Duratech 2.5l Engine V6

NE01−I10872796−025 DLITTLEJ

FDUDEK3

001019 NPETTY HSCHUMAN DSCHILTG

A1 ADDED NEW ENGINE CODE ON FR 3C NE01−E11173291−000 010130 SROBERT4

SROBERT4

MRILEY2 DLIRETTE X CAD: Y

RHAESE

B1 ADDED VEHICLE DESIGNATIONS ON FRAME 3C 010402 NE01−E11183277−048 RWOLFFIS FDUDEK3 RHAESE

CAD: Y

NEAL PETTY (313)84−50491 DAVE SCHILTGES (313)84−58975

HOWARD SCHUMAN (313)59−46662

il1s7e−030002−e0543d−−01.dg

IL1S7E−030002−E0543D DLITTLEJ FDUDEK3 001019

ENGINE ASSEMBLY PROCEDURE AND INSTRUCTION 2001 2.5L−4V CD132/SW164/MPV CLEVELAND ENGINE PLANT #2

52

INDEX ITEM

FRAME

GENERAL SPECIFICATIONS: 3B 3 3B 3C 3A 3B 3B 3A 3A 3A 3A 3 3C 3 3A

BALANCING INSTRUCTIONS DIMENSIONING EMISSION CONTROL EQUIPMENT ENGINE APPLICATION CODES ENGINE ELECTRICAL EQUIPMENT ENGINE LUBRICATION REQUIREMENTS ENGINE PAINT INSTRUCTIONS NOTES BEFORE STARTING ENGINE OIL CLEANLINESS PERFORMANCE AND ENGINE ECONOMY TEST PRODUCTION HOT TEST SEALING AND LUBRICATING INDEX SHIPPING PLUGS AND DUNNAGE CAPS TORQUE VALUES FOR PARTS AS SUPPLIED VACUUM SYSTEM CONNECTION SPECIFICATIONS

INSTALLATION: A/C COMPRESSOR & CLUTCH ASY

42

ACCESSORY DRIVE PULLEY AND WATER PUMP BELT TENSIONER ASY

48

AIR BYPASS VALVE ASY

32

ALTERNATOR ASY AND ALTERNATOR MOUNTING BRACKET ASY

45,45A

BULKHEAD HOUSING ASY FASTENERS

6C

BULKHEAD HOUSING ASY AND LOWER MAIN BEARINGS

6B

BULKHEAD HOUSING TO CYLINDER BLOCK

6,6A

CAMSHAFT & SPROCKET ASY, BEARING CAPS AND ROLLER FOLLOWERS

14E,14G

CAMSHAFT COVER ASY & CAMSHAFT REAR SEAL RETAINER ASY

21,21A

CAMSHAFT PREASSEMBLY TIMING MARK ALIGNMENT

14F

CRANKCASE EMISSION HOSE

25A

CRANKSHAFT ASY AND UPPER MAIN BEARINGS

5A

CRANKSHAFT, CAMSHAFT SPROCKETS AND DRIVE CHAIN, PREASSEMBLY TIMING MARK ALIGNMENT (LH)

16A

CRANKSHAFT, CAMSHAFT SPROCKETS AND DRIVE CHAIN, TIMING MARK ALIGNMENT (LH & RH)

16C

CRANKSHAFT VIBRATION DAMPER ASY

20

CRANKSHAFT ENDPLAY (LESS PISTONS)

6D

CRANKSHAFT FRONT SEAL ASY, CRANKSHAFT TIMING SENSOR AND CAMSHAFT TIMING SENSOR

19

CRANKSHAFT FRONT SEAL SQUARENESS AND CONCENTRICITY (SERVICE/AUDIT)

19A

CRANKSHAFT REAR OIL SEAL ASY

7

CRANKSHAFT REAR OIL SEAL ASY SQUARENESS & CONCENTRICITY (SERVICE/AUDIT)

7

CRANKSHAFT SLEEVE (AUTO TRANS)

7A

CRANKSHAFT SPROCKET, DRIVE CHAIN, CHAIN GUIDE, TENSIONER ASY AND TENSIONER ARM (LH)

16

CRANKSHAFT SPROCKET, DRIVE CHAIN, CHAIN GUIDE, TENSIONER ASY AND TENSIONER ARM (RH)

16B

CYLINDER BLOCK DOWELS, PLUGS AND OIL FILTER INSERT (SERVICE/AUDIT)

4,4A

CYLINDER HEAD ASY

14C,14D

CYLINDER HEAD ASY VALVES, SPRINGS & LASH ADJUSTERS

14A

CYLINDER HEAD GASKETS AND DOWELS

14B

NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−INDEX−E0543D

001019

−−−

2

52

2A X

INDEX (Continued) ITEM

FRAME

INSTALLATION: CYLINDER HEAD PIPE PLUGS AND DOWELS

14

DRIVE BELT (FEAD) FOR NAAO SW164

47

ELECTRIC IMRC ASY AND BRIDGE

23

ELECTRIC IMRC ASY CABLE ROUTING

30

EGR VACUUM REGULATOR ASY

32A

EGR VALVE ASY AND PLUG

33A

EMISSION VACUUM CONTROL CONNECTOR ASY NAAO & EAO ONLY MPV ONLY

35C,35F

ENGINE ASY CD132 MAZDA MPV AUTO SW EAO AUTO TRANS SW EAO MAN TRANS SW EAO

51E 51C,51D 51 51A 51B

ENGINE EXPLODED VIEWS CD132/SW164 MAZDA MPV

52,52A 52B

ENGINE CODE DECAL AND INK JET APPLICATION

50

EXHAUST MANIFOLD & CONVERTER ASY (RH) AND EGR TUBE ASY FOR NAAO AND EAO

43

FLEXPLATE ASY AND REAR COVER PLATE (AUTO TRANS)

31A

FLYWHEEL ASY AND REAR COVER PLATE (MANUAL TRANS)

31

FRONT COVER ASY, TENSIONER AND IGNITION PULSE RING

17,17A

GROUND STRAP

44

IGNITION COIL ASY, GROUND STRAP, RADIO CAPACITOR (NAAO & MPV) AND BRACKET (EAO)

22

IGNITION WIRE ASY AND FIRING ORDER

22A,29

INLINE CONNECTOR BRACKET

33

INTAKE MANIFOLD ASY (LOWER) AND EMISSION VACUUM CONTROL CONNECTOR ASY

26 THRU 26C

INTAKE MANIFOLD ASY (UPPER)

28,28A

INTAKE MANIFOLD OPENING COVER ASY

33B

LIFTING EYES

34

LINKSHAFT BRACKET ASY AND CYLINDER BLOCK PLUGS

41

OIL COOLER ASY, OIL FILTER ASY AND OIL PRESSURE SWITCH ASY

40

OIL LEVEL INDICATOR TUBE ASY AND OIL LEVEL INDICATOR ASY

38

OIL PAN ASY

18,18A

OIL PAN BAFFLE

10,10A

OIL PUMP ASY

9

OIL PUMP SCREEN AND COVER ASY

11

OIL SEPARATOR ASY, WATER INLET TUBE AND CUP PLUG

12

PCV CONNECTOR & HOSE ASY TO UPPER INTAKE MANIFOLD ASY FITTING AND EMISSION VACUUM CONTROL CONNECTOR ASY ROUTING

36

PISTON, PIN, RINGS AND CONNECTING ROD ASY

8,8A,8B

PISTON & CONNECTING ROD ASY BEARINGS AND ROD CAP ASY

8C,8D

POWER STEERING PUMP MOUNTING BRACKET ASY

13

NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−INDEX−E0543D

001019

−−−

2A

52

2B X

INDEX

(Continued)

ITEM

FRAME

INSTALLATION: POWER STEERING PUMP & BRACE ASY AND PULLEY

46

SELECTFIT MAIN BEARING GRADE CHART

5

SPARK PLUG ASY

15

THROTTLE BODY ASY

39,39A

THROTTLE POSITION SENSOR CONNECTION AND IPS CONNECTION

39B

WATER BYPASS HOSE ASY

25

WATER PUMP ASY

24

WATER PUMP DRIVE BELT (READ)

49

WIRING HARNESS ASY

27,27A

WIRING HARNESS ASY TO IDLE SPEED VALVE, ECT SENSOR AND IMRC CONNECTOR

37B

WIRING HARNESS ASY TO IGNITION COIL

37A

WIRING HARNESS ASY TO MOUNTING STUDS, CID SENSOR, HDR SENSOR AND OIL PRESSURE SWITCH

37

NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

2B

52

3 X

GENERAL SPECIFICATIONS NOTE: PART NUMBERS LISTED MUST BE VERIFIED WITH LATEST ENGINEERING PARTS LIST OR NOTICE.

TORQUE VALUES FOR PARTS AS SUPPLIED NOTE: PRIOR TO SERVICE RE−INSTALLATION OR REPLACEMENT OF FASTENERS, ALL THREADS AND CONTACT SURFACES MUST BE LUBRICATED WITH WSE−M2C908−A OR WSS−M2C910−A1 OIL. NOTE: REFER TO WERS TO VERIFY TORQUE VALUES. NOTE: PIPE PLUG TORQUES IN ALUMINUM, MUST BE CHECKED WHEN ENGINE IS WARM.

DIMENSIONING ALL DIMENSIONS ARE IN MILLIMETERS UNLESS OTHERWISE SPECIFIED.

SEALING AND LUBRICATING INDEX SEALER/ADHESIVE

DESCRIPTION

FRAMES

WSE−M4G323−A6

SEALANT, SILICONE RBBER, OXIME CURED, VERY HIGH VISCOSITY

6,6A,17,18, 20 & 21

WSK−M2G349−A7

ADHESIVE, ANAEROBIC, RETAINING

12

WSK−M2G349−A10

ADHESIVE, ANAEROBIC, THREAD LOCKING

12

LUBRICANT ESE−M99B176−A

LUBRICANT, SYNTHSTIC RUBBER

25

ESE−M99B144−B

SURFACTANT, COLORED LUBRIANT, RUBBER HOSE AND TUBING

3,24

WSE−M99C45−A2

LUBRICANT, VACUUM TUBING AND HOSE

36

WSE−M2C908−A

OIL ENGINE, API SG, SAE 50, ASSEMBLY FLUID

3A,6A,7,8,8C,14A, 14E,14G,19,20,40

WSS−M2C914−A

OIL, ENGINE, ILSAC GF−3, INITAIL FILL SAE 5W−20

ESE−M99C103−B1

OIL ADDITIVE, FLOURESCENT−NON TINTING, LEAK DETECTION

3B

CLEAN, ENGINE DEGREASER

6A

GASOLINE, UNLEADED, INITIAL FILL, REGULAR GRADE

3A

OIL

3A & 3B

CLEANER WSE−M5B392−A

FUEL WSE−M4C112−A

NOTE: ESE−M99B144−B HOSE ASSEMBLY SURFACTANT ONLY (DO NOT MIX). USE TO FACILITATE HOSE ASSEMBLY. ALL OTHER LUBRICANTS ARE NOT PERMITTED. MAY BE APPLIED TO I.D. AND O.D. OF HOSE. SPRAY NOT PERMITTED. NOTE: ALL GASKETS AND SEALING SURFACES MUST BE CLEAN AND FREE OF ALL FOREIGN MATTER PRIOR TO ASSEMBLY.

NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

3

52

3A X

GENERAL SPECIFICATIONS (Continued)

OIL CLEANLINESS ASSEMBLY OIL (WSE−M2C908−A) BEING APPLIED TO ENGINE COMPONENTS AND THE INITIAL OIL FILL (WSS−M2C914−A) AT THE DELIVERY POINT TO THE ENGINE MUST MEET THE FOLLOWING REQUIREMENTS FOR PARTICLE SIZE AND COUNT: PARTICLE SIZE (MICRONS)

MAX LIMIT (PARTICLES PER MILLILITER)

0−30 31−50 51−70 >71

NO LIMIT 50 30 10

ENGAGEMENT SPECIFICATIONS FOR ALL VACUUM SYSTEM CONNECTIONS HOSE/VACUUM CONNECTIONS: ALL HOSE, VACUUM TUBING CONNECTIONS, CONNECTOR BLOCKS AND CAPS MUST BE BOTTOMED OR WITHIN 2.5mm (.10 INCHES) MAXIMUM OF BEING BOTTOMED ON THE COMPONENT CONNECTION. ASSEMBLY AID: WATER MAY BE USED TO FACILITATE THE ASSEMBLY OF ALL CONNECTOR ASSEMBLY COMPONENTS. THE WATER MUST BE APPLIED USING A PLASTIC SPRAY BOTTLE WITH AN ATOMIZER SETTING AT "MIST".

PRODUCTION HOT TEST THE PRODUCTION HOT TEST IS TO BE PERFORMED IN ACCORDANCE WITH SPECIFICATION − ENGINE ASSEMBLY PRODUCTION HOT TESTING ES−F53E−6007−AA. USE TESTING WSE−M4C112−A FUEL. NOTE: DRAIN COOLANT AFTER TEST AND INSTALL RELEASED DRAIN PLUGS IN CYLINDER BLOCK ASSEMBLY (−6010−).

PERFORMANCE AND OIL ECONOMY TEST (DYNAMOMETER TEST) THE PERFORMANCE AND OIL ECONOMY TEST MUST BE PERFORMED IN ACCORDANCE WITH SPECIFICATION − ENGINE ASSEMBLY − AS PURCHASED ES−F53E−6007−AA. USE WSE−M4C112−A FUEL.

NOTES BEFORE STARTING ENGINE BEFORE STARTING AN ENGINE, CHECK TO REFER TO THAT VACUUM HOLES ARE PLUGGED OR CONNECTED AS REQUIRED. FOR INSTALLATION OF OIL LEVEL INDICATOR REFER TO FRAME 38. FOR INITIAL OIL FILL REFER TO FRAME 3B.

ENGINE ELECTRICAL EQUIPMENT FOR ENGINE ELECTRICAL EQUIPMENT INSTALLATION REFER TO THE MANUAL "ELECTRICAL EQUIPMENT INSTALLATION" FOR THE PARTICULAR MODEL APPLICATION.

NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

3A

52

3B X

GENERAL SPECIFICATIONS (Continued)

EMISSION CONTROL EQUIPMENT FOR INSTALLATION OF EMISSION CONTROL EQUIPMENT REFER TO MODEL YEAR AFFECTED "ENGINE EQUIPMENT INSTALLATION" MANUAL.

BALANCING INSTRUCTIONS REFER TO ES−F53E−6007−AA FOR ENGINE MASS BALANCE REQUIREMENTS.

ENGINE LUBRICATION REQUIREMENTS ADD THE FOLLOWING AMOUNT OF WSS−M2C914−A FOR INITIAL OIL FILL AS SHOWN IN CHART BELOW:

OIL (SAE SW−20)

NOTE: 18 − 22ml OF ESE−M99C103−B1 DYE MUST BE ADDED FOR IN PLANT OIL LEAK DETECTION. INITIAL OIL FILL:

6.0 quarts (FAO AND EAO)

CUSTOMER OIL FILL:

5.0 qt WITHOUT OIL FILTER (FAO) 5.5 qt WITH OIL FILTER (FAO) 5.0 liters WITHOUT OIL FILTER (EAO) 5.5 liters WITH OIL FILTER (EAO)

AFTER INITIAL OIL FILL, AND PRIOR TO HOT TEST, SPIN THE OIL PUMP IN THE NORMAL OPERATING DIRECTION, AT 1000 − 2000 RPM FOR A MINIMUM OF (10) SECONDS, IN ORDER TO FILL THE OILING SYSTEM.

AFTER HOT TEST , WITH ENGINE HORIZONTAL, CHECK OIL LEVEL. READING ON INDICATOR MUST BE WITHIN Y=3mm OF THE FULL MARK.

− Y MIN

+ Y

OIL LEVEL

MAX

ENGINE PAINT INSTRUCTIONS ALL ENGINE COMPONENTS REQUIRING PAINT WILL BE PRE−PAINTED AS COMPONENTS PRIOR TO SHIPPING TO THE ENGINE ASSEMBLY AREA. FOR SPECIFICATIONS ON COMPONENT PAINT REQUIREMENTS SEE THE RESPECITIVE DETAIL OR ASSEMBLY DRAWING.

NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

3B

52

3C X

GENERAL SPECIFICATIONS (Continued)

ENGINE APPLICATION CODES

B1

TRANSMISSION

CODES

MANUAL

1A−831−AA

AUTO

1G−402−AB

COUGAR

MANUAL

1G−403−AB

SW164 NAAO H/O COUGAR SVT

MANUAL

1G−433−AA

AUTO

1G−400−AA

MANUAL

1G−401−AA

AUTO

1G−404−AA

AUTO

KG−440−AA

VEHICLE CD132 EAO MONDEO

SW164 AUSTRALIA

SW164 NAAO COUGAR

SW164 NAAO COUGAR W/17" WHEELS OPTION A1

J16E MPV

SHIPPING PLUGS AND DUNNAGE CAPS ALL INTERNAL ENGINE CAVITIES TO BE PLUGGED FOR ENGINE SHIPMENT TO B & A, SPECIFICALLY AS FOLLOWS:

ITEM TO BE PLUGGED

PLUG INSTALLATION POINT

CAMSHAFT COVER ASY (−6A505−/−6582−) CYLINDER HEAD ASY LH (−6050−) EMISSION VACUUM CONTROL CONN. (−9E498−) EXHAUST MANIF RH (−5G236−) FOR CDW/SW ONLY CONNECTOR ASY (−9E498−) INTAKE MANIFOLD ASY−LOWER (−9J447−) OIL COOLER ASY (−6A642−) PCV HOSE & VALVE ASY (−6C324−) THROTTLE BODY ASY (−9E926−) WATER PUMP INLET HOSE (−8A567−) PART OF (−8501−) ASY WIRE CONNECTOR COVER (−9H989−)

NE01−E11183277−048 V−ENGINE ILLUSTRATION

FINAL DRESS FINAL DRESS ASY/FINAL DRESS FINAL DRESS FINAL DRESS AFTER HOT TEST FINAL DRESS FINAL DRESS FINAL DRESS FINAL DRESS AFTER HOT TEST

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

010402

B1

3C

52

4 X

CYLINDER BLOCK DOWELS, PLUGS AND OIL FILTER INSERT (SERVICE AUDIT)

−6890− (11mm HEX) INSERT − OIL FILTER MOUNTING BOLT (TORQUE 27−40 Nm)

−6010− BLOCK ASY − CYLINDER

FOR CD132 NAAO SW164 ONLY

1 W706860 PIN − 8mm X 18.25 SOLID DOWEL CHAMFER HARDEND (2) REQ

B

A

W701546 CUP PLUG (19.35)

W701516 (8mm HEX) 3/8−18 PLUG SOCKET HEX (TORQUE 20 Nm THEN ROTATE 180 )

1 FRONT OF ENGINE

(9.5 8.5)

(7.6 5.0)

1 (DOWEL) (BLOCK ASY − CYLINDER)

(BLOCK ASY − CYLINDER)

(CUP PLUG) SECTION A

SECTION B

TYPICAL (2) PLACES

030101 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

4

52

4A .5

CYLINDER BLOCK DOWELS AND PLUGS (Continued) (SERVICE AUDIT)

W701517 (1/2 HEX) 1/2−14 PIPE PLUG (TORQUE 40 Nm THEN ROTATE 180 )

A

1

FRONT OF ENGINE

1 W701202 PIN − 16.005 X 19 HOLLOW DPWEL (16 X 19) (2) REQ

−6010− BLOCK ASY − CYLINDER

W701517 (1/2 HEX) 1/2−14 PIPE PLUG (TORQUE 40 Nm THEN ROTATE 180 )

(9.5 8.5)

1 (DOWEL)

(BLOCK ASY − CYLINDER) SECTION A TYPICAL (2) PLACES

030101 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

4A

52

5 .5

SELECT−FIT MAIN BEARING GRADE CHART SELECT−FIT MAIN BEARING PROCEDURE 1. READ THE ELEVEN CHARACTER CODES ON THE CYLINDER BLOCK FACE AND THE CRANKSHAFT FLANGE. THEY ARE ARRANGED AS FOLLOWS: *####*####*. THE FIRST TWO NUMBERS AFTER THE FIRST ASTERISK MAKE UP THE CODE FOR MAIN #1 AND THE NEXT TWO NUMBERS FOR MAIN #2. THE FIRST TWO NUMBERS AFTER THE SECOND ASTERISK MAKE UP THE CODE FOR MAIN #3 AND THE LAST TWO NUMBERS FOR MAIN #4. 2. LOOK AT THE SELECT−FIT CHART BELOW AND FOR EACH MAIN, MATCH THE BLOCK AND CRANKSHAFT CODE WITH ITS CORRESPONDING COLUMN OR ROW. BY READING ACROSS THE CRANKSHAFT ROW AND DOWN THE BLOCK COLUMN, SELECT THE PROPER GRADE BEARING FOR EACH MAIN. (E.G. IF THE BLOCK CODE IS *0609*0711* AND THE CRANKSHAFT CODE IS *8480*8082*, MAIN #1 SHOULD BE BUILT WITH GRADE 1 BEARINGS, AS DETERMINED BY THE INTERSECTION OF THE 06 BLOCK COLUMN AND THE 84 CRANKSHAFT ROW. MAINS 2,3, AND 4 SHOULD ALL BE GRADE 2.) (CRANKSHAFT) FRONT OF ENGINE (HOUSING − ENGINE BULKHEAD)

SELECT−FIT CODE SHOWN OUT OF SEQUENCE FOR CHART CONGRUITY (CYLINDER BLOCK ASY)

CRANKSHAFT CODE

BLOCK CODE 98

99

00 01

02

03 04 05

06

07

08

09 10 11

12

13

14

15

16

17

18

19

20

21

91

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

2

2

2

2

2

2

90

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

2

2

2

2

2

2

2

89

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

2

2

2

2

2

2

2

2

88

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

2

2

2

2

2

2

2

2

2

87

1

1

1

1

1

1

1

1

1

1

1

1

1

2

2

2

2

2

2

2

2

2

2

2

86

1

1

1

1

1

1

1

1

1

1

1

1

2

2

2

2

2

2

2

2

2

2

2

2

85

1

1

1

1

1

1

1

1

1

1

1

2

2

2

2

2

2

2

2

2

2

2

2

2

84

1

1

1

1

1

1

1

1

1

1

2

2

2

2

2

2

2

2

2

2

2

2

2

3

83

1

1

1

1

1

1

1

1

1

2

2

2

2

2

2

2

2

2

2

2

2

2

3

3

82

1

1

1

1

1

1

1

1

2

2

2

2

2

2

2

2

2

2

2

2

2

3

3

3

81

1

1

1

1

1

1

1

2

2

2

2

2

2

2

2

2

2

2

2

2

3

3

3

3

80

1

1

1

1

1

1

2

2

2

2

2

2

2

2

2

2

2

2

2

3

3

3

3

3

79

1

1

1

1

1

2

2

2

2

2

2

2

2

2

2

2

2

2

3

3

3

3

3

3

78

1

1

1

1

2

2

2

2

2

2

2

2

2

2

2

2

2

3

3

3

3

3

3

3

77

1

1

1

2

2

2

2

2

2

2

2

2

2

2

2

2

3

3

3

3

3

3

3

3

76

1

1

2

2

2

2

2

2

2

2

2

2

2

2

2

3

3

3

3

3

3

3

3

3

75

1

2

2

2

2

2

2

2

2

2

2

2

2

2

3

3

3

3

3

3

3

3

3

3

74

2

2

2

2

2

2

2

2

2

2

2

2

2

3

3

3

3

3

3

3

3

3

3

3

73

2

2

2

2

2

2

2

2

2

2

2

2

3

3

3

3

3

3

3

3

3

3

3

3

72

2

2

2

2

2

2

2

2

2

2

2

3

3

3

3

3

3

3

3

3

3

3

3

3

71

2

2

2

2

2

2

2

2

2

2

3

3

3

3

3

3

3

3

3

3

3

3

3

3

70

2

2

2

2

2

2

2

2

2

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

69

2

2

2

2

2

2

2

2

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

68

2

2

2

2

2

2

2

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

5

52

5A X

CRANKSHAFT ASY AND UPPER MAIN BEARINGS

−6303− CRANKSHAFT

−6A341− WASHER − CRANKSHAFT MAIN CENTER BEARING THRUST UPPER

W701528 KEY − 4.76 X 53.5 WOODDRUFF SPECIAL

MAXIMUM KEY HEIGHT (2.350 mm) ALONG COMPLETE KEY LENGTH WHEN PRESSED ON CRANKSHAFT POST.

−6333− BEARING − CRANKSHAFT MAIN FRONT (4) REQ

(BLOCK ASY − CYLINDER)

BACKGROUND DETAIL MAY NOT BE PICTORALLY ACCURATE FOR ALL APPLICATIONS

FRONT OF ENGINE

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52

6 .7

BULKHEAD HOUSING TO CYLINDER BLOCK SEALANT WSE−M4G323−A6 SEALER (1mm DIA) BEAD (3mm DIA) BEAD AT GROOVES

SEALANT PATH

FRONT OF ENGINE

(3mm) BEAD AREA (1mm) BEAD AREA

(BLOCK ASY − CYLINDER)

NOTE: VIEW SIMPLIFIED FOR INSTALLATION CLARITY.

(6)

(6) VIEW A

SEE FRAMES 6A & 6B

ASSEMBLY PROCEDURE 1.

THE BLOCK/BULKHEAD MATING SURFACES MUST NOT HAVE ANY RESIDUES THAT REDUCE THE BONDING (OR ADHESION) OF THE WSE−M4G323−A6 SEALANT TO THE SURFACES. THE CONTAMINANTS THAT ARE LIKELY TO OCCUR ARE: − − − − − −

030101

MACHINING COOLANTS WASH OR SOAP RESIDUE OIL (BEARING PRELUBE, ETC.) WATER (WET) DUST, METAL CHIPS SEALANT RESIDUE (FROM PREVIOUS ASSEMBLY)

NOTE: THESE MATERIALS WILL REDUCE SEALER BONDING WHETHER THEY ARE WET OR DRY. THEREFORE, BOTH THE BLOCK AND BULKHEAD MATING SURFACES MUST BE WIPED WITH CLEANER.

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52

6A .7

BULKHEAD HOUSING TO CYLINDER BLOCK (Continued) ASSEMBLY PROCEDURE (CONTINUED) 1.

A)

ALL TRACES OF PREVIOUSLY APPLIED SEALANT MUST BE COMPLETELY REMOVED BY SCRAPING THE SURFACES (WITHOUT DAMAGING EITHER SURFACE).

B) CLEANER. AFTER WIPING EACH SURFACE WITH THE "WET" RAG, EACH SURFACE MUST BE WIPED WITH A DRY RAG TO REMOVE EXCESS CLEANER. BOTH SURFACES MUST BE ALLOWED TO DRY FOR A MINIMUM OF (2) MINUTES PRIOR TO APPLICATION OF THE WSE−M4G323−A6 SEALANT. C)

THE BULKHEAD SURFACE MUST BE CLEANED BEFORE IT IS PLACED IN THE "SURFACE DOWN" POSITION ON THE ASSEMBLY PALLET. IN ADDITION, WHEN PLACED ON THE ASSEMBLY PALLET THE BULKHEAD SHOULD NOT REST ON THE BLOCK MATING SURFACE.

D)

THE BULKHEAD SURFACE MUST BE CLEANED AFTER INSTALLATION OF CRANKSHAFT BEARINGS AND CRANKSHAFT TO REMOVE ANY RUNOFF OF BEARING PRELUBE OIL.

2.

SELECT CORRECT BEARING GRADES FOR EACH OF THE FOUR MAINS USING THE PROCEDURE ON FRAME 5.

3.

VERIFY ALL SADDLES IN BLOCK, BULKHEAD AND BEARINGS ARE CLEAN AND FREE OF CHIPS, DIRT, PAINT AND FOREIGN MATERIAL.

4.

INSTALL UPPER MAIN BEARINGS IN CYLINDER BLOCK.

5.

VISUALLY CHECK SEATING AND SQUARENESS OF ALL BEARINGS AND INSURE ALL OILING HOLES ALIGN WITH CYLINDER BLOCK OIL FEED HOLES.

6.

INSTALL CRANKSHAFT IN CYLINDER BLOCK WITH CARE TO PREVENT DAMAGE TO BEARING FACES OR CORNERS. APPLY WSE−M2C908−A OIL TO CRANKSHAFT JOURNALS PRIOR TO INSTALLATION.

7.

PUSH CRANKSHAFT TO ITS MAXIMUM REARWARD POSITION.

8.

INSTALL THRUST WASHER BETWEEN CRANKSHAFT REAR THRUST SURFACE AND REAR OF CYLINDER BLOCK. ALIGN ASSEMBLY TAB ON WASHER TO MATCHING SPOTFACE ON CYLINDER BLOCK. APPLY WSE−M2C908−A OIL TO CRANKSHAFT THRUST SURFACE AND WASHER.

9.

INSTALL LOWER MAIN BEARINGS AND THRUST BEARING IN BULKHEAD.

BEFORE APPLYING SEALER SEE NOTE BELOW: NOTE: INSTALL THE BULKHEAD AND TORQUE ALL BOLTS TO SPECIFICATION WITHIN (4) MINUTES. SEE FRAME 6C FOR BOLT TORQUE SEQUENCE AND SPECIFICATIONS. REMOVE THE SQUEEZED−OUT WSE−M4G323−A6 SEALER AT THE FRONT COVER SURFACE. 10.

APPLY A BEAD OF WSE−M4G323−A6 SEALER TO THE CYLINDER BLOCK SURFACE AS SHOWN ON FRAME 6. NOTE: THE SEALANT BEAD MUST TERMINATE (6mm) FROM THE REAR CRANKSHAFT SEAL BORE ON BOTH SIDES (SEE FRAME 6).

11. INSTALL BULKHEAD/BEARING ASSEMBLY ON CYLINDER BLOCK. APPLY A LOAD OF (110 N) ON BULKHEAD TO FULLY ENGAGE WITH INTERFERENCE FIT DOWELS ON CYLINDER BLOCK. 12.

INSTALL (4) M10 BOLTS, (10) M8 BOLTS, AND (4) M8 STUDS, (4) M10 STUDS (DO NOT LUBRICATE FASTENERS). (TORQUE 3−5Nm). NOTE: DO NOT ROTATE CRANKSHAFT UNTIL ALL BULKHEAD MAIN BEARING BOLTS ARE TORQUED TO SPECIFICATION. INSTALL (5) PERIMETER BOLTS (DO NOT LUBRICATE FASTENERS). (TORQUE 3−5 Nm).

13.

APPLY A LOAD 534−667 N FORWARD AND 89−178 N REARWARD ON CRANKSHAFT TO ALIGN REAR FLANGE OF LOWER THRUST BEARING WITH THRUST WASHER.

14.

TORQUE BULKHEAD BOLTS TO SPECIFICATION. (SEE FRAME 6C WITH CRANKSHAFT HELD IN FORWARD POSITION).

15.

CHECK CRANKSHAFT END PLAY. TO BE WITHIN (0.110−0.232mm). (SEE FRAME 6D)

16.

CHECK CRANKSHAFT TORQUE TO TURN. NOTE: MAIN BEARING TO CRANKSHAFT JOURNAL SURFACE ASSEMBLED CLEARANCE IS (0.025−0.050mm) AT CROWN.

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52

6B X

BULKHEAD HOUSING ASY AND LOWER MAIN BEARINGS −6F095− HOUSING−ENGINE BULKHEAD

NOTE: TORQUE ALL BULKHEAD HOUSING TO CYLINDER BLOCK BOLTS/STUDS WITHIN (4) MINUTES OF INSTALLATION

(DOWEL− HOLLOW) (8) REQ

−6A339− BEARING−CRANKSHAFT MAIN CENTER LOWER

−6A338− BEARING−CRANKSHAFT MAIN FRONT LOWER (3) REQ

(SEE FRAME 6) A

(CRANKSHAFT)

(BLOCK ASY− CYLINDER) BACKGROUND DETAIL MAY NOT BE PICTORALLY ACCURATE FOR ALL APPLICATIONS

FRONT OF ENGINE

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6C .6

BULKHEAD HOUSING ASY FASTENERS 19

17

21

= BOLT = STUD 5

1

3

7

13

9

11

15

10

12

16

2

4

8

FRONT OF ENGINE

14

6

(HOUSING− ENGINE BULKHEAD)

20

HOLE NO 18−19−20 21−22

18

22

FASTENER

DESCRIPTION

W701554 (10mm HEX)

M8 X 1.25 X 79.3 BOLT & WASHER PILOT

F43E−6345−CB (13mm HEX)

M8 X 1.25 X 95.3 BOLT & WASHER PILOT

F43E−6345−DC (13mm HEX)

M10 X 1.5 X 106 BOLT & WASHER PILOT

YL8E−6D311−BA (13mm HEX)

M6 X 1.0 X 19.5/ M8 X 1.25 X 95.1 STUD & WASHER PILOT

YL8E−6D311−AA

M10 X 1.5 X 105.5/ M8 X 1.25 X 95.1 STUD & WASHER PILOT

1−2−3−4−17

13−14−15 16

5−6−7−8

9−10−11−12

FINAL TORQUE PROCEDURE PRODUCTION METHOD (MULTI−SPINDLE) 1.

TORQUE FASTENERS

1

THRU

8

TO (25 Nm).

2.

TORQUE FASTENERS

9

THRU

16

TO (40 Nm).

3.

ROTATE FASTENERS

1

THRU

16

(90 ).

4.

TORQUE FASTENERS

17

THRU

22

TO (20−30 Nm).

SINGLE WRENCH METHOD (SERVICE−REPAIR)

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1.

TORQUE FASTENERS

1

THRU

8

TO (22−28 Nm).

2.

TORQUE FASTENERS

9

THRU

16

TO (37−43 Nm).

3.

ROTATE FASTENERS

1

THRU

16

AN ADDITIONAL (85 −95 ).

4.

TORQUE FASTENERS

17

THRU

22

TO (20−30 Nm).

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52

6D .5

CRANKSHAFT ENDPLAY (LESS PISTONS)

FRONT OF ENGINE

1

CRANKSHAFT ENDPLAY (0.135 − 0.255 mm FIM)

(DIAL INDICATOR)

REFERENCE: CHECK CRANKSHAFT END PLAY BY APPLYING A 534−668N (120−150 LB) FORCE FORWARD AND THEN A 89−178N (20−40 LB) FORCE REARWARD.

1 FIM = FULL INDICATOR MOVEMENT

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7 1

CRANKSHAFT REAR OIL SEAL ASY FRONT OF ENGINE NOTE: LUBRICATE SEAL BORE BEFORE INSTALLATION

−6701− REAR OIL SEAL (INSTALLATION TOOL)

SURFACE "R"

ASSEMBLY PROCEDURE 1.

APPLY WSE−M2C908−A OIL TO OD OF CRANKSHAFT FLANGE AND TO ID OF CRANKSHAFT SEAL BORE (IN BULKHEAD/BLOCK ASSEMBLY).

2.

INSTALL REAR SEAL (−6701−) ON INSTALLATION TOOL WITH FLAT SIDE TOWARD REAR (SPRING TOWARDS ENGINE) AND PRESS SEAL INTO SEAL BORE AND OVER CRANKSHAFT FLANGE. NOTE: THE CRANKSHAFT OIL SEAL MUST BE PRESSED INTO THE BLOCK ASSEMBLY WITHIN (2) MINUTES OF BULKHEAD−TO−BLOCK FASTENER RUNDOWN (FRAME 6C). NOTE: REAR FACE OF SEAL MUST BE FLUSH TO (2mm) BELOW SURFACE "R".

CRANKSHAFT REAR OIL SEAL ASY (SQUARENESS & CONCENTRICITY−SERVICE AUDIT) FRONT OF ENGINE

(DIAL INDICATOR)

(CRANKSHAFT) DO NOT EXCEED THE FOLLOWING SPECIFICATIONS WHEN CRANKSHAFT IS HAND ROTATED. 1. (0.50 FIM) SEAL BORE IN RELATION TO CENTERLINE OF CRANKSHAFT (SEAL MUST NOT BE INSTALLED).

031001

2. (0.05 FIM) OF SEAL FACE REAR SURFACE IN RELATION TO REAR FACE OF CRANKSHAFT.

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52

7A .6

CRANKSHAFT SLEEVE (AUTO TRANS) FOR SW164 AUTO ONLY

FRONT OF ENGINE

(CRANKSHAFT)

A

−7G371− SLEEVE−TRANSMISSION CRANKSHAFT

(CRANKSHAFT)

−7G371− SLEEVE−TRANSMISSION CRANKSHAFT

(13.6 11.6) NOTE: INSTALL SLEEVE UNTIL BOTTOMED IN CRANKSHAFT PRIOR TO FLEXPLATE INSTALLATION. SECTION A

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52

8 .75

PISTON, PIN, RINGS AND CONNECTING ROD ASY

NOTE: SEE FRAME 8A & 8B FOR VIEWS A & B

−6140− RETAINER− PISTON PIN (2) REQ

−6110− PISTON A

B

1

(IDENTIFICATION BUMP) −6135− PIN−PISTON

NOTE: ROD CAN BE INSTALLED INTO PISTON WITH IDENTIFICATION BUMPS IN EITHER DIRECTION. −6200− CONNECTING ROD ASY NOTE: SEE FRAME 8C FOR ROD CAP INSTALLATION.

NOTE: PISTON & ROD AUTOMATED ASSEMBLY ALWAYS ASSEMBLES BUMPS OPPOSITE FRONT OF PISTON. NOTE: PISTON MAY BE HEATED TO 60 F−350 F TO ALLOW PIN TO SLIDE INTO PLACE FOR THIS ASSEMBLY PROCESS.

1 NOTE: PRIOR TO PISTON PIN INSTALLATION, COAT BOTH PISTON PIN BORES WITH WSE−M2C908−A OIL. OIL COVERAGE TO BE 360 AROUND BOTH PISTON PIN BORES. NOTE: PIN TO ROD CLEARANCE (.004−.020) NOTE: PIN FIT TO PISTON − (.002) INTERFERENCE − (.009) CLEARANCE AT 20 C (68 F)

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52

8A .75

PISTON, PIN, RINGS AND CONNECTING ROD ASY FOR ALL EXCEPT H/O (Continued)

NOTE: − PISTON RING END GAP MEASURED AT (81.655) GAGE DIAMETER − COMPRESSION RING END GAP UPPER (0.10−0.25) LOWER (0.27−0.42)

−6150− PISTON RING−UPPER COMPRESSION NOTE: INSTALL EITHER DIRECTION

− OIL RING SEGMENT END GAP (0.15−0.65)

(.04−.075) (.04−.085)

−6152− PISTON RING − LOWER COMPRESSION NOTE: ASSEMBLE SCRAPER GROOVE DOWN WITH RESPECT TO DOME OF PISTON. −6161− PISTON RING SPACER OIL CONTROL NOTE: ORIENT GAP SUCH THAT CUT ENDS ARE POINTED TOWARD PISTON DOME. −6159− PISTON RING − SEGMENT OIL CONTROL (2) REQ VIEW A

CENTER LINE OF PISTON PARALLEL TO WRIST PIN BORE

UPPER COMPRESSION RING GAP LOCATION (RETAINER− PISTON PIN) (PIN−PISTON)

(30 )

(30 )

OIL CONTROL SEGMENT RING GAP LOCATION

OIL CONTROL SEGMENT RING GAP LOCATION

EXPANDER RING AND LOWER COMPRESSION RING GAP LOCATION. VIEW B NOTE: FOR INSTALLATION OF UPPER AND LOWER COMPRESSION RINGS UTILIZE RING EXPANDER TOOL.

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52

8B .75

PISTON, PIN, RINGS AND CONNECTING ROD ASY FOR H/O ONLY (Continued) NOTE: FOR INSTALLATION OF UPPER AND LOWER COMPRESSION RINGS UTILIZE RING EXPANDER TOOL.

NOTE: − PISTON RING END GAP MEASURED AT (81.655) GAGE DIAMETER − COMPRESSION RING END GAP UPPER (0.10−0.25) LOWER (0.27−0.42) − OIL RING SEGMENT END GAP (0.15−0.65)

−6150− PISTON RING−UPPER COMPRESSION NOTE: INSTALL EITHER DIRECTION (.04−.075) (.04−.085)

−6152− PISTON RING − LOWER COMPRESSION NOTE: ASSEMBLE SCRAPER GROOVE DOWN WITH RESPECT TO DOME OF PISTON. −6161− PISTON RING SPACER OIL CONTROL NOTE:

−6159− PISTON RING − SEGMENT OIL CONTROL (2) REQ VIEW A

CENTER LINE OF PISTON PARALLEL TO WRIST PIN BORE

UPPER COMPRESSION RING GAP LOCATION (RETAINER− PISTON PIN)

(30 )

(30 )

OIL CONTROL SEGMENT RING GAP LOCATION

(PIN−PISTON)

OIL CONTROL SEGMENT RING GAP LOCATION

8H EXPANDER RING AND LOWER COMPRESSION RING GAP LOCATION.

COLOR CODE: YELLOW VIEW

B

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52

8C .75

PISTON & CONNECTING ROD ASY BEARINGS AND ROD CAP ASY NOTE: PRIOR TO PISTON/CONNECTING ROD ASY INSTALLATION, COAT ALL CYLINDER BORE SURFACES, CRANKSHAFT PINS & JOURNALS WITH WSE−M2C908−A OIL. NOTE: OPERATOR TO CHECK FOR RINGS PRESENT, GAP ALIGNMENT & RING MOVEMENT PRIOR TO STUFFING.

(GUIDE TOOL)

−6211− BEARING− CONNECTING ROD (6) REQ VIEW A

FRONT OF ENGINE

−6210− CAP−CONNECTING ROD (6) REQ

−6100− PISTON & CONNECTING ROD ASY (6)REQ −6211− BEARING− CONNECTING ROD (6) REQ

(PISTON RING COMPRESSOR TOOL) NOTE: CONNECTING ROD BOLTS MAY BE TORQUE TO YIELD A MAXIMUM OF (3) TIMES (ONCE AT ROD MACHINING AND TWICE AT ENGINE ASY)

−6214− (11mm HEX) MJ9 X 1 X 40 BOLT PILOT (2) PER CAP (PART OF −6200− ASY) TORQUE TO YIELD

(CYLINDER BLOCK ASY)

PRODUCTION RUNDOWN METHOD PRE−TORQUE BOTH FASTENERS. THEN TORQUE (40 Nm). THEN ROTATE (85 −95 ) MONITOR PRETHRESHOLD ANGLE. ELASTIC SLOPE AND POST ELASTIC TORQUE

FRONT OF ENGINE

SINGLE WRENCH METHOD − SERVICE TORQUE BOTH FASTENERS (20−25 Nm). THEN TORQUE BOTH FASTENERS (40−45 Nm). THEN ROTATE (90 −120 )

1 4

(BRG−CONN ROD) (CAP)

2 5 3

(2 MAX)

6 PARTING FACE

(2 MAX)

(BRG−CONN ROD)

(ROD) VIEW A

NOTE: ALIGNMENT OF BEARING MATING SURFACES MUST NOT EXCEED (2mm) FROM PARTING SURFACES. NOTE: DIAMETRAL ROD BEARING CLEARANCE AT CROWN IS TO BE (.028−.066)

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52

8D .35

PISTON & CONNECTING ROD ASY, BEARINGS AND ROD CAP ASY (Continued) DIMENSION "Z"−TWO READINGS FRONT AND REAR D DIMENSION "Z"

(BLOCK ASY− CYLINDER)

TOP OF BLOCK (DECK)

CL OF PISTON PARALLEL WITH CL OF CRANKSHAFT

TOP OF PISTON (FRONT FACE OF BLOCK) (CYLINDER BORE) (PISTON ASY) VIEW B

ASSEMBLE WITH ARROW TOWARDS FRONT OF ENGINE

(PISTON ASY) VIEW C

CYLINDER BLOCK BORE DIAMETER

PISTON DIAMETER UNCOATED

PISTON DIAMETER COATED

7

81.640 − 81.650

81.610 − 81.620

81.630 − 81.650

8

81.651 − 81.660

81.618 − 81.632

81.638 − 81.662

9

81.661 − 81.670

81.630 − 81.640

81.650 − 81.670

GRADE

BEFORE TAKING MEASUREMENTS ("Z" DIMENSION),BE SURE PISTON IS AT TDC. DIMENSION "Z" TOP OF PISTON (−0.415mm) BELOW TO (0.115mm) ABOVE TOP OF BLOCK. MEASURE AT TDC (AVERAGE OF TWO READINGS FRONT AND REAR SHOWN ABOVE). BOTH MEASUREMENTS MUST BE TAKEN PARALLEL TO CRANKSHAFT AXIS. A STRAIGHT LINE BETWEEN THE (2) READINGS MUST PASS THRU THE TRUE CENTER OF THE PISTON. MEASURE CYLINDER BLOCK BORE DIAMETER AT GAGE LOCATION SHOWN BELOW AND MARK OUTSIDE OF BLOCK WITH APPROPRIATE NUMBER TO IDENTIFY BORE GRADE SIZE. PISTON DOMES ARE MARKED WITH GRADE NUMBERS. INSTALL PISTON AND ROD ASY. TO CYLINDER BORE WITH MATCHING NUMBERS. NOTE: TO PREVENT DAMAGE TO PISTONS AFTER ASSEMBLY, POSITION CRANKSHAFT SO PISTONS ARE BELOW DECK. C

(BLOCK ASY−CYLINDER)

(ROD ASY−CONNECTING)

(PISTON & CONNECTING ROD ASY)

B

IDENTIFICATION ON CAP AND ROD MUST REMAIN ALIGNED AND RETAINED AS A MATCHED SET

(CRANKSHAFT)

(BEARING−CONNECTING ROD) (CRANKSHAFT) (49.95−50.05)

(BEARING−CONNECTING ROD) CL OF CRANKSHAFT

(BLOCK ASY−CYLINDER GAGE LOCATION)

031102

(CAP)

A

SECTION D

NE01−I10872796−025 V−ENGINE ILLUSTRATION

VERTICAL DIAMETRICAL BEARING ASSEMBLED CLEARANCE (0.028−0.066)

ROD ASY−CONNECTING TO CRANKSHAFT SIDE CLEARANCE (0.10−0.30) VIEW A

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52

9 .5

OIL PUMP ASSEMBLY

−6621− PUMP ASY−OIL LESS SCREEN & COVER

2

4 FRONT OF ENGINE

1

(BLOCK ASY− CYLINDER)

3

W500300 (8mm HEX) M6 X 1.0 X 33.5 BOLT HEX FLANGE HD (TORQUE TO 8−12 Nm) (4) REQ

ASSEMBLY PROCEDURE 1.

ROTATE INNER ROTOR OF OIL PUMP ASY (−6621−) TO ALIGN WITH FLATS ON CRANKSHAFT POST.

2.

ALIGN OIL PUMP ASY WITH CRANKSHAFT AXIALLY AND CAREFULLY INSTALL ONTO CRANKSHAFT UNTIL SEATED AGAINST CYLINDER BLOCK ASY.

3.

INSTALL (4) M6 BOLTS AND TORQUE TO SPECIFICATION.

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52

10 .7

OIL PAN BAFFLE

W701542 (10mm HEX) M6 X 1 NUT HEX FLANGE FREE RUNNER (TORQUE 5Nm THEN ROTATE 45 ) (4) REQ

−6687− BAFFLE

(BULKHEAD HOUSING STUD) (4) PLACES

(HOUSING− ENGINE BULKHEAD)

FRONT OF ENGINE

BACKGROUND DETAIL MAY NOT BE PICTORALLY ACCURATE FOR ALL APPLICATIONS

030203 NE01−I10872796−025 V−ENGINE ILLUSTRATION

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52

10A .6

OIL PAN BAFFLE (CONTINUED)

W701582 (13mm HEX) M8 X 1.25 NUT HEX FLANGE FREE RUNNER) (TORQUE 15 Nm THEN ROTATE 45 ) (3) REQ

(BULKHEAD HOUSING STUD) (3) PLACES (HOUSING− ENGINE BULKHEAD)

FRONT OF ENGINE

BACKGROUND DETAIL MAY NOT BE PICTORALLY ACCURATE FOR ALL APPLICATIONS

030203 NE01−I10872796−025 V−ENGINE ILLUSTRATION

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52

11 .6

OIL PUMP SCREEN AND COVER ASY W701582 (13mm HEX) M8 X 1 NUT HEX FLANGE FREE RUNNER (TORQUE 5 Nm THEN ROTATE 45 )

−6622− SCREEN & COVER ASY−OIL PUMP

W700005 (8mm HEX) M6 X 1 X 25.25 SCREW HEX FLANGE PILOT (TORQUE 8−12 Nm) (2) REQ A

(BULKHEAD HOUSING STUD)

BACKGROUND DETAIL MAY NOT BE PICTORALLY ACCURATE FOR ALL APPLICATIONS

(PUMP ASY−OIL LESS SCREEN & COVER)

FRONT OF ENGINE

(SCREEN & COVER ASY−OIL PUMP)

ASSEMBLY PROCEDURE 1.

INSERT SCREEN AND COVER ASSEMBLY (−6622−) TUBE END INTO OIL PUMP AND SUPPORT BRACKET ONTO BULKHEAD HOUSING STUD.

2.

INSTALL (2) M6 BOLTS AND (1) M6 NUT AS SHOWN AND TORQUE TO SPECIFICATION.

("O" RING PART OF −6622− ASY)

VIEW A

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52

12 .6

OIL SEPARATOR ASY, WATER INLET TUBE AND CUP PLUG (INSTALLATION TOOL)

NOTE: PCV VALVE PART OF −6B673− W701504 (8mm HEX) M6 X 1 X 23.25 BOLT & WASHER HEX FLANGE HD PILOT (TORQUE 8−12 Nm) (2) REQ

−8A505− TUBE−WATER INLET NOTE: INSTALL TO A HEIGHT OF (37.5−38.5)

−6B673− SEPARATOR ASY−OIL APPLY (2mm) BEAD OF WSK−M2G349−A7 SEALER

A

−6B752− GASKET−OIL SEPARATOR (BLOCK ASY− CYLINDER)

W701923 35mm CUP PLUG NOTE: APPLY (2mm) BEAD OF WSK−M2G349−A10 SEALER TO CUP PLUG OR BORE

FRONT OF ENGINE

B

(BLOCK ASY− CYLINDER) (38.5 37.5)

(11.0 9.0)

(BLOCK ASY− CYLINDER)

030801

(CUP PLUG)

(TUBE−WATER INLET)

SECTION B

VIEW A

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52

13 .7

POWER STEERING PUMP MOUNTING BRACKET ASY

W704693 M8 X 1.25 X 99 BOLT HEX FLANGE HD PILOT (TORQUE 20−30 Nm) (2) REQ−FRONT

W704694 M8 X 1.25 X 71 BOLT HEX FLANGE HD PILOT (TORQUE 20−30 Nm) (2) REQ−REAR

−3K738− BRACKET ASY− POWER STEERING PUMP MOUNTING

FRONT OF ENGINE

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14 X

CYLINDER HEAD PIPE PLUGS AND DOWELS (INSTALLED IN CYLINDER HEAD MACHINING AREA) −6050− HEAD ASY− CYLINDER LH

W701515 (1/4 HEX) 1/4−18 PLUG SOCKET HEX (TORQUE 14 Nm THEN ROTATE 180 ) (2) REQ

A FRONT OF ENGINE

−6049− HEAD ASY− CYLINDER RH

W701518 (5/8 HEX) 1−11.5 PIPE PLUG (TORQUE 90 Nm THEN ROTATE 180 ) (2) REQ

W701501 PIN 10 X 49.25 DOWEL (2) REQ

(29.5 29.0) (DOWEL)

W701515 (1/4 HEX) 1/4−18 PLUG (TORQUE 14 Nm THEN ROTATE 180 ) (2) REQ (HEAD ASY− CYLINDER)

SECTION A

TYPICAL (2) PLACES −6049− HEAD ASY− CYLINDER RH NOTE: H/O I.D. HOLE PORTS ARE EXTRUDE HONED.

−6050− HEAD ASY− CYLINDER LH

FRONT OF ENGINE W701515 (1/4 HEX) [1/4−18] PLUG SOCKET HEX (TORQUE 14 Nm THEN ROTATE 180 ) (3) REQ LH CYLINDER HEAD ASY (2) REQ RH CYLINDER HEAD ASY

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14A X

CYLINDER HEAD ASY VALVES, SPRINGS & LASH ADJUSTERS

1 −6C501−

ADJUSTER ASY − VALVE LASH (12) REQ NOTE: LASH ADJUSTER MUST BE PUMPED UP PRIOR TO INSTALLATION.

−6518− KEY − VALVE SPRING RETAINER (24) REQ MUST BE PROPERLY SEATED

−6514− RETAINER − VALVE SPRING (12) REQ

1 NOTE: LUBRICATE BORE WITH WSE−M2C908−A OIL PRIOR TO INSTALLATION

−6513− SPEC − SPRING VALVE (12) REQ

(GARTER SPRING) −6A517− SEAL ASY − VALVE STEM (12) REQ MUST BE INSTALLED BEFORE INSERTING VALVE (−6507−/−6505−) AND BOTTOMED ON VALVE GUIDE NOTE: GARTER SPRING MUST BE PRESENT

FRONT OF ENGINE

(HEAD ASY − CYLINDER)

−6505− VALVE − EXHAUST (6) REQ

NOTE: APPLY WSE−M2C908−A OIL TO ENTIRE I.D. OF VALVE GUIDE PRIOR TO VALVE INSTALLATION. VALVE MUST ROTATE FREELY.

VALVE STEM TO GUIDE CLEARANCE:

−6507− VALVE − INTAKE (6) REQ

INTAKE: (0.020−0.069) EXHAUST: (0.046−0.095)

VALVE SPRING INSTALLED HEIGHT (SERVICE/AUDIT) (HEAD ASY − CYLINDER)

TOP OF SPRING

SPRING SEAT

INSTALLED SPRING HEIGHT (SEE CHART)

MAINTAIN SPECIFIED VALVE SPRING INSTALLED HEIGHT BY VARYING THIS DIMENSION PER AFFECTED CYLINDER HEAD DETAIL DRAWING

VALVES

GAGE LINE RIGHT SIDE LEFT SIDE

SHOWN TYPICAL

INTAKE AND EXHAUST

INSTALLED SPRING HEIGHT

ALL

FOR 95% PRODUCTION

39.69−40.29

FOR 100% PRODUCTION

39.49−40.49

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14B .5

CYLINDER HEAD GASKETS AND DOWELS

(BLOCK ASY − CYLINDER)

(9.0 8.0) DOWEL SECTION C

−6051− GASKET − CYLINDER HEAD

W704688 PIN − 16.4 X 19.25 HOLLOW DOWEL − SPLIT (2) REQ AS SHOWN (EACH SIDE) NOTE: MUST BE BOTTOMED (SEE SECTION C )

A

C

B

D

(BLOCK ASY − CYLINDER)

FRONT OF ENGINE

−6083− GASKET − CYLINDER HEAD NOTE: APPLY LOCAL PRESSURE AROUND DOWEL TO SNAP−FIT GASKET IN PLACE (2) PLACES AT ONCE

FRONT OF ENGINE

(DOWEL) VIEW B

VIEW A (GASKET RH)

(GASKET LH)

RIGHT SIDE LEFT SIDE

SHOWN TYPICAL

VIEW D

(BLOCK ASY − CYLINDER)

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52

14C .7

CYLINDER HEAD ASY RIGHT SIDE LEFT SIDE

NOTE: REMOVE THRUST CAPS, SHIP ON PALLET AND NESTED OVER CAMSHAFTS

SHOWN TYPICAL −6065− (15mm HEX) M10 X 1.5 X 154.8 BOLT & WASHER ASY HEX FLANGE HD PILOT (8) REQ PER HEAD

NOTE: SEE FRAME 14D FOR ASSEMBLY PROCEDURE

(HEAD ASY − CYLINDER)

(GASKET − CYLINDER HEAD)

FRONT OF ENGINE

(BLOCK ASY − CYLINDER)

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14D .7

CYLINDER HEAD ASY (Continued)

5

6

3

2

1

4

7

8

SINGLE WRENCH CYLINDER HEAD TORQUE SEQUENCE FRONT OF ENGINE

SINGLE WRENCH METHOD (SERVICE & REPAIR) 1.

INSTALL HD ASY−CYL/HD ASY−CLY LH (−6049−/−6050−) OVER DOWELS.

2.

INSTALL M10 BOLTS (8) EACH SIDE AND PRETORQUE AS FOLLOWS: A. TORQUE ALL BOLTS TO (32−38 Nm) IN NUMERICAL SEQUENCE SHOWN. B. ROTATE ALL BOLTS (85 −95 ) IN NUMERICAL SEQUENCE SHOWN.

3.

BACK OUT ALL BOLTS (8) EACH SIDE A MINIMUM OF ONE FULL TURN (360 ).

4.

TIGHTEN ALL BOLTS (8) EACH SIDE TO SPECIFICATION AS FOLLOWS; A. TORQUE ALL BOLTS TO (32−38 Nm) IN NUMERICAL SEQUENCE SHOWN. B. ROTATE ALL BOLTS (85 −95 ) IN NUMERICAL SEQUENCE SHOWN. C. ROTATE ALL BOLTS AN ADDITIONAL (85 −95 ) IN NUMERICAL SEQUENCE SHOWN.

RIGHT SIDE LEFT SIDE

5

6

1

2

3

4

7

8

SHOWN TYPICAL

MULTI−SPINDLE CYLINDER HEAD TORQUE SEQUENCE FRONT OF ENGINE

PRODUCTION METHOD (MULTI−SPINDLE) 1.

INSTALL HD ASY−CYL/HD ASY−CLY LH (−6049−/−6050−) OVER DOWELS.

2.

INSTALL M10 BOLTS (8) EACH SIDE PRE−TORQUE TO SEAT ALL BOLTS. SIMULTANEOUSLY (18−22 Nm)

3.

RETORQUE BOLTS 1−4 (35 Nm THEN ROTATE 180 )

4.

RETORQUE BOLTS 5−8 (35 Nm THEN ROTATE 180 )

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52

14E .5

CAMSHAFT & SPROCKET ASY, BEARING CAPS AND ROLLER FOLLOWERS W705391 (8mm HEX) M6 X 1 X 43.25 BOLT HEX FLANGE HD PILOT (TORQUE 8−12 Nm) (16) REQ

NOTE: SEE FRAME 14G FOR ASSEMBLY PROCEDURE & TORQUE SEQUENCE

RIGHT SIDE LEFT SIDE −6A258− CAP − CAMSHAFT BEARING (6) REQ

SHOWN TYPICAL

1 −6B280− CAP ASY − CAMSHAFT BEARING (2) REQ

2 −6A267− CAMSHAFT ASY − INTAKE LH FRONT OF ENGINE NOTE: CAMSHAFT SPROCKETS DETAIL MAY NOT BE PICTORALLY ACCURATE.

(HEAD ASY − CYLINDER)

−6529− ARM ASY − VALVE ROCKER (12) REQ

(ADJUSTER ASY− VALVE LASH) (12) REQ

2 −6A269− CAMSHAFT ASY − EXHAUST LH

1 (CAMSHAFT)

1 NOTE: CAP TO BE INSTALLED LAST & REMOVED FIRST (ARM ASY − VALVE ROCKER)

2 NOTE: LUBRICATE CAMSHAFT JOURNALS AND LOBES WITH WSE−M2C908−A OIL PRIOR TO INSTALLATION.

QUALITY AUDIT ONLY (0.50−1.11) GAP MEASURED ON CAP BASE CIRCLE WITH ADJUSTER FULLY COLLAPSED.

VIEW FOR GAP

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52

14F .5

CAMSHAFT PRE−ASSEMBLY TIMING MARK ALIGNMENT

1.

SET CRANKSHAFT AT (30 ) BTDC

2. INSTALL CAMSHAFTS INTO CYLINDER HEADS WITH TIMING MARKS AS SHOWN 3. ROTATE CRANK TO (5 ) BTDC

(86.82 ) (102.75 ) (2.35 ) (13.56 )

(35 ) TDC

0

0

LOCATE CRANKSHAFT KEY AT (35 ) (5 BTDC) AFTER INSTALLING CAMSHAFTS

0

NOTE: CAMSHAFT SPROCKETS DETAIL MAY NOT BE PICTORALLY ACCURATE.

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14F

14G .35

CAMSHAFT ASY, CAMSHAFT BEARING CAPS, LASH ADJUSTERS, AND ROLLER FOLLOWERS 1 NOTE: (Continued) COLOR CODE: YELLOW FOR H/O ONLY

1

11 5L

1L

12

#1

2

9

1

#5 5R

2 (THRUST CAP)

13 2L

#1

1R

10

1

3 (THRUST CAP)

3 14

#5

6L

4 4

11 2R

6R

BLUE STRIPE

12

1 BLUE STRIPE 15

5 5 3L

16

7L

13

6 6

7R

3R

14

1 ORANGE STRIPE 17

7 7 4L

18

8L

8

9L

1 BLUE

9

STRIPE

15

8 4R

8R

16

10

FRONT OF ENGINE

CAMSHAFT BEARING CAP TORQUE SEQUENCE ASSEMBLY PROCEDURE

NOTE: RE−INSTALL CAMSHAFT BEARING CAPS AT THEIR CORRECT NUMBERED LOCATION.

1.

LOAD (12) LASH ADJUSTERS (−6C501−) IN CYLINDER HEADS.

2.

APPLY WSE−M2C908−A OIL TO CAMSHAFT JOURNALS, LOBES, VALVE TIP PADS, ROLLER FOLLOWER SURFACES, ADJUSTER SOCKETS AND #1 CAM CAP THRUST GROOVE PRIOR TO INSTALLATION.

3.

LOAD (12) ROLLER FOLLOWER (−6529−), AND CAMSHAFT (−6250−) INTO CYLINDER HEAD THEN POSITION CAMSHAFT CAPS OVER CAMSHAFT, ENGAGING DOWELS IN CAM TOWERS.

4.

DEPRESS CAMSHAFT AND CAMSHAFT CLUSTER CAPS. (INSURE ALL COMPONENTS ARE PROPERLY ALIGNED) AND TORQUE ALL BOLTS SIMULTANEOUSLY TO (8−12 Nm).

5.

CAMSHAFT END PLAY (0.025−0.165 FIM) CHECK AT TORQUE (41−68 Nm).

ASSEMBLY PROCEDURE (SINGLE WRENCH METHOD)

030901

1.

INSTALL THRUST CAM CAP (−6B280−) LAST AND REMOVE IT FIRST.

2.

LOAD (12) LASH ADJUSTERS (−6C501−) IN CYLINDER HEADS.

3.

APPLY WSE−M2C908−A OIL (OR EQUIVALENT) TO CAMSHAFT JOURNALS, LOBES, VALVE TIP PADS, ROLLER FOLLOWER SURFACES, ADJUSTER SOCKETS AND #1 CAM CAP THRUST GROOVE PRIOR TO INSTALLATION.

4.

LOAD (12) ROLLER FOLLOWER (−6529−), AND CAMSHAFTS (−6A266 R.H. INT. −6A267− LH INT, −6A269− RH EXH & −6A269−LH EXH) INTO CYLINDER HEADS WITH TIMING MARKS AS SHOWN FRAME 14F.

5.

POSITION CAMSHAFT CAPS OVER CAMSHAFTS, ENGAGING DOWELS IN CAM TOWERS. SNUG DOWN ALL CAPS BOLTS DIAGONALLY FROM CENTER OUT. TORQUE ALL BOLTS (8−12 Nm) IN SEQUENCE SHOWN.

6.

CAMSHAFT END PLAY (0.025−0.165 FIM) CHECK AT TORQUE (41−68 Nm). NOTE: CAMSHAFT END PLAY (0.025−0.165 Nm) FORCE OF 133−222 N (30−50 LBS) IS REQUIRED TO CHECK END PLAY OF CAMSHAFT MAX FORCE OF 222 N (50 LBS) SHOULD NOT BE EXCEEDED, AS DAMAGE TO THRUST CAPS MAY RESULT.

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15 .35

SPARK PLUG ASY RIGHT SIDE LEFT SIDE

SHOWN TYPICAL NOTE: CAMSHAFT SPROCKETS DETAIL MAY NOT BE PICTORALLY ACCURATE.

−12405− SPARK PLUG ASY (TORQUE 9−20 Nm) (6) REQ

FOR CD132,SW164 & MPV COLOR CODE: BLACK (AWSF32F)

FOR HO COLOR CODE: PURPLE (AWSF22F)

(HEAD ASY − CYLINDER)

FRONT OF ENGINE

PRODUCTION METHOD (MULTI−SPINDLE) 1. PRETORQUE TO SEAT PLUGS 2. RETORQUE PLUGS TO SPECIFICATION (9−20 Nm)

SINGLE WRENCH METHOD (SERVICE AND REPAIR) 1. INSTALL PLUGS AND SEAT 2. TIGHTEN PLUGS TO SPECIFICATION (9−20 Nm)

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52

16 .7

CRANKSHAFT SPROCKET, DRIVE CHAIN, CHAIN GUIDE, TENSIONER ASY AND TENSIONER ARM (LH)

(CAMSHAFT ASY − INTAKE LH) (CAMSHAFT ASY − EXHAUST LH)

(DOWEL)

−6M274− ARM ASY − TIMING CHAIN TENSIONER LH

−6B274− GUIDE ASY − TIMING CHAIN LH

2

−6L266− TENSIONER − TIMING CHAIN

2

2

(CRANKSHAFT)

FRONT OF ENGINE

−6306− GEAR − CRANKSHAFT

2 W701524 (10mm HEX) M8 X 1.25 X 49.3 BOLT & WSHR HEX FLANGE HD PILOT (TORQUE 20−30 Nm) (4) REQ COLOR CODE: GOLD

NOTE: CAMSHAFT SPROCKETS DETAIL MAY NOT BE PICTORALLY ACCURATE.

−6268− CHAIN − TIMING NOTE: ALIGN TIMING LINKS WITH TIMING MARKS ON SPROCKETS

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52

16A .5

CRANKSHAFT, CAMSHAFT SPROCKETS AND DRIVE CHAIN, PRE−ASSEMBLY TIMING MARK ALIGNMENT (LH)

1. ROTATE CRANKSHAFT (120 ) CLOCKWISE TO (115 ) ATDC 2. INSTALL RH CAM DRIVE COMPONETS. (SEE FRAME 16B)

(26.82 ) (102.75 ) (2.35 )

(73.56 )

(85 ) (107 ) 0

0

TIMING MARK AT (107 )

CRANKSHAFT KEY AT (85 ) (115 ) ATDC

NOTE: CAMSHAFT SPROCKETS DETAIL MAY NOT BE PICTORALLY ACCURATE.

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52

16B .35

CRANKSHAFT SPROCKET, DRIVE CHAIN, CHAIN GUIDE, TENSIONER ASY AND TENSIONER ARM (RH) (CAMSHAFT ASY − INTAKE RH)

1

NOTE: WEAR FACE COLOR: TAN ON ON RH GUIDE AND RH ARM

(CAMSHAFT ASY − EXHAUST RH) W701232 (10mm HEX) M8 X 1.25 X 35 BOLT & WASHER HEX FLANGE HD PILOT (TORQUE 20−30 Nm) (2) REQ COLOR CODE: BLACK 2

1 −6M256− GUIDE ASY − TIMING CHAIN (RH)

1 −6K255− TENSIONER ARM ASY (RH)

2

(CRANKSHAFT)

(DOWEL)

−6L266− TENSIONER − TIMING CHAIN (RH)

FRONT OF ENGINE

W701524 (110mm HEX) M8 X 1.25 X 49.3 BOLT & WASHER HEX FLANGE HD PILOT (TORQUE 20−30 Nm) (2) REQ COLOR CODE: GOLD

2

2 −6268− CHAIN − TIMING NOTE: ALIGN TIMING LINKS WITH TIMING MARKS ON SPROCKETS

NOTE: CAMSHAFT SPROCKETS DETAIL MAY NOT BE PICTORALLY ACCURATE.

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52

16C .35

CRANKSHAFT, CAMSHAFT SPROCKETS AND DRIVE CHAIN, TIMING MARK ALIGNMENT (LH & RH) NOTE: TYPICAL ALIGNMENT WHEN ROTATED FORWARD TO TDC STROKE #1 CYLINDER. NOTE: AT TDC COMP STROKE #1 CYLINDER MARKS ON BACK SIDE OF CAM SPROCKETS ALIGN AS SHOWN.

(36.70 )

(97.77 )

(7.43 )

(63.49 )

0

0

TIMING MARK AT (133 ) TDC

NOTE: CAMSHAFT SPROCKETS DETAIL MAY NOT BE PICTORALLY ACCURATE.

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52

17 .35

FRONT COVER ASY, TENSIONER AND IGNITION PULSE RING (HEAD ASY − CYLINDER)

NOTE: TORQUE FASTENERS WITHIN (6) MINUTES OF APPLYING WSE−M4G323−A6 SEALER. FRONT OF ENGINE

NOTE: PRIOR TO FRONT COVER ASY INSTALLATION, WIPE OFF EXCESS SEALER AT CYLINDER HEAD/BLOCK JOINTS.

A

A B

B

(CRANKSHAFT) (BLOCK ASY − CYLINDER)

(HOUSING − ENGINE BULKHEAD)

NOTE: SEE FRAME 17A FOR FASTENER LOCATION AND TORQUE SEQUENCE MPV CDW/SW

NOTE: BLUE PAINT STRIPE

W704920 M8 X 60 BOLT & WSHR HEX FLANGE HD PILOT

SHOWN TYPICAL

−6C086− COVER ASY − ENGINE FRONT

C

(BLOCK ASY − CYLINDER)

WSE−M4G323−A6 SEALER

−6B209− TENSIONER ASY − ENGINE DRIVE BELT

IGNITION PULSE RING NOTE: THE PULSE RING TEETH MUST FACE FOWARD

−12A227− RING − IGNITION PULSE CRANKSHAFT SENSOR (HEAD ASY − CYLINDER)

(HOUSING − ENGINE BULKHEAD) WSE−M4G323−A6 SEALER

VIEW B

TYPICAL APPLY (6mm) DIAMETER DOT (APPROX) OF WSE−M4G323−A6 SEALER ON CYLINDER BLOCK & BULKHEAD HOUSING INTERSECTION. (2) PLACES B

(BLOCK ASY − CYLINDER) FRONT OF ENGINE

VIEW A

VIEW C

TYPICAL APPLY (6mm) DIAMETER DOT (APPROX) OF WSE−M4G323−A6 SEALER ON CYLINDER HEAD & CYLINDER BLOCK INTERSECTION. (4) PLACES A

031403 031004 NE01−I10872796−025 V−ENGINE ILLUSTRATION

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52

17A .45

FRONT COVER ASY FASTENERS = STUD = BOLT

14 −6C086− COVER ASY − ENGINE FRONT

15

10 11 4 3 16

13

9 12

8

7

1 2 6 MPV CDW/SW

5

SHOWN TYPICAL

VIEW − FRONT OF COVER HOLE NO.

3−4−8−10 11−14−15−16

2−5−6 7−9−12−13

DESCRIPTION

FASTENER

W706961 (13mm HEX)

M8 X 1.25 X 40 M6 X 1 X 20 STUD & WASHER ASY HD SHLDR PILOT

W701525 (10mm HEX)

M8 X 1.25 X 51.8 BOLT & WASHER ASY HEX FLNG HD PILOT

W701712 (13mm HEX)

M8 X 47.5 M6 X 20 STUD & WSHR−HEX FLNG HD PILOT

1

NOTE: TORQUE ALL FASTENERS (20−30 Nm) IN SEQUENCE: 1−16

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52

18 .4

OIL PAN ASY FOR CD132/SW164 & MPV NOTE: PARTS MARKED 1 ARE PART OF OIL PAN ASY.

(HOUSING − ENGINE BULKHEAD)

(COVER ASY − ENGINE FRONT)

5 7

6

4 FRONT OF ENGINE

3 2 1

1 GASKET − OIL PAN

8 9 15 1 DRAIN PLUG (TORQUE 22−30 Nm)

A

10 11 12

= BOLT

14

13

1 W701605 M8 X 1.25 X 34.3 BOLT & WASHER HEX FLANGE HD PILOT (TORQUE 20−30 Nm) (11) PLACES

1 W701606 M8 X 1.25 X 33 + M6 X 1 X 22.5 STUD & WASHER HEX CONL SHLDR PILOT (TORQUE 20−30 Nm) (4) PLACES

= STUD

−6675− PAN ASY − OIL

2

NOTE: ALIGN TRANSMISSION MOUNTING FACE OF OIL PAN WITH REAR FACE OF CYLINDER BLOCK. IT SHOULD HAVE MAXIMUM MISMATCH OF (0.25mm)UNDERFLUSH.

WSE−M4G323−A6 SEALER

IF STEP IS GREATER THAN ABOVE SPECIFICATION SHIMMING WILL BE REQUIRED. (SEE FRAME 18A)

2

NOTE: APPLY (10mm) DIAMETER DOT (APPROX) OF WSE−M4G323−A6 SEALER TO OIL PAN GASKET (−6710−) IN (2) LOCATIONS. REFER TO VIEW A.

(PAN ASY − OIL)

VIEW A TYPICAL (2) PLACES

NOTE: OIL PAN ASY MUST BE INSTALLED AND TORQUED TO SPECIFICATIONS WITHIN (6) MINUTES MAX. OF APPLYING SEALER.

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52

18A .5

OIL PAN ASY (Continued) FOR CD132/SW164 (MANUAL TRANS) & MPV ASSEMBLY PROCEDURE 1. ENSURE THAT OIL PAN GASKET (−6710−) IS CORRECTLY ASSEMBLED TO OIL PAN ASY (−6675−). 2. APPLY SEALER TO OIL PAN GASKET AS INDICATED ON FRAME 18. TORQUE WITHIN (6) MINUTES. 3. INSTALL OIL PAN AND GASKET ASY TO BULKHEAD HOUSING. 4. ALIGN TRANSMISSION FACE OF OIL PAN WITH REAR FACE OF CYLINDER BLOCK TO WITHIN (0.00 TO −0.25mm) UNDERFLUSH. WITH REAR FACE OF BLOCK. 5. ENGAGE AND RUN DOWN FASTENERS 1−15 SIMULTANEOUSLY (TORQUE 20−30 Nm). 6. GAGE STEP BETWEEN REAR FACE OF CYLINDER BLOCK AND TRANSMISSION MOUNTING FACE OF OIL PAN. ACCEPT ALL ASSEMBLIES THAT GAGE (0.00 TO 0.25mm). ASSEMBLIES THAT GAGE BETWEEN (−0.26 AND −0.50mm) UNDERFLUSH TO REAR FACE OF BLOCK MAY BE REPAIRED BY USING A (0.25mm) SHIM (SILVER)ON EACH AFFECTED SIDE OF OIL PAN. ASSEMBLIES THAT GAGE BETWEEN (−0.51 AND −0.75mm) UNDERFLUSH TO REAR FACE OF BLOCK MAY BE REPAIRED BY USING A (0.50mm) SHIM (GOLD)ON EACH AFFECTED SIDE OF OIL PAN. IF STEP GAGES GREATER THAN (−0.75mm) UNDERFLUSH OR IF TRANSMISSION MOUNTING FACE PROTRUDES OVERFLUSH. TO REAR FACE OF CYLINDER BLOCK, THEN REMOVAL AND

SERVICE AUDIT 1.

INSTALL OIL PAN TO TRANSMISSION RETAINING FASTENERS FINGER TIGHT. THIS WILL ALIGN TWO FACES PRIOR TO TORQUING OIL PAN.

2.

TIGHTEN OIL PAN FASTENERS TO SPECIFICATION, THEN TIGHTEN TRANSMISSION TO OIL PAN FASTENERS.

FRONT OF ENGINE

−6C629− SPACE − ENGINE OIL PAN

A

FOR MANUAL TRANS ONLY (OIL PAN ASY) −6C629− SPACER − ENGINE OIL PAN

−6C629− SPACER − ENGINE OIL PAN

FOR AUTO & MANUAL TRANS

FOR AUTO TRANS ONLY VIEW A

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52

19 1

CRANKSHAFT FRONT SEAL ASY, CRANKSHAFT TIMING SENSOR AND CAMSHAFT TIMING SENSOR MPV CDW/SW

SHOWN TYPICAL

−6B288− SENSOR ASY − CANSHAFT TIMING

W500214 (8mm HEX) M6 X 1 X 23.25 SCREW HEX FLANGE HD PILOT (TORQUE 8−12 Nm) (1) REQ EACH SENSOR −6C315− SENSOR ASY − CRANKSHAFT TIMING (INSTALLATION TOOL)

FRONT OF ENGINE (CRANKSHAFT) SURFACE "S" (COVER ASY − ENGINE FRONT)

−6700− SEAL ASY−CRANKSHAFT FRONT NOTE: LUBRICATE SEAL BORE IN COVER BEFORE INSTALLING

ASSEMBLY PROCEDURE 1. CHECK RELATIONSHIP OF SEAL BORE TO CENTERLINE OF CRANKSHAFT (SEE SECTION A ON FRAME 19A FOR SPECIFICATION). 2. APPLY WSE−M2C908−A OIL TO I.D. OF CRANKSHAFT SEAL BORE (IN FRONT COVER ASY) 3. INSTALL CRANKSHAFT SEAL (−6700−) IN FRONT COVER ASY (SPRING SIDE TOWARD ENGINE) USING INSTALLATION TOOL. NOTE: INSTALLED SEAL DEPTH: FLUSH TO (1mm) BELOW SURFACE "S". THIS IS NOT A MEASURE OF SEAL SQUARENESS (SEE SERVICE/AUDIT ON FRAME 19A). 4. CHECK SEAL SQUARENESS (SEE FRAME 19A). 5. INSTALL (2) SENSORS (−6C315− & −6B288−) IN FRONT COVER ASY 6. INSTALL (2) M6 BOLTS AND TORQUE TO SPECIFICATION.

031400 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

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19

52

19A .55

CRANKSHAFT FRONT SEAL SQUARENESS AND CONCENTRICITY (SERVICE/AUDIT)

CL OF CRANKSHAFT (CRANKSHAFT)

(0.50 FIM)

A (COVER ASY − ENGINE FRONT) (CRANKSHAFT) FRONT OF ENGINE

(COVER ASY − ENGINE FRONT)

SECTION A

FRONT OF ENGINE

CHECKING CONCENTRICITY DO NOT EXCEED THE FOLLOWING SPECIFICATIONS: (0.50 FIM)OF FRONT COVER SEAL BORE IN RELATION TO FRONT FACE OF CRANKSHAFT (SEAL MUST NOT BE INSTALLED) SEE SECTION A. (0.50 FIM)OF SEAL FRONT FACE SURFACE IN RELATION TO SEALING SURFACE OF DAMPER.

(DAMPER SEALING SURFACE) (CRANKSHAFT)

(0.50 FIM)

(DIAL INDICATOR) FRONT OF ENGINE

CHECKING SQUARENESS 030203 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

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19A

52

20 .5

CRANKSHAFT VIBRATION DAMPER ASY

−6316− DAMPER ASY − CRANKSHAFT VIBRATION NOTE: INSTALL AT A MAXIMUM PRESS FORCE OF (19.125 N)

A

FOR CD132 ONLY

FRONT OF ENGINE

A

FOR SW164/ MPV/HO ONLY

W701512 M12 X 1.5 X 52.5 BOLT HEX FLANGE HD PILOT 1. PRE−TORQUE TO (120 Nm) 2. BACKOUT A MINIMUM OF ONE FULL TURN (360 ) 3. TORQUE (47−53 Nm) 4. ROTATE (85 −95 )

(COVER ASY − ENGINE FRONT) (CRANKSHAFT)

W701511 FLAT WASHER

ASSEMBLY PROCEDURE 1.

SEAL SURFACE MUST BE FREE OF DIRT AND OIL.

2.

APPLY WSE−M4G323−A6 SEALER TO CRANKSHAFT DAMPER. (SEE VIEW B).

3.

INSTALL CRANKSHAFT DAMPER ASY (−6316−) AS SHOWN

4.

TORQUE M12 BOLT TO SPECIFICATION.

(DAMPER ASY − CRANKSHAFT VIBRATION)

(DAMPER ASY − CRANKSHAFT VIBRATION)

B

NOTE: APPLY WSE−M4G323−A6 SEALER TO KEYWAY SLOT PRIOR TO DAMPER AND BOLT INSTALLATION. SEAL SURFACE MUST BE FREE OF DIRT AND OIL. VIEW

030901 NE01−I10872796−025 V−ENGINE ILLUSTRATION

(CRANKSHAFT)

B

SECTION A

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

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20

52

21 .6

CAMSHAFT COVER ASY & CAMSHAFT REAR SEAL RETAINER ASY NOTE: SEE FRAME 21A FOR TORQUE SEQUENCE. LEFT SIDE RIGHT SIDE

SHOWN TYPICAL

NOTE: PARTS MARKED 2 ARE PART OF CAMSHAFT COVER ASY

(HEAD ASY − CYLINDER) (PILOT TOOL)

−6A505− COVER ASY − VALVE ROCKER ARM LH −6582− COVER ASY − VALVE ROCKER ARM NOTE: H/O BLACK COVERS

2 −6766−

−6B293− RETAINER ASY − CAMSHAFT SEAL REAR NOTE: INSTALL PRIOR TO CAMSHAFT COVER ASY NOTE: USE PILOT TOOL TO PROTECT "LIP" FROM DAMAGE.

VIEW A

CAP ASY − OIL FILL (PART OF −6A505− ASY ONLY)

W701242 M6 X 1 X 43.25 BOLT & WSHR HEX FLANGE HD PILOT (TORQUE 8−12 Nm) (2) REQ

2 M6 X 1 X 34 BOLT HEX FLANGE PILOT (TORQUE 8−12 Nm) (6) REQ (LH) (3) REQ (RH)

2 M6 X 1 X 34/

1

M5 X 0.8 X 21 STUD HEX FLANGE PILOT (TORQUE 8−12 Nm) (5) REQ (LH) (7) REQ (RH)

FRONT OF ENGINE

1 (RETAINER ASY − CAMSHAFT SEAL REAR) NOTE: DO NOT EXCEED (45) MINUTES DURATION BEFORE FINAL TORQUE SPEC IS ACHIEVED.

A

1

(COVER ASY − ENGINE FRONT)

1 APPLY (8mm) DIAMETER DROP OF WSE−M4G323−A6 SEALER. TO FRONT COVER GASKET INTERSECTION (6) PLACES (2 PER RH CAM COVER). (4 PER LH CAM COVER). NOTE: TORQUE ALL CAM COVER FASTENERS WITHIN (6) MINUTES OF APPLYING WSE−M4G323−A6 SEALER. WHEN (6) MINUTE CRITERIA CANNOT BE MET: PRE−TORQUE ALL FASTENERS TO (3 Nm).

1

NOTE: CAMSHAFT SPROCKETS DETAIL MAY NOT BE PICTORALLY ACCURATE. (HEAD ASY − CYLINDER)

031004 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

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21

52

21A .5

CAMSHAFT COVER ASY (Continued)

= STUD = BOLT

6

8 4

3

5

2

10

10

2

1

11

7

1 8 3

9

9

6

4

5 7

−6582− CAMSHAFT COVER ASY (RH)

−6A505− CAMSHAFT COVER ASY (LH)

FRONT OF ENGINE

CAMSHAFT COVER TORQUE SEQUENCE

031004 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

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21A

52

22 .35

IGNITION COIL ASY, GROUND STRAP, RADIO CAPACITOR ASY (NAAO & MPV) AND BRACKET (EAO) W706995 M5 X 0.8 X 29 BOLT HEX FLANGE HD (TORQUE 5−7 Nm) (3) REQ −18B960− BRACKET & CAPACITOR ASY− RADIO IGNITION INTERFERENCE

FOR EAO CD132/SW164 −19A095− GROUND STRAP NOTE: SEE FRAME 44 FOR INSTALLATION OF OTHER END

−12029− COIL ASY−IGNITION FRONT OF ENGINE

(COVER ASY−VALVE ROCKER ASY)

ORIENT CAPACITOR AS SHOWN

VIEW A

A

W706995 M5 X 0.8 X 29 BOLT HEX FLANGE HD (TORQUE 5−7 Nm) (3) REQ −18B960− BRACKET & CAPACITOR ASY− RADIO IGNITION INTERFERENCE

FOR NAAO SW164 AND MPV

−19A095− GROUND STRAP NOTE: SEE FRAME 44 FOR INSTALLATION OF OTHER END

−12029− COIL ASY−IGNITION FRONT OF ENGINE

(COVER ASY−VALVE ROCKER ASY)

030702 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

22

52

22A .5

IGNITION WIRE ASY (RH)

−12281− WIRE & BRACKET ASY− COIL TO SPARK PLUG LH NOTE: SEE FRAME 29 FOR FINAL INSTALLATION

−12280− WIRE & BRACKET ASY− COIL TO SPARK PLUG RH

FRONT OF ENGINE

(COVER ASY−VALVE ROCKER ARM RH)

(COIL ASY− IGNITION) NOTE: SPARK PLUG BOOT MUST BE FULLY SEATED ON SPARK PLUG TO ENSURE UMBRELLA SEAL TO CAM COVER

BACKGROUND DETAIL MAY NOT BE PICTORALLY ACCURATE FOR ALL APPLICATIONS

030703 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

22A

52

23 .57

ELECTRIC IMRC ASY & BRIDGE

W701669 M6 X 1 X 33.25 BOLT & WSHR HEX FLNG HD PILOT (TORQUE 8−12 Nm)

−9J559− CONTROL ASY−ENGINE AIR SHUT OFF

NOTE: SEE FRAME 30 FOR CABLE INSTALLATION

(COVER ASY−VALVE ROCKER ARM LH)

−9C836− BRACKET ASY− THROTTLE CONTROL LINKAGE LH

FOR CD/SW ONLY

FRONT OF ENGINE

030402 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

23

52

24 .5

WATER PUMP ASY

FRONT OF ENGINE

(TUBE−WATER INLET) (HEAD ASY− CYLINDER LH)

2

BACKGROUND DETAIL MAY NOT BE PICTORALLY ACCURATE FOR ALL APPLICATIONS

A

W701544 M6 X 1 X 69.25 BOLT & WASHER ASY HEX FLANGE HD PILOT (TORQUE 10 Nm THEN ROTATE 85 −95 ) (3) REQ

1 −8501− PUMP ASY−WATER

ASSEMBLY PROCEDURE 1 1. INSTALL WATER PUMP ASY (−8501−) AND POSITION TO REAR FACE OF CYLINDER HEAD ASY (LH) 2. ALIGN HOLES. INSERT M6 BOLTS AND TORQUE TO SPECIFICATION. 3. CLAMP HOSE TO WATER INLET TUBE.

2 ENGAGEMENT SPECIFICATIONS FOR

VIEW A

CLAMP MUST BE INSTALLED BETWEEN TWO PAINT STRIPES ON HOSE UNLESS OTHERWISE STATED. NOTE: HOSE ALIGNMENT PRIOR TO CLAMP POSITIONING MUST BE POSITIONED STRAIGHT UNLESS OTHERWISE STATED.

ALL COOLING COMPONENT HOSE ASSEMBLIES: ALL HOSE CONNECTIONS AND COMPONENTS TO BE BOTTOMED OR WITHIN (2.5) MAXIMUM OF BEING BOTTOMED ON THE COMPONENT CONNECTION.

1 NOTE: LUBRICATE WATER PUMP ASY HOSE OR WATER INLET TUBE WITH ESE−M99B144−B SURFACTANT PRIOR TO INSTALLATION.

030503 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

24

52

25 .5

WATER BYPASS HOSE ASY

FRONT OF ENGINE

W701632 M6 X 1 X 32.5 X M5 X 0.8 X 17.5 STUD & WASHER HEX FLANGE (TORQUE 8−12 Nm)

1

−8548− HOSE−WATER BYPASS

(HEAD ASY− CYLINDER LH)

BACKGROUND DETAIL MAY NOT BE PICTORALLY ACCURATE FOR ALL APPLICATIONS

−10884− SENDER ASY− COOLANT TEMPERATURE

"O" RING (2) REQ (PART OF −8548− ASY) APPLY ESE−M99B176−A LUBRICANT NOTE: VISUALLY INSPECT "O" RING AND MATING SURFACE FOR DIRT OR CONTAMINANTS PRIOR TO INSTALLATION.

W701669 M6 X 1 X 33.25 BOLT & WASHER HEX FLANGE PILOT (TORQUE 8−12 Nm)

1 NOTE:

SEE FRAME 30 FOR INSTALLATION OF IMRC CABLE TO THIS STUD

FOR MPV ONLY (HEAD ASY−CYLINDER RH)

FRONT OF ENGINE

FOR CD132 ONLY

1 −8548− HOSE−WATER BYPASS

(HEAD ASY− CYLINDER LH)

030305

−10884− SENDER ASY− COOLANT TEMPERATURE

"O" RING (2) REQ (PART OF −8548− ASY) APPLY ESE−M99B176−A LUBRICANT NOTE: VISUALLY INSPECT "O" RING AND MATING SURFACE FOR DIRT OR CONTAMINANTS PRIOR TO INSTALLATION.

W701632 M6 X 1 X 32.5 X M5 X 0.8 X 17.5 STUD & WASHER HEX FLANGE (TORQUE 8−12 Nm)

W701669 M6 X 1 X 33.25 BOLT & WASHER HEX FLANGE PILOT (TORQUE 8−12 Nm)

FOR SW164 ONLY

NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

25

52

25A .60

CRANKCASE EMISSION HOSE

FRONT OF ENGINE

−6K817− HOSE−CRANKCASE EMISSION VALVE TO INTAKE MANIFOLD

(SEPARATOR ASY−OIL)

BACKGROUND DETAIL MAY NOT BE PICTORALLY ACCURATE FOR ALL APPLICATIONS

030801 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

25A

52

26 .6

INTAKE MANIFOLD ASY (LOWER) AND EMISSION VACUUM CONTROL CONNECTOR FOR NAAO SW164 W701592 M6 X 1 X 66.25 BOLT & WASHER HEX FLANGE HD (TORQUE 8−12 Nm) (8) REQ

NOTE: SEE FRAME 26C FOR TORQUE SEQUENCE

FRONT OF ENGINE −9J447− MANIFOLD ASY− INTAKE LOWER

−9J447− MANIFOLD ASY− INTAKE LOWER

B

FOR NAAO H/O ONLY

A

VIEW B

−9439− GASKET− INTAKE MANIFOLD TO CYLINDER HEAD (2) REQ

(HEAD ASY− CYLINDER)

1 LOCATING PIN (2) PLACES PER GASKET

030109

FOR ALL NAAO EXCEPT H/O

SECTION A (TYPICAL)

NE01−I10872796−025 V−ENGINE ILLUSTRATION

−9E498− CONNECTOR ASY− EMISSION VACUUM CONTROL MAIN NOTE: FOR ENGAGEMENT SPECS SEE FRME 3A NOTE: SEE FRAMES 35, 35C AND 36 FOR CONTINUATION OF −9E498− ASY

(GASKET−INTAKE MANIFOLD TO CYLINDER HEAD)

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

26

52

26A .5

INTAKE MANIFOLD ASY (LOWER) AND EMISSION VACUUM CONTROL CONNECTOR FOR MPV AND EAO SW164 W701592 M6 X 1 X 66.25 BOLT & WASHER HEX FLANGE HD (TORQUE 8−12 Nm) (8) REQ

−9E498− CONNECTOR ASY− EMISSION VACUUM CONTROL MAIN NOTE: FOR ENGAGEMENT SPECS SEE FRAME 3A 2 NOTE: SEE FRAME 35, 35C AND 36 FOR CONTINUATION OF −9E498− ASY

−9J447− MANIFOLD ASY− INTAKE LOWER

FOR CD132/SW164 AND MPV

2

−9J447− MANIFOLD ASY− INTAKE LOWER

A

FOR EAO SW164 H/O ONLY NOTE: GREEN INJECTORS

FRONT OF ENGINE

BACKGROUND DETAIL MAY NOT BE PICTORALLY ACCURATE FOR ALL APPLICATIONS

A

(HEAD ASY− CYLINDER)

VIEW A

1 LOCATING PIN (2) PLACES PER GASKET

030103

−9439− GASKET−INTAKE MANIFOLD TO CYLINDER HEAD (2) REQ

SECTION A (TYPICAL)

NE01−I10872796−025 V−ENGINE ILLUSTRATION

NOTE: SEE FRAME 26C FOR TORQUE SEQUENCE

(GASKET−INTAKE MANIFOLD TO CYLINDER HEAD)

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

26A

52

26B .5

INTAKE MANIFOLD ASY (LOWER) FOR CD132 ONLY

W701592 M6 X 1 X 66.25 BOLT & WASHER HEX FLANGE HD (TORQUE 8−12 Nm) (8) REQ

NOTE: SEE FRAME 26C FOR TORQUE SEQUENCE

FRONT OF ENGINE −9J447− MANIFOLD ASY− INTAKE LOWER

−9439− GASKET−INTAKE MANIFOLD TO CYLINDER HEAD (2) REQ

A (HEAD ASY− CYLINDER)

1 LOCATING PIN (2) PLACES PER GASKET

030103

SECTION A (TYPICAL)

NE01−I10872796−025 V−ENGINE ILLUSTRATION

(GASKET−INTAKE MANIFOLD TO CYLINDER HEAD)

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

26B

52

26C .5

INTAKE MANIFOLD ASY (LOWER) (Continued)

7

8

3

4

1

2

FRONT OF ENGINE

5

(MANIFOLD ASY− INTAKE LOWER)

6

MANUAL TORQUE SEQUENCE

NAAO EAO/MPV

030103 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

SHOWN TYPICAL

001019

−−−

26C

52

27 .5

030403

V−ENGINE ILLUSTRATION

NE01−I10872796−025

WIRING HARNESS ASY FOR SW164 AND CD132 ALL CONNECTORS MARKED ARE B & A INSTALLED 11

12 −12A581− WIRING ASY − ENGINE CONTROL SENSOR

VIEW A

FOR EAO SW AND CD

FRONT OF ENGINE

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

12

8

11

FOR NAAO ONLY

5

6

1

4

−−−

FOR NAAO SW ONLY

10

13

2

27

001019

1 2 3 4

3

7

5

TO SENSOR ASY − CAMSHAFT TIMING (SEE FRAME 37) TO SWITCH ASY − OIL PRESSURE (SEE FRAME 37) TO SENSOR ASY − CRANKSHAFT TIMING (SEE FRAME 37) TO ELECTRIC IMRC (SEE FRAME 37B) TO INJECTOR ASY − FUEL (6) REQ

7 8 9 10 11 12

52

27A

6

TO BODY ASY − AIR INTAKE CHARGE THROTTLE (SEE FRAME 37B)

13

TO SENDER ASY − COOLANT TEMPERATURE (SEE FRAME 37B) TO COIL ASY − IGNITION (SEE FRAME 37A) TO VALVE ASY − IDEL AIR CONTROL (SEE FRAME 37B) TO SENSOR ASY − EXHAUST GAS OXYGEN TO CAPACITION ASY − RADIO IGNITION INTERFRENCE (SEE FRAME 37A) TO −12A522− WIRING ASY TO PRESSURE REGULATOR (NAAO ONLY) (SEE FRAME 39B)

X

030403

V−ENGINE ILLUSTRATION

NE01−I10872796−025

WIRING HARNESS ASY FOR MPV ONLY ALL CONNECTORS MARKED ARE B & A INSTALLED

11 −12A581− WIRING ASY − ENGINE CONTROL SENSOR

FRONT OF ENGINE

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

11

8

10 9

5

1

6

4

7

−−− 2

1

001019

27A

2 3 4 3

5

TO SENSOR ASY − CAMSHAFT TIMING (SEE FRAME 37) TO SWITCH ASY − OIL PRESSURE (SEE FRAME 37) TO SENSOR ASY − CRANKSHAFT TIMING (SEE FRAME 37) TO ELECTRIC IMRC (SEE FRAME 37B) TO INJECTOR ASY − FUEL (6) REQ

7 8 9 11 12

28

6

52

TO BODY ASY − AIR INTAKE CHARGE THROTTLE (SEE FRAME 37B)

TO SENDER ASY − COOLANT TEMPERATURE (SEE FRAME 37B) TO COIL ASY − IGNITION (SEE FRAME 37A) TO VALVE ASY − IDEL AIR CONTROL (SEE FRAME 37B) TO CAPACITION ASY − RADIO IGNITION INTERFRENCE (SEE FRAME 37A) TO −12A522− WIRING ASY

X

INTAKE MANIFOLD ASY (UPPER) W701520 (10mm HEX) M6 X 1 X 49.5 BOLT HEX FLANGE HD PILOT (TORQUE 8−12 Nm) (6) REQ

−9424− MANIFOLD ASY − INTAKE

−9S479− ISOLATOR − INTAKE MANIFOLD (6) REQ

BACKGROUND DETAIL MAY NOT BE PICTORALLY ACCURATE FOR ALL APPLICATIONS

−9H486− GASKET − INTAKE MANIFOLD UPPER

NOTE: SEE FRAME 28A TORQUE SEQUENCE

1 1

NOTE: INTAKE MANIFOLD IS BLACK FOR H/O APPLICATIONS

1

FRONT OF ENGINE

A

1

(MANIFOLD ASY − INTAKE LOWER)

SECTION A

1 LOCATING PIN (2) PLACES PER GASKET

030104 NE01−I10872796−025 V−ENGINE ILLUSTRATION

(TYPICAL)

(GASKET − INTAKE MANIFOLD UPPER)

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

28

52

28A .5

INTAKE MANIFOLD ASY (UPPER) (Continued)

(MANIFOLD ASY − INTAKE)

5

1

6

3

2

4

FRONT OF ENGINE

MANUAL TORQUE SEQUENCE

030104 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

28A

52

29 .45

IGNITION WIRE ASY (LH) AND FIRING ORDER

1

(WIRE & BRACKET ASY − COIL SPARK PLUG LH) NOTE: SEE FRAME 22A FOR INITIAL INSTALLATION FRONT OF ENGINE

A

(COVER ASY − VALVE ROCKER ARM LH)

6

5

4

FIRING ORDER: 1−4−2−5−3−6 BACKGROUND DETAIL MAY NOT BE PICTORALLY ACCURATE FOR ALL APPLICATIONS

1

NOTE: INSTALLED AFTER ENGINE MOUNT BRACKET AT B & A

NOTE: SPARK PLUG BOOT MUST BE FULLY SEATED ON SPARK PLUG TO ENSURE UMBRELLA SEAL TO CAM COVER

3

2

1

2

3

5

6

4

1

VIEW A

030703 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

29

52

30 .4

ELECTRIC IMRC ASY CABLE ROUTING BACKGROUND DETAIL MAY NOT BE PICTORALLY ACCURATE FOR ALL APPLICATIONS (IMRC CABLE) W701669 (10mm HEX) M6 X 1 X 33.25 BOLT & WSHR HEX FLANGE HD PILOT (TORQUE 8−12 Nm) (2) REQ

1 1 TO HOSE − WATER BYPASS STUD NOTE: SEE FRAME 25 FOR STUD CLARIFICATION

FRONT OF ENGINE

(HOSE − WATER BYPASS STUD) (CONTROL ASY − ENGINE AIR SHUT OFF) NOTE: SEE FRAME 23 FOR INITIAL INSTALLATION

(BRACKET ASY − THROTTLE CONTROL INTAKE LH)

FOR CD132/SW164 ONLY

INSTALLED VIEW

030402 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

30

52

31 .5

FLYWHEEL ASY AND REAR COVER PLATE (MANUAL TRANS)

(CRANKSHAFT) (BLOCK ASY − CYLINDER) (DOWEL) (2) REQ FRONT OF ENGINE

COLOR CODE: YELLOW

FOR H/O ONLY

A

−6A373− PLATE ENGINE RER COVER NOTE: STAKE REAR COVER PLATE (2) PLACES TOP & BOTTOM OF EACH DOWEL (SEE VIEW A)

−6375− FLYWHEEL ASY W701559 (17mm HEX) M10 X 1 X 20 BOLT HEX LOCK HD (TORQUE 73−87 Nm) (8) REQ

STAKE LOCATION

(DOWEL)

(PLATE − ENGINE REAR COVER)

VIEW A TYPICAL (2) PLACES

031103 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

31

52

31A .4

FLEXPLATE ASY AND REAR COVER PLATE (AUTO TRANS) FOR SW164 ONLY

FRONT OF ENGINE

(CRANKSHAFT) (BLOCK ASY − CYLINDER) (DOWEL) (2) REQ

A

−6A373− PLATE ENGINE RER COVER NOTE: STAKE REAR COVER PLATE (2) PLACES TOP & BOTTOM OF EACH DOWEL

−6375− FLEXPLATE ASY

FOR SW164 ONLY W701559 (17mm HEX) M10 X 1 X 20 BOLT HEX LOCK HD (TORQUE 73−87 Nm) (8) REQ

STAKE LOCATION

(DOWEL)

(PLATE − ENGINE REAR COVER)

VIEW A TYPICAL (2) PLACES

031103 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

31A

52

32 .4

AIR BYPASS VALVE ASY

FRONT OF ENGINE −9F715− VALVE ASY − IDLE AIR CONTROL

W701669 (10mm HEX) M6 X 1 X 33.25 BOLT & WSHR HEX FLANGE HD PILOT (TORQUE 8−12 Nm)

−9F670− GASKET − AIR BYPASS VALVE

(MANIFOLD ASY − INTAKE)

W701632 (10mm HEX) M6 X 1 X 32.5 + M5 X 0.8 X 17.5 STUD & WSHR HEX FLANGE HD PILOT (TORQUE 8−12 Nm)

030802 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

32

52

32A .65

EGR VACUUM REGULATOR ASY NAAO SW164 ONLY

FRONT OF ENGINE

W701708 (7mm HEX) M5 X 0.8 X 23.25 BOLT & WASHER ASY HEX FLANGE HD (TORQUE 5−7 Nm) WITH INSERTS (2) REQ

−9J459− CONTROL ASY − EGR VACUUM REGULATOR

(MANIFOLD ASY − INTAKE)

030804 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

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−−−

32A

52

33 .65

INLINE CONNECTOR BRACKET

W701539 (8mm HEX) M5 X 0.8 NUT (TORQUE 5−7 Nm) (2) REQ

−14A206− BRACKET − WIRING CONNECTOR

(COVER ASY − VALVE ROCKER ARM ASY − STUD) (2) PLACES

FRONT OF ENGINE

BACKGROUND DETAIL MAY NOT BE PICTORALLY ACCURATE FOR ALL APPLICATIONS

031402 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

33

52

33A .75

EGR VALVE ASY AND PLUG

(MANIFOLD ASY − INTAKE) −9D460− VALVE ASY − EXHAUST RECIRULATING

FOR NAAO SW164 ONLY

(GASKET − EGR VALVE) (PART OF −9D460− ASY) FRONT OF ENGINE

W701625 (10mm HEX) M8 X 1.25 X 39 SCREW & WSHR HEX FLNG HD PILOT (PART OF −9D460− ASY) (TORQUE 20−30 Nm) (2) REQ

(MANIFOLD ASY − INTAKE)

48ZE−3209 3/4 PLUG

FOR MPV ONLY

FRONT OF ENGINE

BACKGROUND DETAIL MAY NOT BE PICTORALLY ACCURATE FOR ALL APPLICATIONS

030804 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

33A

52

33B X

INTAKE MANIFOLD OPENING COVER ASY FOR EAO SW AND CD132

(MANIFOLD ASY − INTKAE)

−9D440− COVER ASY − INTAKE MANIFOLD OPENING

FRONT OF ENGINE

W701625 (10mm HEX) M8 X 1.25 X 39 SCREW & WSHR HEX FLNG HD PILOT (PART OF −9D460− ASY) TORQUE 20−30 Nm (2) REQ

BACKGROUND DETAIL MAY NOT BE PICTORALLY ACCURATE FOR ALL APPLICATIONS

030804 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

33B

52

34 X

LIFTING EYES

FRONT OF ENGINE

W701628 (18mm HEX) M12 X 1.75 X 39.3 X M8 X 1.25 X 20.3 STUD HEX FLANGE HD PILOT (TORQUE 100−125 Nm)

(HEAD ASY − CYLINDER LH)

A

(EYE − ENGINE LIFTING) −17A084− EYE − ENGINE LIFTING LH

(IMRC CABLE) NOTE: ROUTE IMRC CABLE UNDER HOOK ON LIFTING EYE.

−17A084− EYE − ENGINE LIFTING RH

VIEW A

FRONT OF ENGINE

(HEAD ASY − CYLINDER) W701627 (18mm HEX) M12 X 1.75 X 39.3 BOLT HEX FLANGE HD PILOT (TORQUE 100−125 Nm)

030106 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

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34

52

35 .7

EMISSION VACUUM CONTROL CONNECTOR ASY FOR NAAO SW164 ONLY

−9E498− CONNECTOR ASY − EMISSION VACUUM CONTROL MAIN NOTE: SEE FRAME 3A FOR ENGAGEMENT SPECS 2 1

2 2 1 1 NOTE:

3

SEE FRAMES 26 AND 36 FOR CONNECTION TO FUEL INJECTOR PRESSURE SENSOR

4

(VALVE ASY − EXHAUST RECIRULATING) (MANIFOLD ASY − INTAKE) FRONT OF ENGINE

2 1

3

(CONTROL ASY − EGR VACUUM REGULATOR)

ALL CONNECTORS MARKED 2 ARE B & A INSTALLED SEE FRAME 35D FOR CONNECTIONS & SHIPPING POSITION

030803 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

35

52

35A .5

EMISSION VACUUM CONTROL CONNECTOR ASY FOR EAO SW164 ONLY

−9E498− CONNECTOR ASY − EMISSION VACUUM CONTROL MAIN NOTE: SEE FRAME 3A FOR ENGAGEMENT SPECS 1

2 2 2

1 NOTE: 1

SEE FRAMES 26 AND 36 FOR CONNECTION TO FUEL PRESSURE REGULATOR ASY

(MANIFOLD ASY − INTAKE) 1

FRONT OF ENGINE

ALL CONNECTORS MARKED 2 ARE B & A INSTALLED SEE FRAME 35D FOR CONNECTIONS & SHIPPING POSITION

030803 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

35A

52

35B .5

EMISSION VACUUM CONTROL SEAL FOR CD132 ONLY

−9H490− SEAL − VACUUM OUTLET MANIFOLD

(MANIFOLD ASY − INTAKE) FRONT OF ENGINE

030803 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

35B

52

35C .5

EMISSION VACUUM CONTROL CONNECTOR ASY FOR MPV ONLY

−9E498− CONNECTOR ASY − EMISSION VACUUM CONTROL MAIN NOTE: SEE FRAME 3A FOR ENGAGEMENT SPECS 1 4

2

2

2

FRONT OF ENGINE

3

2 (MANIFOLD ASY − INTAKE) 1

ALL CONNECTORS MARKED 2 ARE B & A INSTALLED SEE FRAME 35E FOR CONNECTIONS & SHIPPING POSITION

030803 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

35C

52

35D .5

EMISSION VACUUM CONTROL CONNECTOR ASY (Continued) FOR NAAO SW164 ONLY

1

TO MANIFOLD ASY − INTAKE

2

TO VALVE − EXHAUST RECIRCULATING

3

CONTROL ASY − EGR VACUUM REGULATION

4

TO INJECTOR PRESSURE SENSOR

2 1

−9E498− CONNECTOR ASY − EMISSION VACUUM CONTROL MAIN NOTE: SEE FRAME 3A FOR ENGAGEMENT SPECS FRONT OF ENGINE

3 4

030803 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

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35D

52

35E .5

EMISSION VACUUM CONTROL CONNECTOR ASY (Continued) FOR EAO SW164 ONLY

1

TO MANIFOLD ASY − INTAKE

2

TO FUEL PRESSURE REGULATOR

1

−9E498− CONNECTOR ASY − EMISSION VACUUM CONTROL MAIN NOTE: SEE FRAME 3A FOR ENGAGEMENT SPECS

2

FRONT OF ENGINE

030803 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

35E

52

35F .5

EMISSION VACUUM CONTROL CONNECTOR ASY (Continued) FOR MPV ONLY

1

TO MANIFOLD ASY − INTAKE

2

TO SPEED CONTROL

3

TO FUEL PRESSURE REGULATOR

4

TO FUEL PRESSURE SOLENOID (MAZDA INSTALL)

4 2

1

−9E498− CONNECTOR ASY − EMISSION VACUUM CONTROL MAIN NOTE: SEE FRAME 3A FOR ENGAGEMENT SPECS

3

FRONT OF ENGINE

030803 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

35F

52

36 .5

PCV CONNECTOR & HOSE ASY TO UPPER INTAKE MANIFOLD ASY FITTING AND EMISSION VACUUM CONTROL CONNECTOR ASY ROUTING

BACKGROUND DETAIL MAY NOT BE PICTORALLY ACCURATE FOR ALL APPLICATIONS

FRONT OF ENGINE

(IMRC CABLE)

(CONNECTOR ASY − EMISSION VACUUM CONTROL MAIN) NOTE: TUCK VACUUM LINE BEHIND IMRC CABLE

FOR NAAO ONLY

PCV CONNECTOR & HOSE ASY NOTE: SEE FRAME 25A FOR INITIAL INSTALLATION

(MANIFOLD ASY − INTAKE)

NOTE: WSE−M99C45−A2 HOSE ASSEMBLY SURFACTANT ONLY (DO NOT MIX). USE TO FACILITATE HOSE ASSEMBLY. ALL OTHER LUBRICANTS ARE NOT PERMITTED. MAY BE APPLIED TO I.D. AND O.D. OF HOSE. SPRAY NOT PERMITTED.

030801 030803 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

36

52

37 .7

WIRING HARNESS ASY TO MOUNTING STUDS, CAMSHAFT TIMING SENSOR ASY, CRANKSHAFT TIMING SENSOR ASY AND OIL PRESSURE SWITCH (COVER ASY−VALVE ROCKER ARM STUD) FRONT OF ENGINE (SENSOR ASY− CAMSHAFT TIMING)

BACKGROUND DETAIL MAY NOT BE PICTORALLY ACCURATE FOR ALL APPLICATIONS

(FRONT COVER STUD) (2) PLACES

SHOWN OUT OF SEQUENCE FOR CHART CONGRUITY

ALL CONNECTORS MARKED ARE B & A INSTALLED

TO SWITCH ASY− OIL PRESSURE (SEE VIEW A)

TO SENSOR ASY− CAMSHAFT TIMING

A

WIRING RETAINER (5) PLACES

TO SENSOR ASY− CRANKSHAFT TIMING (COVER ASY−VALVE ROCKER ARM STUD)

(SENSOR ASY− CRANKSHAFT TIMING)

TO SWITCH ASY− OIL PRESSURE

(SWITCH ASY− OIL PRESSURE)

TO −12A522− WIRING HARNESS ASY (BRACKET− WIRING CONNECTOR) FRONT OF ENGINE

030403

(WIRING ASY− ENGINE CONTROL SENSOR) FRONT OF ENGINE

VIEW A

NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

37

52

37A .6

WIRING HARNESS ASY TO IGNITION COIL TO COIL ASY− IGNITION

(CAPACITOR ASY−RADIO IGNITION INTERFERENCE)

FRONT OF ENGINE TO CAPACITOR ASY− RADIO IGNITION INTERFERENCE (COVER ASY−VALVE ROCKER ARM STUD)

(COIL ASY− IGNITION)

(WIRING ASY− ENGINE CONTROL SENSOR)

FOR NAAO & MPV ONLY SEE FRAMES 27 & 27A FOR INITIAL INSTALLATION

SHOWN OUT OF SEQUENCE FOR CHART CONGRUITY

ALL CONNECTIONS SHOWN ARE FOR −9H589− WIRING HARNESS ASY

ALL CONNECTORS MARKED ARE B & A INSTALLED TO COIL ASY− IGNITION

(WIRING ASY− ENGINE CONTROL SENSOR)

FRONT OF ENGINE (COIL ASY− IGNITION)

(COVER ASY−VALVE ROCKER ARM STUD)

TO CAPACITOR ASY− RADIO IGNITION INTERFERENCE

FOR EAO ONLY

030403 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

37A

52

37B .5

WIRING HARNESS ASY TO IDLE SPEED VALVE, ECT SENSOR AND IMRC CONNECTOR

(VALVE ASY−IDLE AIR CONTROL)

A

TO VALVE ASY−IDLE AIR CONTROL

(WIRING ASY− ENGINE CONTROL SENSOR)

FRONT OF ENGINE TO SENDER ASY− COOLANT TEMPURATURE (SENDER ASY− COOLANT TEMPURATURE)

ALL CONNECTORS MARKED ARE B & A INSTALLED

SEE FRAMES 27 & 27A FOR INITIAL INSTALLATION ALL CONNECTIONS SHOWN ARE FOR −9H589− WIRING HARNESS ASY

(CONTROL ASY−ENGINE AIR SHUT OFF)

SHOWN OUT OF SEQUENCE FOR CHART CONGRUITY

TO CONTROL ASY−ENGINE AIT SHUT OFF

FRONT OF ENGINE

BACKGROUND DETAIL MAY NOT BE PICTORALLY ACCURATE FOR ALL APPLICATIONS

FRONT OF ENGINE

(WIRING ASY− ENGINE CONTROL SENSOR)

(VALVE ASY−IDLE AIR CONTROL STUD)

VIEW A

(HEGO SENSOR)

030403 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

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37B

52

38 .6

OIL LEVEL INDICATOR TUBE ASY AND OIL LEVEL INDICATOR ASY

(TUBE ASY−OIL LEVEL INDICATOR) NOTE: MUST BE BOTTOMED OUT AS SHOWN (HOUSING− ENGINE BULKHEAD)

SECTION A (HEAD ASY− CYLINDER LH)

−6750− INDICATOR ASY− OIL LEVEL NOTE: ORIENT OIL LEVEL INDICATOR AS SHOWN

W701822 (13mm HEX) M6 X 1 X 22.5 + M6 X 1 X 14.5 STUD & WSHR HEX FLANGE HD PILOT (TORQUE 8−12 Nm)

A

−6754− TUBE ASY−OIL LEVEL INDICATOR

FOR CD132/SW164 ONLY

(HOUSING− ENGINE BULKHEAD)

FRONT OF ENGINE

XU3E−6754−AD TUBE ASY

FOR MPV ONLY

NOTE: ORIENT OIL LEVEL INDICATOR AS SHOWN COLOR CODE (ON HANDLE): MPV − RED O’RING CD132/SW164 − YELLOW O’RING

030202 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

38

52

39 .6

THROTTLE BODY ASY

FRONT OF ENGINE

(MANIFOLD ASY− INTAKE)

W701519 (8mm HEX) M6 X 1 X 33.25 BOLT & WSHR HEX FLANGE HD PILOT (TORQUE 8−12 Nm) (3) REQ

−9E936− GASKET−AIR CHARGE CONTROL TO INTAKE MANIFOLD

1 −9E926−

BODY ASY−AIR INTAKE CHARGE THROTTLE

FOR AUTO TRANS ONLY

1

W701632 (10mm HEX) M6 X 1 X 32.5 + M5 X 0.8 X 17.5 STUD & WSHR HEX FLANGE HD PILOT (TORQUE 8−12 Nm)

NOTE: SEE FRAME 39A FOR MAN TRANS AND H/O THROTTLE BODY ASY’S

AUTO TRANS MAN TRANS & H/O

SHOWN TYPICAL

BACKGROUND DETAIL MAY NOT BE PICTORALLY ACCURATE FOR ALL APPLICATIONS

030802 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

39

52

39A .65

THROTTLE BODY ASY (Continued) −9E926− BODY ASY−AIR INTAKE CHARGE THROTTLE W701632 (10mm HEX) M6 X 1 X 32.5 + M5 X 0.8 X 17.5 STUD & WSHR HEX FLANGE HD PILOT (TORQUE 8−12 Nm) (3) REQ

SV T

−9E936− GASKET−AIR CHARGE CONTROL TO INTAKE MANIFOLD

W701519 (8mm HEX) M6 X 1 X 32.5 + M5 X 0.8 X 17.5 STUD & WSHR HEX FLANGE HD PILOT (TORQUE 8−12 Nm) (3) REQ

FOR H/O ONLY

−9E926− BODY ASY−AIR INTAKE CHARGE THROTTLE W701519 (8mm HEX) M6 X 1 X 33.25 BOLT & WSHR HEX FLANGE HD PILOT (TORQUE 8−12 Nm) (3) REQ

−9E936− GASKET−AIR CHARGE CONTROL TO INTAKE MANIFOLD W701632 (10mm HEX) M6 X 1 X 33.25 BOLT & WSHR HEX FLANGE HD PILOT (TORQUE 8−12 Nm)

FOR MANUAL TRANS ONLY

030802 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

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39A

52

39B 1

THROTTLE POSITION SENSOR CONNECTION (FOR ALL) AND IPS CONNECTION (FOR NAAO ONLY)

FRONT OF ENGINE

(BODY ASY−AIR INTAKE CHARGE THROTTLE)

TO BODY ASY− AIR INTAKE CHARGE THROTTLE

(WIRING−ENGINE CONTROL SENSOR)

TO INJECTOR PRESSURE SENSOR

(MANIFOLD ASY− INTAKE LOWER)

NOTE: ONCE ENGAGED, SLIDE RED SAFETY TOWARD SENSOR

AUTO TRANS MAN TRANS & H/O

SHOWN TYPICAL BACKGROUND DETAIL MAY NOT BE PICTORALLY ACCURATE FOR ALL APPLICATIONS

030403 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

39B

52

40 .8

OIL COOLER ASY, OIL FILTER ASY AND OIL PRESSURE SWITCH ASY

FRONT OF ENGINE

−9278− SWITCH ASY− OIL PRESSURE Nm (TORQUE 12−16 Nm)

(BLOCK ASY− CYLINDER)

1 GASKET (PART OF −6A642− ASY) NOTE: LUBRICATE WITH WSE−M2C908−A OIL PRIOR TO INSTALLATION

2 LOCATING PIN (INSERT)

FOR CD132 & NAAO SW164 −6A642− COOLER ASY−CRANKCASE OIL NOTE: POSITION TUBES AS SHOWN

2

FOR ALL EAO SW164 , H/O & MPV

1

OIL COOLER INSERT (PART OF −6A642− ASY) (TORQUE 55−60 Nm)

GASKET (PART OF −6714− ASY) NOTE: LUBRICATE WITH WSE−M2C908−A OIL PRIOR TO INSTALLATION

−6714− FILTER ASY−OIL TORQUE 14−17 Nm A

ASSEMBLY PROCEDURE (LOCATING PIN) 1. INSTALL LOCATING PIN ON OIL IT INTO CAST SLOT IN CYLINDER BLOCK. (CAST SLOT IN CYLINDER BLOCK)

2. ROTATE OIL COOLER CLOCKWISE UNTIL IT STOPS. 3. TORQUE AS SPECIFIED. VIEW A

030202 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

40

52

41 .65

LINKSHAFT BRACKET ASY AND CYLINDER BLOCK PLUGS

(BLOCK ASY− CYLINDER)

W701548 (14.30mm HEX) 3/4−14 PIPE PLUG HEX SOCKET (TORQUE 10Nm THEN ROTATE 720 ) ALTERNATE TORQUE: (TORQUE 10Nm THEN TORQUE 40Nm) (1) REQ EACH SIDE NOTE: INSTALL AFTER HOT TEST

FRONT OF ENGINE

−3K305− BRACKET ASY− FRONT WHEEL DRIVE LINK SHAFT

FOR SW164 ONLY W500233 (13mm HEX) M10 X 1.5 X 25 BOLT HEX FLANGE HD (TORQUE 40−55 Nm) (3) REQ

050404 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

41

52

42 .75

A/C COMPRESSOR & CLUTCH ASY FOR NAAO SW164 ONLY

FRONT OF ENGINE

(BLOCK ASY− CYLINDER

1

1

(HOUSING− ENGINE BULKHEAD)

−19D629− COMPRESSOR & CLUTCH ASY−A/C 1 NOTE: HOLLOW DOWEL (PART OF −19D629− ASY) (2) PLACES

W701626 (10mm HEX) M8 X 1.25 X 111.3 BOLT HEX HD PILOT (TORQUE 20−30 Nm) (3) REQ

030501 NE01−I10872796−025 V−ENGINE ILLUSTRATION

BACKGROUND DETAIL MAY NOT BE PICTORIALLY ACCURATE FOR ALL APPLICATIONS

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

42

52

43 .65

EXHAUST MANIFOLD & CONVERTER ASY (RH) FOR ALL CD AND SW AND EGR TUBE ASY FOR NAAO SW (VALVE ASY− EXHAUST RECIRCULATING)

FRONT OF ENGINE

−9J433− TRANSDUCER ASY−EGR

FOR NAAO SW ONLY

(HEAD ASY− CYLINDER)

−9D477− TUBE ASY−EGR (TORQUE 35−45 Nm) BOTH ENDS

FOR NAAO SW ONLY −9448− GASKET− EXAUST MANIFOLD

W701732 (5mm HEX) M8 X 1.25 X 15 X M8 X 1.25 X 23 STUD (TORQUE 10−13 Nm) (6) PLACES PER SIDE NOTE: INSTALL SHORT END OF STUD INTO CYLINDER HEAD ASY

W705609 (27mm HEX) CAP (TORQUE 35−45 Nm)

FOR EAO SW AND CD ONLY

W701706 (13mm HEX) M8 X 1.25 NUT HEX FLANGE HEAD (TORQUE 18−22 Nm) (6) REQ −5G236− MANIFOLD & CONVERTER ASY− EXHAUST RH BACKGROUND DETAIL MAY NOT BE PICTORIALLY ACCURATE FOR ALL APPLICATIONS

030104 NE01−I10872796−025 V−ENGINE ILLUSTRATION

SINGLE WRENCH METHOD TORQUE SEQUENCE 1−6 PERFORM TORQUE SEQUENCE TWICE

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

43

52

44 .6

GROUND STRAP

FRONT OF ENGINE

(HEAD ASY− CYLINDER)

1 GROUND STRAP

W701539 (8mm HEX) M5 X 0.8 NUT (TORQUE 5−7 Nm)

A

W701643 (13mm HEX) M5 X .8 X 15 / M6 X 1 X 19.25 STUD & WASHER HEX FLANGE HD PILOT (TORQUE 8−12 Nm) (2) REQ

(60 )

1

NOTE: SEE FRAME 23 FOR INITIAL INSTALLATION OF GROUND STRAP

(30 )

BACKGROUND DETAIL MAY NOT BE PICTORALLY ACCURATE FOR ALL APPLICATIONS NOTE: ORIENT STRAP AS SHOWN VIEW A

050501 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

44

52

45 .65

ALTERNATOR ASY AND ALTERNATOR MOUNTING BRACKET ASY FOR SW164 ONLY

(COVER ASY− ENGINE FRONT)

1

NOTE: BACKGROUND DETAIL MAY NOT BE PICTORIALLY ACCURATE FOR ALL APPLICATIONS 2

FRONT OF ENGINE

HOLLOW DOWEL (PART OF −10239− ASY) (2)REQ

W705832 (6mm HEX) M10 X 1.5 X 21/ M10 X 1.5 X 29 STUD STUD (TORQUE 10−15 Nm) W701524 (10mm HEX) M8 X 1.25 X 49.3 BOLT & WASHER HEX FLANGE HD PILOT (TORQUE 20−30 Nm) (3) REQ

−10239− BRACKET ASY− ALTERNATOR MOUNTING

W705831 (15mm HEX) M10 X 1.5 NUT (TORQUE 40−55 Nm) W701521 (13mm HEX) M10 X 1.5 X 85.3 BOLT HEX FLANGE HD PILOT (TORQUE 40−55 Nm) (2) REQ

−10300− ALTERNATOR ASY

UNIQUE FOR EAO

030504 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

45

52

45A .5

ALTERNATOR MOUNTING BRACKET ASY FOR MPV ONLY

(COVER ASY− ENGINE FRONT)

1 (BLOCK ASY− CYLINDER) 3

2

HOLLOW DOWEL (PART OF −10239− ASY) (2)REQ

FRONT OF ENGINE

−10239− BRACKET ASY− ALTERNATOR MOUNTING

W701524 (10mm HEX) M8 X 1.25 X 49.5 BOLT & WSHR− HEX FLNG HD PILOT (TORQUE 20−30 Nm) (3)REQ

030504 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

45A

52

46 X

POWER STEERING PUMP & BRACE ASY AND PULLEY FOR CD/SW ONLY

(COVER ASY−ENGINE FRONT STUD) (6) PLACES

(BRACKET− POWER STEERING)

CAP COLOR: CD132− ORANGE SW164− YELLOW −3D639− PUMP PULLEY & BRACKET ASY−POWER STEERING

UNIQUE FOR CD 2 W707172 (13mm HEX) M8 X 21.5 BOLT & WSHR HEX FLNG CONCL 8 (TORQUE 20−30 Nm) (2) REQ −3A733− PULLY−POWER STEERING PUMP

A

2

1

3

FRONT OF ENGINE

W701542 (10mm HEX) M6 X 1 NUT HEX FLANGE HD (TORQUE 8−12 Nm) (6) REQ

3 W500319 (10mm HEX)

M8 X 1.25 X 84.3 BOLT HEX FLANGE PILOT (TORQUE 20−30 Nm) (2) REQ NOTE: MUST BE RUN DOWN FIRST

(COVER ASY− ENGINE FRONT)

W701522 (10mm HEX) M8 X 1.25 X 19 BOLT & WASHER ASY HEX FLANGE HD PILOT (TORQUE 20−30 Nm) (4) REQ

14 15

10

11

1

4

NOTE: "DIMPLE" ON PULLEY MUST FACE FORWARD

3

NOTE: SEE FRAME 17A FOR IDENTIFICATION OF HOLE NUMBERS SHOWN

VIEW A (FRONT) STUD LOCATION

(6) PLACES

030503 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

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46

52

47 .5

DRIVE BELT (FEAD) FOR NAAO SW164

(PULLEY−POWER STEERING PUMP)

(TENSIONER ASY)

−8620− BELT−DRIVE (COMPRESSOR & CLUTCH ASY−A/C)

A

(ALTERNATOR ASY)

(DAMPER ASY− CRANKSHAFT VIBRATION) FRONT OF ENGINE B

(TENSIONER ASY)

P/S

TEN. ALT C/S

A/C

(BELT−DRIVE) NOTE: ROUTE BELT BEHIND TENSIONER AS SHOWN

VIEW A FRONT OF ENGINE

VIEW B

030507 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

47

52

48 .4

ACCESSORY DRIVE PULLEY AND WATER PUMP BELT TENSIONER ASY

(CAMSHAFT ASY− INTAKE LH)

FRONT OF ENGINE

−6A359− PULLEY− ACCESSORY DRIVE NOTE: MAX PRESS (15kN)

A

BACKGROUND DETAIL MAY NOT BE PICTORALLY ACCURATE FOR ALL APPLICATIONS (8.14−9.14) (WATER PUMP TENSIONER MOUNTING SURFACE) (PULLEY− ACCESSORY DRIVE)

SECTION A INSTALLED

FRONT OF ENGINE

−8W508− TENSIONER ASY− WATER PUMP BELT

W701520 (8mm HEX) M6 X 1 X 49.5 BOLT HEX FLANGE HD PILOT (TORQUE 8−12 Nm)

030502

(PUMP ASY−WATER)

NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

48

52

49 .5

WATER PUMP DRIVE BELT (READ) (PULLEY− ACCESSORY DRIVE)

FRONT OF ENGINE

−8K543− BELT−WATER PUMP DRIVE

A

(PUMP ASY− WATER)

BACKGROUND DETAIL MAY NOT BE PICTORALLY ACCURATE FOR ALL APPLICATIONS

AUX

TEN

W/P

VIEW A

030502 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

49

52

50 .45

ENGINE CODE DECAL AND INK JET APPLICATION

−6E072− LABEL−ENGINE CODE INFORMATION

FRONT OF ENGINE

NOTE: DECAL INSTALLATION PROCEDURE 1. SURFACE MUST BE CLEAN, DRY AND FREE OF OIL. IF OIL HAS CONTAMINATED THE SURFACE, IT MUST BE CLEANED WITH SOLVENT. 2. ADHESIVE MUST NOT TOUCH ANY FOREIGN SURFACE PRIOR TO APPLICATION. 3. IF DECAL HAS BEEN POORLY APPLIED (EXCESSIVE WRINKLES OR MIS−POSITIONED) OR IF IT HAS BEEN DAMAGED IN ANY WAY, IT MUST BE REMOVED AND REPLACED WITH A NEW DECAL.

NOTE: LOCATION OF INK JET IS IS (30 ) CLOCKWISE FROM OFFSET OF BOLT (FLYWHEEL ASY)

(30 )

(FLYWHEEL ASY) CL OF BOLT

INK JET

FRONT OF ENGINE

(25 )

A

VIEW A

FOR CD132/SW164 ONLY AUTOMATIC MANUAL

SHOWN TYPICAL

000103 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

50

52

51 .5

ENGINE ASY − LEFT REAR VIEW 2001 2.5L−4V SW EAO AUTO TRANS

FRONT OF ENGINE

030002 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

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51

52

51A .35

ENGINE ASY − LEFT REAR VIEW 2001 2.5L−4V SW EAO MAN TRANS

FRONT OF ENGINE

030002 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

51A

52

51B .35

ENGINE ASY − RIGHT FRONT VIEW 2001 2.5L−4V SW EAO

FRONT OF ENGINE

030002 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

51B

52

51C .4

ENGINE ASY − RIGHT FRONT VIEW MAZDA MPV AUTO

FRONT OF ENGINE

030002 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

51C

52

51D .45

ENGINE ASY − LEFT REAR VIEW MAZDA MPV AUTO

FRONT OF ENGINE

030002 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

51D

52

51E .4

ENGINE ASY − RIGHT FRONT VIEW 2001 2.5L−4V CD132

FRONT OF ENGINE

030002 NE01−I10872796−025 V−ENGINE ILLUSTRATION

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001019

−−−

51E

52

52 .4

W701625 FR 33B

9D440 FR 33B

9E498 SW164 FR 35A W701632 FR 39

2001 CD132 & EAO SW164 9H990 CD132 ONLY FR 35B W701520 (6) REQ FR 28

9E926 FR 39

12281 FR 22A

9H589 FR 27

9S479 (6) REQ FR 28

W701519 FR 39 9E926 FR 39A

9424 FR 28

9J559 FR 23 W701669 (3) REQ FR 23

W701632 FR 32 9H486 (2) REQ FR 28

9F715 FR 32 W701669 FR 32

18B960 FR 22

12280 FR 22A

W701592 (8) REQ FR 26

9F670 FR 32 W701539 (2) REQ FR 33

W706995 (3) REQ FR 23

14A206 FR 33

6159 (12) REQ FR 8A

19A095 FR 23 12029 FR 23

W701559 (8) REQ FR 31

6110 (6) REQ FR 8

6375 MANUAL FR 31

6582 FR 21 W705391 (32) REQ FR 14E 6B280 (4) REQ FR 14E

6A258 (12) REQ FR 14E 6A266 FR 14E

6A373 MANUAL FR 31 12405 (6) REQ FR 15

6A268 FR 14E

6518 (48) REQ FR 14A

6C501 (24) REQ FR 14A W701515 (4) REQ FR 14 W701732 (6) PLACES PER SIDE FR 43 9448 FR 43

6B673 FR 12 6B752 FR 12 6211 (12) REQ FR 8C 8A505 FR 12

6200 (6) REQ FR 8 6214 (12) REQ FR 8C W701517 FR 4A

W701202 (2) REQ FR 4A W701548 (2) REQ FR 41

3K305 SW ONLY FR 41 6514 (24) REQ FR 14A 6513 (24) REQ FR 14A W500233 6A517 (3) REQ (24) REQ SW ONLY FR 14A FR 41

6065 (16) REQ FR 14C

6529 (24) REQ FR 14E

6152 (6) REQ FR 8A 6151 (6) REQ 6135 FR 8A (6) REQ FR 8 6140 (12) REQ FR 8

6150 (6) REQ FR 8A

6049 FR 14C

17A084 FR 34

W701518 FR 14 W701501 FR 14 6507 (6) REQ 6505 FR 14A (6) REQ FR 14A

W701627 FR 34

W705609 FR 43

5G236 FR 43

9J447 CD132 FR 26B

6010 FR 4 6A341 FR 5A

6701 FR 7 7G371 AUTO SW164 FR 7A

W701632 FR 25 W701669 FR 25

9278 FR 40 W701516 FR 4 W706860 (2) REQ FR 4 W701546 FR 4 6A642 HO ONLY FR 40 W701517 6 8 90 FR 4A FR 40 6333 6714 (4) REQ FR 40 FR 5A 6K255 FR 16B W701528 FR 5A 6M256 W500300 FR 16B (4) REQ FR 9 6621 FR 9

6L266 FR 16B W701524 (2) REQ FR 16B

6687 FR 10 W701582 FR 11 6622 FR 11 W700005 (2) REQ FR 11 6710 FR 18 6C629 AS NEEDED FR 18A 6675 FR 18

W701606 (4) PLACES FR 18

6A505 FR 21

6A267 FR 14E

6A269 FR 14E 6050 FR 14A W701515 (5) REQ FR 14

8548 FR 25

W701501 FR 14

6083 FR 14B

17A084 FR 34

W701518 FR 14

6750 FR 38

W701822 FR 38

W701628 FR 34

6754 FR 38

W701232 (2) REQ FR 16B

6268 FR 16

6268 FR 16B 6L266 FR 16

6A338 (3) REQ FR 6B

W701542 (4) REQ FR 10

6B293 FR 21

W701520 FR 48 W701544 (3) REQ FR 24

W701504 (2) REQ FR 12 W704694 6K817 (2) REQ REAR FR 25A FR 13 W704693 (2) REQ FRONT FR 13 3K738 FR 13

6303 FR 5A

6A339 FR 6B

6766 FR 21

8501 FR 24

W701643 (2) REQ FR 44

W704688 (2) REQ FR 14B

W701706 (6) REQ FR 43

FR 49 6A359 FR 48 8W508 FR 48

9439 (2) REQ FR 26

6F092 FR 6B

6051 FR 14B

9C836 FR 23 8K543

W701605 (11) PLACES FR 18

6C086 FR 17 12A227 FR 17

6M274 FR 16 6B274 FR 16

6B288 FR 19 W500214 FR 19

3D639 FR 46 W707172 (2) REQ FR 46 3A733 FR 46

W500214 FR 19 6C315 FR 19 W704920 FR 17

6306 FR 16 W701524 (2) REQ FR 16

6B209 FR 17

SW164 ONLY

W705832 FR 45 10300 FR 45 W705831 FR 45 W701521 (2) REQ FR 45

NE01−I10872796−025

10239 FR 45 W701524 (3) REQ FR 45

W701542 (6) REQ FR 46

6700 FR 19 6316 CD132 FR 20 W701511 FR 20

W500319 (2) REQ FR 46 W701512 FR 20

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

W701522 (4) REQ FR 46

001018

−−−

52

52

52A .30

2001 SW164 NAAO

9E498 NAAO FR 35 W701625 (2) REQ FR 33A

12281 FR 22A

W701632 FR 32

W701632 FR 39 9E926 AUTO FR 39

9D460 FR 33A W701519 FR 39

W701520 (6) REQ FR 28 9E936 FR 39

9424 FR 28

9F715 FR 32

18801 FR 22 W701547 (3) REQ FR 22

W701539 (2) REQ FR 33

6518 (8) REQ FR 31

6110 (6) REQ FR 8

6375 MANUAL FR 31

6582 FR 21 W500302 (32) REQ FR 14E 6B280 (4) REQ FR 14E

6A258 (12) REQ FR 14E 6A266 FR 14E 12405 (6) REQ FR 15

6A268 FR 14E

6065 (16) REQ FR 14C

6529 (24) REQ FR 14E 6C501 (24) REQ FR 14A W701515 (4) REQ FR 14E 17A084 FR 34 W701732 (6) PLACES PER SIDE FR 43 9448 FR 43

6152 (6) REQ FR 8A 6151 (6) REQ FR 8A 6135 (6) REQ FR 8 6140 (12) REQ FR 8

6159 (12) REQ FR 8A

12029 FR 22

9J433 FR 43

W701592 (8) REQ FR 26

6150 (6) REQ FR 8A

14A206 FR 33

19A095 FR 22

W701627 FR 34

6200 (6) REQ FR 8

6B673 FR 12 6B752 FR 12 6211 (12) REQ FR 8C 8A505 FR 12

W701548 6A373 (2) REQ MANUAL FR 4A FR 31 W701548 6518 (2) REQ (48) REQ 3K305 F R 4 1 FR 41 FR 14A 6514 (24) REQ FR 14A 6513 (24) REQ W500233 FR 14A (3) REQ 6A517 FR 41 (24) REQ FR 14A 6049 6701 FR 14C FR 7 W701518 FR 14 7G371 AUTO FR 7A W701501 FR 14 6A339 6505 FR 6B 6507 (6) REQ (6) REQ FR 14A FR 14A

6A359 FR 48 8W508 FR 48

9439 (2) REQ FR 26 W701504 (2) REQ FR 12 W704694 (2) REQ REAR FR 13 W704693 (2) REQ FRONT FR 13 3K738 FR 13

6010 FR 4 6A341 FR 5A

6A505 FR 21

6A269 FR 14E

W701669 FR 25

W701515 (5) REQ FR 14 8548 FR 25

W701501 FR 14 6051 FR 14B

W701643 (2) REQ FR 44

17A084 FR 34

W701518 FR 14

6750 FR 38

W701822 FR 38

W701628 FR 34

6754 FR 38

6A642 HO ONLY FR 40

W701517 FR 4A

6890 6333 FR 4 (4) REQ 6714 FR 5A W701528 6M256 FR 5A FR 16B W701232 W500300 6K255 (2) REQ FR 16B (4) REQ FR 16B FR 4 6621 FR 4

6268 FR 16B

6268 FR 16 6L266 FR 16

6A338 (3) REQ FR 6B

6L266 FR 16B

6687 FR10 W701582 (4) REQ FR 10A

6B293 FR 21

W701632 FR 25

6303 FR 5A

W704688 (2) REQ FR 14B

W701706 (6) REQ FR 43

6K817 FR 25A

6766 FR 21

8501 FR 24 6A267 FR 14E

W701520 W701544 FR 48 (3) REQ FR 24

9278 FR 40 W701516 FR 4 W706860 (2) REQ FR 4 W701546 FR 4

6F092 FR 6B

6051 FR 14B

9C836 FR 23 8K543 FR 49

9J447 FR 26

6214 (12) REQ FR 8C W701517 FR 4A

9D477 FR 43

5G236 FR 43

9J559 FR 23 W701669 (3) REQ FR 23

9H486 (2) REQ FR 26

W701669 FR 32 9F670 FR 32 W701708 FR 32A 9J459 FR 32A

12280 FR 22A

9H589 FR 27

9S479 (6) REQ FR 28

W701542 FR10 6622 FR 11 W700005 (2) REQ FR 11 6710 FR 18

6750 AS NEEDED FR 18A

W701524 (2) REQ FR 16B 6M274 FR 16 6B274 FR 16

12A227 FR 17

6306 FR 16 W701524 (2) REQ FR 16

6675 FR 18

6B288 FR 19 W500214 FR 19

19D629 NAAO FR 42

W500214 FR 19 6C315 FR 19

W701521 (2) REQ FR 45

NE01−I10872796−025

3D639 FR 46 W707172 (2) REQ FR 46 3A733 FR 46

W701522 (4) REQ FR 46

W701626 (3) REQ W500319 FR 42 (2) REQ W701542 FR 46 (6) REQ FR 46

W705832 FR 45 10300 FR 45 W705831 FR 45

W701605 (11) PLACES W701606 FR 18 (4) PLACES FR 18

6C086 FR 17 6B209 FR 17

10239 FR 45 W701524 (3) REQ FR 45

6700 FR 19 6316 FR 20 W701511 FR 20 W701512 FR 20

8620 FR 47

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001018

−−−

52A

52

52B .30

W701632 (FR 39) 9E926 (FR 39)

3209 (FR 33A)

W701519 (FR 39)

12281 (FR 22A)

19A095 (FR 22)

6110 (6) REQ (FR 8)

6582 (FR 21)

6B280 (4) REQ (FR 14E)

6A258 (12) REQ (FR 14E)

6A268 (FR 14E)

W701539 (FR 44) 19A095 (FR 44) W701643 (FR 44)

6200 (6) REQ (FR 8C)

W500302 (32) REQ (FR 14E)

6529 (24) REQ (FR 14E) 6C501 (24) REQ (FR 14A) W701515 (4) REQ (FR 14)

6518 (48) REQ (FR 14A) 6514 (24) REQ (FR 14A) 6513 (24) REQ (FR 14A) 6A517 (24) REQ (FR 14A) 6049 (FR 14) W701518 (FR 14)

6065 (16) REQ (FR 14C)

17A084 (FR 34)

W701548 (2) REQ (FR 41)

6010 (FR 4) 6333 (4) REQ (FR 5A)

W701520

6A267 (FR 14E)

(FR 48) W701544 (3) REQ (FR 48)

W701632 (FR 25) W701669 (FR 25)

6A505 (FR 21)

W701517 (FR 4A) W701528 (FR 5A)

6A341 (FR 5A)

W701515 (5) REQ (FR 14) 8548 (FR 25)

W701501 (FR 14) 6051 (FR 14B)

17A084 (FR 34)

W701518 (FR 14)

6K255 (FR 16B)

6750 (FR 38) W701822 (FR 38)

W701628 (FR 34)

6754 (FR 38)

6M256 (FR 16B)

W500300 (4) REQ (FR 9) 6621 (FR 9)

6701 (FR 7)

6A269 (FR 14E)

6A642 (FR 40) 6714 (FR 40)

W701232 (2) REQ (FR 16B)

6268 (FR 16B)

6268 (FR 16) 6L266 (FR 16)

6303 (FR 5A)

6A339 (FR 6B)

6A338 (3) REQ (FR 6B)

6L266 (FR 16B)

6F092 (FR 6B)

6051 (FR 14B)

6766 (FR 21) 6B293 (FR 21) 8W508 (FR 48) 8501 (FR 24)

9278 (FR 40) W701516 (FR 4) W706860 (2) REQ (FR 4) W701546 (FR 4)

W701517 (FR 4A) W701548 (2) REQ (FR 4A)

W701501 (FR 14) 6505 6507 (6) REQ (6) REQ (FR 14A) (FR 14A)

W701732 (6) PLACES PER SIDE (FR 43) W701627 (FR 34)

8K543 (FR 49)

6A359 (FR 48)

6214 (12) REQ (FR 8C)

6A266 (FR 14E)

12405 (6) REQ (FR 15)

W701592 (8) REQ (FR 26A) 9J447 (FR 26A)

9439 (2) REQ (FR 26A) 6140 (12) REQ (FR 8) W701504 (2) REQ (FR 12) W704694 6K817 6B673 (2) REQ REAR (FR 25A) (FR 12) (FR 13) 6B752 W704693 (FR 12) (2) REQ FRONT 6211 (FR 13) (12) REQ 3K738 (FR 8C) (FR 13) 8A505 (FR 12)

6159 (12) REQ (FR 8A)

12029 (FR 22)

W701669 (3) REQ (FR 23)

9H486 (2) REQ (FR 28)

6152 (6) REQ (FR 8A) 6151 (6) REQ (FR 8A) 6135 (6) REQ (FR 8)

6150 (6) REQ (FR 8A)

14A206 (FR 33)

9J559 (FR 23)

9424 (FR 28)

W701547 (3) REQ (FR 22) W701539 (2) REQ (FR 33)

12A581 (FR 27A)

9S479 (6) REQ (FR 28)

9F670 (FR 32) 9F715 (FR 32)

W701669 (FR 32)

18801 (FR 22)

2001 MAZDA MPV W701520 (6) REQ (FR 28)

9E936 (FR 39)

W701632 (FR 32)

12280 (FR 22A)

9E498 (FR 35C)

W704688 (2) REQ (FR 14B)

6687 (FR 10) W701542 (4) REQ (FR 10)

6C086 (FR 17)

W701524 (2) REQ (FR 16B) 6M274 (FR 16) 6B274 (FR 16)

W701542 (FR 11) 6622 (FR 11) W700005 (2) REQ (FR 11)

12A227 (FR 17)

W500214 (FR 19)

6306 (FR 16)

6C315 (FR 19) 6B209 (FR 17)

W701524 (2) REQ (FR 16)

6710 (FR 18)

6750 AS NEEDED (FR 18A)

10239 (FR 45A) W701524 (3) REQ (FR 45A)

6675 (FR 18)

W701606 (4) PLACES (FR 18)

W701605 (11) PLACES (FR 18)

6B288 (FR 19) W500214 (FR 19)

NE01−I10872796−025

6700 (FR 19) 6316 (FR 20) W701511 (FR 20) W701512 (FR 20)

2001 2.5L−4V CD132/SW164/MPV

IL1S7E−030002−E0543D

001018

−−−

52B

52

LAST .30