timing cover, front of engine, 5 bolts
2. oil pan 10 bolts
3. glow plug relay, under glow plug 4 and 5, 2 bolts
4. oil filter housing, located on the back right corner of the engine, just above the starter
5. oil filter drops in housing
6. oil filter lid, 2 bolts
7. crank pulley, 1 nut on the front
8. belt tensioner, 1 bolt
9. alternator bracket, left side of engine, next to crank pulley, 2 bolts on the back of it, just below dipstick tube
10. alternator, mounts to alternator bracket, held with 2 bolts
11. power steering pump. located below fuel filter, 2 bolts behind the pulley and 2 on the back
12. water pump, located above alternator, 2 bolts 1 at top and 1 underneath behind the pulley
13. engine fan bolts to water pump with 1 bolt
14. alternator belt just slips on by hand
15. air filter housing bolts to the intake manifold, 2 bolts, bolt 1 in between the runners for cylinder 1 and 2 while bolt 2 is between cylinder 5 and 6
16. air filter drops into air filter housing
17. air filter housing lid drops onto air filter housing, no bolts
18. starter bolts with 2 bolts on the right side of engine, (same side as the mopar engines, mounts to engine like i4)

turbo kit

parts that are changed and added

intake and exhaust manifold, turbo

turbo exhaust manifold bolts on same as regular manifold

turbo bolts to manifold with 2 bolts, 1 on the front of the flange and 1 on the back

turbo intake manifold bolts same as regular manifold