duratech 2.5l engine v6

NE01I10872796025 DLITTLEJ FDUDEK3

001019 NPETTY HSCHUMAN DSCHILTG MRILEY2 DLIRETTE X CAD: Y

A1 ADDED NEW ENGINE CODE ON FR 3C NE01E11173291000 010130 SROBERT4 SROBERT4 RHAESE B1 ADDED VEHICLE DESIGNATIONS ON FRAME 3C 010402 NE01E11183277048 RWOLFFIS FDUDEK3 RHAESE

CAD: Y

NEAL PETTY (313)8450491 DAVE SCHILTGES (313)8458975

HOWARD SCHUMAN (313)5946662

il1s7e030002e0543d01.dg

IL1S7E030002E0543DDLITTLEJ FDUDEK3 001019

ENGINE ASSEMBLY PROCEDURE AND INSTRUCTION 2001 2.5L4V CD132/SW164/MPV CLEVELAND ENGINE PLANT #2

52

INDEX ITEMGENERAL SPECIFICATIONS: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 3B 3 3B 3C 3A 3B 3B 3A 3A 3A 3A 3 3C 3 3A

FRAME

INSTALLATION:A/C COMPRESSOR & CLUTCH ASY ACCESSORY DRIVE PULLEY AND WATER PUMP BELT TENSIONER ASY AIR BYPASS VALVE ASY ALTERNATOR ASY AND ALTERNATOR MOUNTING BRACKET ASY BULKHEAD HOUSING ASY FASTENERS BULKHEAD HOUSING ASY AND LOWER MAIN BEARINGS BULKHEAD HOUSING TO CYLINDER BLOCK CAMSHAFT & SPROCKET ASY, BEARING CAPS AND ROLLER FOLLOWERS CAMSHAFT COVER ASY & CAMSHAFT REAR SEAL RETAINER ASY CAMSHAFT PREASSEMBLY TIMING MARK ALIGNMENT CRANKCASE EMISSION HOSE CRANKSHAFT ASY AND UPPER MAIN BEARINGS CRANKSHAFT, CAMSHAFT SPROCKETS AND DRIVE CHAIN, PREASSEMBLY TIMING MARK ALIGNMENT (LH) CRANKSHAFT, CAMSHAFT SPROCKETS AND DRIVE CHAIN, TIMING MARK ALIGNMENT (LH & RH) CRANKSHAFT VIBRATION DAMPER ASY CRANKSHAFT ENDPLAY (LESS PISTONS) CRANKSHAFT FRONT SEAL ASY, CRANKSHAFT TIMING SENSOR AND CAMSHAFT TIMING SENSOR CRANKSHAFT FRONT SEAL SQUARENESS AND CONCENTRICITY (SERVICE/AUDIT) CRANKSHAFT REAR OIL SEAL ASY CRANKSHAFT REAR OIL SEAL ASY SQUARENESS & CONCENTRICITY (SERVICE/AUDIT) CRANKSHAFT SLEEVE (AUTO TRANS) CRANKSHAFT SPROCKET, DRIVE CHAIN, CHAIN GUIDE, TENSIONER ASY AND TENSIONER ARM (LH) CRANKSHAFT SPROCKET, DRIVE CHAIN, CHAIN GUIDE, TENSIONER ASY AND TENSIONER ARM (RH) CYLINDER BLOCK DOWELS, PLUGS AND OIL FILTER INSERT (SERVICE/AUDIT) CYLINDER HEAD ASY CYLINDER HEAD ASY VALVES, SPRINGS & LASH ADJUSTERS CYLINDER HEAD GASKETS AND DOWELS 42 48 32 45,45A 6C 6B 6,6A 14E,14G 21,21A 14F 25A 5A 16A 16C 20 6D 19 19A 7 7 7A 16 16B 4,4A 14C,14D 14A 14B

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IL1S7EINDEXE0543D

2

2AX

INDEX (Continued) ITEMINSTALLATION:CYLINDER HEAD PIPE PLUGS AND DOWELS DRIVE BELT (FEAD) FOR NAAO SW164 ELECTRIC IMRC ASY AND BRIDGE ELECTRIC IMRC ASY CABLE ROUTING EGR VACUUM REGULATOR ASY EGR VALVE ASY AND PLUG EMISSION VACUUM CONTROL CONNECTOR ASY NAAO & EAO ONLY MPV ONLY ENGINE ASY CD132 MAZDA MPV AUTO SW EAO AUTO TRANS SW EAO MAN TRANS SW EAO ENGINE EXPLODED VIEWS CD132/SW164 MAZDA MPV ENGINE CODE DECAL AND INK JET APPLICATION EXHAUST MANIFOLD & CONVERTER ASY (RH) AND EGR TUBE ASY FOR NAAO AND EAO FLEXPLATE ASY AND REAR COVER PLATE (AUTO TRANS) FLYWHEEL ASY AND REAR COVER PLATE (MANUAL TRANS) FRONT COVER ASY, TENSIONER AND IGNITION PULSE RING GROUND STRAP IGNITION COIL ASY, GROUND STRAP, RADIO CAPACITOR (NAAO & MPV) AND BRACKET (EAO) IGNITION WIRE ASY AND FIRING ORDER INLINE CONNECTOR BRACKET INTAKE MANIFOLD ASY (LOWER) AND EMISSION VACUUM CONTROL CONNECTOR ASY INTAKE MANIFOLD ASY (UPPER) INTAKE MANIFOLD OPENING COVER ASY LIFTING EYES LINKSHAFT BRACKET ASY AND CYLINDER BLOCK PLUGS OIL COOLER ASY, OIL FILTER ASY AND OIL PRESSURE SWITCH ASY OIL LEVEL INDICATOR TUBE ASY AND OIL LEVEL INDICATOR ASY OIL PAN ASY OIL PAN BAFFLE OIL PUMP ASY OIL PUMP SCREEN AND COVER ASY OIL SEPARATOR ASY, WATER INLET TUBE AND CUP PLUG PCV CONNECTOR & HOSE ASY TO UPPER INTAKE MANIFOLD ASY FITTING AND EMISSION VACUUM CONTROL CONNECTOR ASY ROUTING PISTON, PIN, RINGS AND CONNECTING ROD ASY PISTON & CONNECTING ROD ASY BEARINGS AND ROD CAP ASY POWER STEERING PUMP MOUNTING BRACKET ASY 14 47 23 30 32A 33A

FRAME

35C,35F 51E 51C,51D 51 51A 51B 52,52A 52B 50 43 31A 31 17,17A 44 22 22A,29 33 26 THRU 26C 28,28A 33B 34 41 40 38 18,18A 10,10A 9 11 12 36 8,8A,8B 8C,8D 13


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2A

2BX

INDEX ITEMINSTALLATION:

(Continued) FRAME46 5 15 39,39A 39B 25 24 49 27,27A 37B 37A 37

POWER STEERING PUMP & BRACE ASY AND PULLEY SELECTFIT MAIN BEARING GRADE CHART SPARK PLUG ASY THROTTLE BODY ASY THROTTLE POSITION SENSOR CONNECTION AND IPS CONNECTION WATER BYPASS HOSE ASY WATER PUMP ASY WATER PUMP DRIVE BELT (READ) WIRING HARNESS ASY WIRING HARNESS ASY TO IDLE SPEED VALVE, ECT SENSOR AND IMRC CONNECTOR WIRING HARNESS ASY TO IGNITION COIL WIRING HARNESS ASY TO MOUNTING STUDS, CID SENSOR, HDR SENSOR AND OIL PRESSURE SWITCH


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2B

3X

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

TORQUE VALUES FOR PARTS AS SUPPLIEDNOTE: PRIOR TO SERVICE REINSTALLATION OR REPLACEMENT OF FASTENERS, ALL THREADS AND CONTACT SURFACES MUST BE LUBRICATED WITH WSEM2C908A OR WSSM2C910A1 OIL. NOTE: REFER TO WERS TO VERIFY TORQUE VALUES. NOTE: PIPE PLUG TORQUES IN ALUMINUM, MUST BE CHECKED WHEN ENGINE IS WARM.

DIMENSIONINGALL DIMENSIONS ARE IN MILLIMETERS UNLESS OTHERWISE SPECIFIED.

SEALING AND LUBRICATING INDEXSEALER/ADHESIVEWSEM4G323A6 WSKM2G349A7 WSKM2G349A10

DESCRIPTIONSEALANT, SILICONE RBBER, OXIME CURED, VERY HIGH VISCOSITY ADHESIVE, ANAEROBIC, RETAINING ADHESIVE, ANAEROBIC, THREAD LOCKING

FRAMES6,6A,17,18, 20 & 21 12 12

LUBRICANTESEM99B176A ESEM99B144B WSEM99C45A2 LUBRICANT, SYNTHSTIC RUBBER SURFACTANT, COLORED LUBRIANT, RUBBER HOSE AND TUBING LUBRICANT, VACUUM TUBING AND HOSE 25 3,24 36

OILWSEM2C908A WSSM2C914A ESEM99C103B1 OIL ENGINE, API SG, SAE 50, ASSEMBLY FLUID OIL, ENGINE, ILSAC GF3, INITAIL FILL SAE 5W20 OIL ADDITIVE, FLOURESCENTNON TINTING, LEAK DETECTION 3A,6A,7,8,8C,14A, 14E,14G,19,20,40 3A & 3B 3B

CLEANERWSEM5B392A CLEAN, ENGINE DEGREASER 6A

FUELWSEM4C112A GASOLINE, UNLEADED, INITIAL FILL, REGULAR GRADE 3A

NOTE: ESEM99B144B 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.


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3AX

GENERAL SPECIFICATIONS (Continued)

OIL CLEANLINESSASSEMBLY OIL (WSEM2C908A) BEING APPLIED TO ENGINE COMPONENTS AND THE INITIAL OIL FILL (WSSM2C914A) AT THE DELIVERY POINT TO THE ENGINE MUST MEET THE FOLLOWING REQUIREMENTS FOR PARTICLE SIZE AND COUNT: PARTICLE SIZE (MICRONS) 030 3150 5170 >71 MAX LIMIT (PARTICLES PER MILLILITER) NO LIMIT 50 30 10

ENGAGEMENT SPECIFICATIONS FOR ALL VACUUM SYSTEM CONNECTIONSHOSE/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 TESTTHE PRODUCTION HOT TEST IS TO BE PERFORMED IN ACCORDANCE WITH SPECIFICATION ENGINE ASSEMBLY PRODUCTION HOT TESTING ESF53E6007AA. USE TESTING WSEM4C112A 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 ESF53E6007AA. USE WSEM4C112A FUEL.

NOTES BEFORE STARTING ENGINEBEFORE 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 EQUIPMENTFOR ENGINE ELECTRICAL EQUIPMENT INSTALLATION REFER TO THE MANUAL "ELECTRICAL EQUIPMENT INSTALLATION" FOR THE PARTICULAR MODEL APPLICATION.


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3BX


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

BALANCING INSTRUCTIONSREFER TO ESF53E6007AA FOR ENGINE MASS BALANCE REQUIREMENTS.

ENGINE LUBRICATION REQUIREMENTSADD THE FOLLOWING AMOUNT OF WSSM2C914A FOR INITIAL OIL FILL AS SHOWN IN CHART BELOW: OIL (SAE SW20)

NOTE: 18 22ml OF ESEM99C103B1 DYE MUST BE ADDED FOR IN PLANT OIL LEAK DETECTION. INITIAL OIL FILL: CUSTOMER OIL FILL: 6.0 quarts (FAO AND EAO) 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 MAX

OIL LEVEL

ENGINE PAINT INSTRUCTIONSALL ENGINE COMPONENTS REQUIRING PAINT WILL BE PREPAINTED AS COMPONENTS PRIOR TO SHIPPING TO THE ENGINE ASSEMBLY AREA. FOR SPECIFICATIONS ON COMPONENT PAINT REQUIREMENTS SEE THE RESPECITIVE DETAIL OR ASSEMBLY DRAWING.


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3B

3CX


B1

ENGINE APPLICATION CODESVEHICLE TRANSMISSIONMANUAL

CODES1A831AA

CD132 EAO MONDEO

SW164 AUSTRALIA COUGAR

AUTO MANUAL

1G402AB 1G403AB

SW164 NAAO H/O COUGAR SVT

MANUAL

1G433AA

AUTO

1G400AA 1G401AA

SW164 NAAO COUGARMANUAL

SW164 NAAO COUGARAUTO 1G404AA

W/17" WHEELS OPTIONA1

J16E MPV

AUTO

KG440AA

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

ITEM TO BE PLUGGED

PLUG INSTALLATION POINTFINAL DRESS FINAL DRESS ASY/FINAL DRESS FINAL DRESS FINAL DRESS AFTER HOT TEST FINAL DRESS FINAL DRESS FINAL DRESS FINAL DRESS AFTER HOT TEST

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 ASYLOWER (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)

NE01E11183277048VENGINE ILLUSTRATION

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IL1S7E030002E0543D

B1

3C

4X

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

6890 (11mm HEX) INSERT OIL FILTER MOUNTING BOLT (TORQUE 2740 Nm)

FOR CD132 NAAO SW164 ONLY

6010 BLOCK ASY CYLINDER

1 W706860PIN 8mm X 18.25 SOLID DOWEL CHAMFER HARDEND (2) REQ

B

A

W701516 (8mm HEX) 3/818 PLUG SOCKET HEX (TORQUE 20 Nm THEN ROTATE 180 )

W701546 CUP PLUG (19.35)

1FRONT OF ENGINE

(9.5 8.5)

(7.6 5.0)

1 (DOWEL)(BLOCK ASY CYLINDER)

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

(CUP PLUG)

030101NE01I10872796025VENGINE ILLUSTRATION

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IL1S7E030002E0543D

4

4A.5

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

W701517 (1/2 HEX) 1/214 PIPE PLUG (TORQUE 40 Nm THEN ROTATE 180 )

AFRONT OF ENGINE

1

1 W701202PIN 16.005 X 19 HOLLOW DPWEL (16 X 19) (2) REQ

6010 BLOCK ASY CYLINDER

W701517 (1/2 HEX) 1/214 PIPE PLUG (TORQUE 40 Nm THEN ROTATE 180 )

(9.5 8.5)

1 (DOWEL)

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


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5.5

SELECTFIT MAIN BEARING GRADE CHARTSELECTFIT MAIN BEARING PROCEDURE1. 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 SELECTFIT 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)

SELECTFIT CODE SHOWN OUT OF SEQUENCE FOR CHART CONGRUITY (CYLINDER BLOCK ASY)

BLOCK CODE98 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 72 71 70 69 68 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 99 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 00 01 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 02 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 03 04 05 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 06 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 07 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 08 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 09 10 11 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 12 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 13 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 14 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 15 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 16 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 17 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 3 18 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 3 3 19 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 20 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 21 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3


CRANKSHAFT CODE

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5AX

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

6333 BEARING CRANKSHAFT MAIN FRONT (4) REQ

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

(BLOCK ASY CYLINDER)

BACKGROUND DETAIL MAY NOT BE PICTORALLY ACCURATE FOR ALL APPLICATIONS

FRONT OF ENGINE


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5A

6.7

BULKHEAD HOUSING TO CYLINDER BLOCK SEALANTSEALANT PATH WSEM4G323A6 SEALER (1mm DIA) BEAD (3mm DIA) BEAD AT GROOVES

FRONT OF ENGINE

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


NOTE: VIEW SIMPLIFIED FOR INSTALLATION CLARITY.

(6)VIEW A

(6) SEE FRAMES 6A & 6B

ASSEMBLY PROCEDURE1. THE BLOCK/BULKHEAD MATING SURFACES MUST NOT HAVE ANY RESIDUES THAT REDUCE THE BONDING (OR ADHESION) OF THE WSEM4G323A6 SEALANT TO THE SURFACES. THE CONTAMINANTS THAT ARE LIKELY TO OCCUR ARE: MACHINING COOLANTS WASH OR SOAP RESIDUE OIL (BEARING PRELUBE, ETC.) WATER (WET) DUST, METAL CHIPS SEALANT RESIDUE (FROM PREVIOUS ASSEMBLY)

030101

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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6

6A.7

BULKHEAD HOUSING TO CYLINDER BLOCK (Continued)ASSEMBLY PROCEDURE (CONTINUED)1. A) 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 WSEM4G323A6 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. THE BULKHEAD SURFACE MUST BE CLEANED AFTER INSTALLATION OF CRANKSHAFT BEARINGS AND CRANKSHAFT TO REMOVE ANY RUNOFF OF BEARING PRELUBE OIL. ALL TRACES OF PREVIOUSLY APPLIED SEALANT MUST BE COMPLETELY REMOVED BY SCRAPING THE SURFACES (WITHOUT DAMAGING EITHER SURFACE).

D) 2. 3.

SELECT CORRECT BEARING GRADES FOR EACH OF THE FOUR MAINS USING THE PROCEDURE ON FRAME 5. VERIFY ALL SADDLES IN BLOCK, BULKHEAD AND BEARINGS ARE CLEAN AND FREE OF CHIPS, DIRT, PAINT AND FOREIGN MATERIAL. INSTALL UPPER MAIN BEARINGS IN CYLINDER BLOCK. VISUALLY CHECK SEATING AND SQUARENESS OF ALL BEARINGS AND INSURE ALL OILING HOLES ALIGN WITH CYLINDER BLOCK OIL FEED HOLES. INSTALL CRANKSHAFT IN CYLINDER BLOCK WITH CARE TO PREVENT DAMAGE TO BEARING FACES OR CORNERS. APPLY WSEM2C908A OIL TO CRANKSHAFT JOURNALS PRIOR TO INSTALLATION. PUSH CRANKSHAFT TO ITS MAXIMUM REARWARD POSITION. 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 WSEM2C908A OIL TO CRANKSHAFT THRUST SURFACE AND WASHER. INSTALL LOWER MAIN BEARINGS AND THRUST BEARING IN BULKHEAD.

4. 5.

6.

7. 8.

9.

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 SQUEEZEDOUT WSEM4G323A6 SEALER AT THE FRONT COVER SURFACE. 10. APPLY A BEAD OF WSEM4G323A6 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 35Nm). NOTE: DO NOT ROTATE CRANKSHAFT UNTIL ALL BULKHEAD MAIN BEARING BOLTS ARE TORQUED TO SPECIFICATION. INSTALL (5) PERIMETER BOLTS (DO NOT LUBRICATE FASTENERS). (TORQUE 35 Nm). 13. 14. 15. 16. APPLY A LOAD 534667 N FORWARD AND 89178 N REARWARD ON CRANKSHAFT TO ALIGN REAR FLANGE OF LOWER THRUST BEARING WITH THRUST WASHER. TORQUE BULKHEAD BOLTS TO SPECIFICATION. (SEE FRAME 6C WITH CRANKSHAFT HELD IN FORWARD POSITION). CHECK CRANKSHAFT END PLAY. TO BE WITHIN (0.1100.232mm). (SEE FRAME 6D) CHECK CRANKSHAFT TORQUE TO TURN. NOTE: MAIN BEARING TO CRANKSHAFT JOURNAL SURFACE ASSEMBLED CLEARANCE IS (0.0250.050mm) AT CROWN.


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6BX

BULKHEAD HOUSING ASY AND LOWER MAIN BEARINGS6F095 HOUSINGENGINE BULKHEAD NOTE: TORQUE ALL BULKHEAD HOUSING TO CYLINDER BLOCK BOLTS/STUDS WITHIN (4) MINUTES OF INSTALLATION

(DOWEL HOLLOW) (8) REQ

6A339 BEARINGCRANKSHAFT MAIN CENTER LOWER

6A338 BEARINGCRANKSHAFT 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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6B

6C.6

BULKHEAD HOUSING ASY FASTENERS19 17

= BOLT = STUD 5 1 3

21

7

13

9

11

15

FRONT OF ENGINE

14

10

12

16

6

2

4

8

(HOUSING ENGINE BULKHEAD)

20

18

22

HOLE NO181920 2122

FASTENER

DESCRIPTIONM8 X 1.25 X 79.3 BOLT & WASHER PILOT M8 X 1.25 X 95.3 BOLT & WASHER PILOT M10 X 1.5 X 106 BOLT & WASHER PILOT M6 X 1.0 X 19.5/ M8 X 1.25 X 95.1 STUD & WASHER PILOT M10 X 1.5 X 105.5/ M8 X 1.25 X 95.1 STUD & WASHER PILOT

W701554 (10mm HEX)

123417 F43E6345CB (13mm HEX)

131415 16

F43E6345DC (13mm HEX)

5678 YL8E6D311BA (13mm HEX)

9101112 YL8E6D311AA

FINAL TORQUE PROCEDURE PRODUCTION METHOD (MULTISPINDLE)1. 2. 3. 4. TORQUE FASTENERS TORQUE FASTENERS ROTATE FASTENERS TORQUE FASTENERS 1 9 1 17 THRU THRU THRU THRU 8 16 16 22 TO (25 Nm). TO (40 Nm). (90 ). TO (2030 Nm).

SINGLE WRENCH METHOD (SERVICEREPAIR)1. 2. 3. TORQUE FASTENERS TORQUE FASTENERS ROTATE FASTENERS TORQUE FASTENERS 1 9 1 17 THRU THRU THRU THRU 8 16 16 22 TO (2228 Nm). TO (3743 Nm). AN ADDITIONAL (85 95 ). TO (2030 Nm).


4.

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IL1S7E030002E0543D

6C

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 534668N (120150 LB) FORCE FORWARD AND THEN A 89178N (2040 LB) FORCE REARWARD.

1 FIM = FULL INDICATOR MOVEMENT


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6D

71

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

6701 REAR OIL SEAL (INSTALLATION TOOL)

SURFACE "R"

ASSEMBLY PROCEDURE1. 2. APPLY WSEM2C908A OIL TO OD OF CRANKSHAFT FLANGE AND TO ID OF CRANKSHAFT SEAL BORE (IN BULKHEAD/BLOCK ASSEMBLY). 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 BULKHEADTOBLOCK FASTENER RUNDOWN (FRAME 6C). NOTE: REAR FACE OF SEAL MUST BE FLUSH TO (2mm) BELOW SURFACE "R".

CRANKSHAFT REAR OIL SEAL ASY (SQUARENESS & CONCENTRICITYSERVICE 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). 2. (0.05 FIM) OF SEAL FACE REAR SURFACE IN RELATION TO REAR FACE OF CRANKSHAFT.

031001


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7

7A.6

CRANKSHAFT SLEEVE (AUTO TRANS) FOR SW164 AUTO ONLY

FRONT OF ENGINE

(CRANKSHAFT)

A

7G371 SLEEVETRANSMISSION CRANKSHAFT

(CRANKSHAFT)

7G371 SLEEVETRANSMISSION CRANKSHAFT

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


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7A

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 PISTONA

B

1

(IDENTIFICATION BUMP) 6135 PINPISTON

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 F350 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 WSEM2C908A 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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8

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 (0.100.25) LOWER (0.270.42) OIL RING SEGMENT END GAP (0.150.65)

6150 PISTON RINGUPPER 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: ORIENT GAP SUCH THAT CUT ENDS ARE POINTED TOWARD PISTON DOME. 6159 PISTON RING SEGMENT OIL CONTROL (2) REQ VIEW A

UPPER COMPRESSION RING GAP LOCATION (RETAINER PISTON PIN) (PINPISTON) OIL CONTROL SEGMENT RING GAP LOCATION

CENTER LINE OF PISTON PARALLEL TO WRIST PIN BORE (30 ) (30 ) 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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8A

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 (0.100.25) LOWER (0.270.42) OIL RING SEGMENT END GAP (0.150.65)

6150 PISTON RINGUPPER 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) REQVIEW A

UPPER COMPRESSION RING GAP LOCATION (RETAINER PISTON PIN) (PINPISTON) OIL CONTROL SEGMENT RING GAP LOCATION

CENTER LINE OF PISTON PARALLEL TO WRIST PIN BORE (30 ) (30 ) OIL CONTROL SEGMENT RING GAP LOCATION

8HEXPANDER RING AND LOWER COMPRESSION RING GAP LOCATION.

COLOR CODE: YELLOWVIEW

B


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8B

8C.75

PISTON & CONNECTING ROD ASY BEARINGS AND ROD CAP ASYNOTE: PRIOR TO PISTON/CONNECTING ROD ASY INSTALLATION, COAT ALL CYLINDER BORE SURFACES, CRANKSHAFT PINS & JOURNALS WITH WSEM2C908A OIL. NOTE: OPERATOR TO CHECK FOR RINGS PRESENT, GAP ALIGNMENT & RING MOVEMENT PRIOR TO STUFFING. 6211 BEARING CONNECTING ROD (6) REQ VIEW A FRONT OF ENGINE

(GUIDE TOOL)

6210 CAPCONNECTING ROD (6) REQ

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

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

PRODUCTION RUNDOWN METHODPRETORQUE 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 SERVICETORQUE BOTH FASTENERS (2025 Nm). THEN TORQUE BOTH FASTENERS (4045 Nm). THEN ROTATE (90 120 ) (BRGCONN ROD) (CAP)

1 4 2 5(2 MAX)

3 6

PARTING FACE 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)

(2 MAX)

(ROD) VIEW A

(BRGCONN ROD)


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8C

8D.35

PISTON & CONNECTING ROD ASY, BEARINGS AND ROD CAP ASY (Continued)DIMENSION "Z"TWO READINGS FRONT AND REAR D DIMENSION "Z" TOP OF BLOCK (DECK) (BLOCK ASY CYLINDER)

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

C OF PISTON L PARALLEL WITH C OF CRANKSHAFT L

ASSEMBLE WITH ARROW TOWARDS FRONT OF ENGINE VIEW C

(PISTON ASY)

GRADE7 8 9

CYLINDER BLOCK BORE DIAMETER81.640 81.650 81.651 81.660 81.661 81.670

PISTON DIAMETER UNCOATED81.610 81.620 81.618 81.632 81.630 81.640

PISTON DIAMETER COATED81.630 81.650 81.638 81.662 81.650 81.670

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 ASYCYLINDER) (PISTON & CONNECTING ROD ASY) (ROD ASYCONNECTING) IDENTIFICATION ON CAP AND ROD MUST REMAIN ALIGNED AND RETAINED AS A MATCHED SET

B

(CRANKSHAFT)

(BEARINGCONNECTING ROD) (CRANKSHAFT) (49.9550.05) (BLOCK ASYCYLINDER GAGE LOCATION) A VERTICAL DIAMETRICAL BEARING ASSEMBLED CLEARANCE (0.0280.066) (BEARINGCONNECTING ROD) C OF CRANKSHAFT L (CAP) ROD ASYCONNECTING TO CRANKSHAFT SIDE CLEARANCE (0.100.30) VIEW A

031102

SECTION D


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8D

9.5

OIL PUMP ASSEMBLY

6621 PUMP ASYOIL LESS SCREEN & COVER

2

4 FRONT OF ENGINE

1


3

W500300 (8mm HEX) M6 X 1.0 X 33.5 BOLT HEX FLANGE HD (TORQUE TO 812 Nm) (4) REQ

ASSEMBLY PROCEDURE1. 2. 3. ROTATE INNER ROTOR OF OIL PUMP ASY (6621) TO ALIGN WITH FLATS ON CRANKSHAFT POST. ALIGN OIL PUMP ASY WITH CRANKSHAFT AXIALLY AND CAREFULLY INSTALL ONTO CRANKSHAFT UNTIL SEATED AGAINST CYLINDER BLOCK ASY. INSTALL (4) M6 BOLTS AND TORQUE TO SPECIFICATION.


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9

10.7

OIL PAN BAFFLE

6687 BAFFLE

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

(BULKHEAD HOUSING STUD) (4) PLACES


FRONT OF ENGINE



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10

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



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10A

11.6

OIL PUMP SCREEN AND COVER ASYW701582 (13mm HEX) M8 X 1 NUT HEX FLANGE FREE RUNNER (TORQUE 5 Nm THEN ROTATE 45 )

6622 SCREEN & COVER ASYOIL PUMP

W700005 (8mm HEX) M6 X 1 X 25.25 SCREW HEX FLANGE PILOT (TORQUE 812 Nm) (2) REQ (BULKHEAD HOUSING STUD)A


(PUMP ASYOIL LESS SCREEN & COVER)

FRONT OF ENGINE

(SCREEN & COVER ASYOIL PUMP)

ASSEMBLY PROCEDURE1. INSERT SCREEN AND COVER ASSEMBLY (6622) TUBE END INTO OIL PUMP AND SUPPORT BRACKET ONTO BULKHEAD HOUSING STUD. INSTALL (2) M6 BOLTS AND (1) M6 NUT AS SHOWN AND TORQUE TO SPECIFICATION.VIEW A

2.

("O" RING PART OF 6622 ASY)


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IL1S7E030002E0543D

11

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 812 Nm) (2) REQ 6B673 SEPARATOR ASYOIL APPLY (2mm) BEAD OF WSKM2G349A7 SEALER

8A505 TUBEWATER INLET NOTE: INSTALL TO A HEIGHT OF (37.538.5)

A

6B752 GASKETOIL SEPARATOR (BLOCK ASY CYLINDER) W701923 35mm CUP PLUG NOTE: APPLY (2mm) BEAD OF WSKM2G349A10 SEALER TO CUP PLUG OR BORE

FRONT OF ENGINE

B

(BLOCK ASY CYLINDER) (38.5 37.5) (TUBEWATER INLET)

(CUP PLUG)

(11.0 9.0)


SECTION B

030801

VIEW A


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12

13.7

POWER STEERING PUMP MOUNTING BRACKET ASY

W704693 M8 X 1.25 X 99 BOLT HEX FLANGE HD PILOT (TORQUE 2030 Nm) (2) REQFRONT

W704694 M8 X 1.25 X 71 BOLT HEX FLANGE HD PILOT (TORQUE 2030 Nm) (2) REQREAR

3K738 BRACKET ASY POWER STEERING PUMP MOUNTING

FRONT OF ENGINE


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13

14X

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

W701515 (1/4 HEX) 1/418 PLUG SOCKET HEX (TORQUE 14 Nm THEN ROTATE 180 ) (2) REQ

A6049 HEAD ASY CYLINDER RH (29.5 29.0) (DOWEL) W701501 PIN 10 X 49.25 DOWEL (2) REQ FRONT OF ENGINE

W701518 (5/8 HEX) 111.5 PIPE PLUG (TORQUE 90 Nm THEN ROTATE 180 ) (2) REQ W701515 (1/4 HEX) 1/418 PLUG (TORQUE 14 Nm THEN ROTATE 180 ) (2) REQ

SECTION A

(HEAD ASY CYLINDER)

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) [1/418] 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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14

14AX

CYLINDER HEAD ASY VALVES, SPRINGS & LASH ADJUSTERS6518 KEY VALVE SPRING RETAINER (24) REQ MUST BE PROPERLY SEATED 6513 SPEC SPRING VALVE (12) REQ 6514 RETAINER VALVE SPRING (12) REQ

1 6C501

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

1 NOTE:LUBRICATE BORE WITH WSEM2C908A OIL PRIOR TO INSTALLATION (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 WSEM2C908A OIL TO ENTIRE I.D. OF VALVE GUIDE PRIOR TO VALVE INSTALLATION. VALVE MUST ROTATE FREELY.

VALVE STEM TO GUIDE CLEARANCE:INTAKE: (0.0200.069) EXHAUST: (0.0460.095)

6507 VALVE INTAKE (6) REQ

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

INSTALLED SPRING HEIGHT (SEE CHART)

SPRING SEAT

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

INTAKE AND EXHAUST ALL39.6940.29 39.4940.49

GAGE LINE RIGHT SIDE LEFT SIDE SHOWN TYPICAL

VALVES INSTALLED SPRING HEIGHTFOR 95% PRODUCTION FOR 100% PRODUCTION


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14A

14B.5

CYLINDER HEAD GASKETS AND DOWELS


(9.0 8.0) DOWEL SECTION C

6051 GASKET CYLINDER HEADA

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

C

B

D


FRONT OF ENGINE

FRONT OF ENGINE

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

VIEW A (GASKET RH)

VIEW B (GASKET LH) RIGHT SIDE LEFT SIDE SHOWN TYPICALVIEW D



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14B

14C.7

CYLINDER HEAD ASYRIGHT SIDE LEFT SIDE SHOWN TYPICAL 6065 (15mm HEX) M10 X 1.5 X 154.8 BOLT & WASHER ASY HEX FLANGE HD PILOT (8) REQ PER HEAD NOTE: REMOVE THRUST CAPS, SHIP ON PALLET AND NESTED OVER CAMSHAFTS NOTE: SEE FRAME 14D FOR ASSEMBLY PROCEDURE

(HEAD ASY CYLINDER)

(GASKET CYLINDER HEAD)

FRONT OF ENGINE



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14C

14D.7

CYLINDER HEAD ASY (Continued)

5

6

3

2

SINGLE WRENCH CYLINDER HEAD TORQUE SEQUENCEFRONT OF ENGINE

1

4

7

8

SINGLE WRENCH METHOD (SERVICE & REPAIR)1. 2. INSTALL HD ASYCYL/HD ASYCLY LH (6049/6050) OVER DOWELS. INSTALL M10 BOLTS (8) EACH SIDE AND PRETORQUE AS FOLLOWS: A. TORQUE ALL BOLTS TO (3238 Nm) IN NUMERICAL SEQUENCE SHOWN. B. ROTATE ALL BOLTS (85 95 ) IN NUMERICAL SEQUENCE SHOWN. 3. 4. BACK OUT ALL BOLTS (8) EACH SIDE A MINIMUM OF ONE FULL TURN (360 ). TIGHTEN ALL BOLTS (8) EACH SIDE TO SPECIFICATION AS FOLLOWS; A. TORQUE ALL BOLTS TO (3238 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

SHOWN TYPICAL

5

6

1

2

MULTISPINDLE CYLINDER HEAD TORQUE SEQUENCEFRONT OF ENGINE

3

4

7

8

PRODUCTION METHOD (MULTISPINDLE)1. 2. 3. 4. INSTALL HD ASYCYL/HD ASYCLY LH (6049/6050) OVER DOWELS. INSTALL M10 BOLTS (8) EACH SIDE PRETORQUE TO SEAT ALL BOLTS. SIMULTANEOUSLY (1822 Nm) RETORQUE BOLTS 14 (35 Nm THEN ROTATE 180 ) RETORQUE BOLTS 58 (35 Nm THEN ROTATE 180 )


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14D

14E.5

CAMSHAFT & SPROCKET ASY, BEARING CAPS AND ROLLER FOLLOWERSNOTE: SEE FRAME 14G FOR ASSEMBLY PROCEDURE & TORQUE SEQUENCE W705391 (8mm HEX) M6 X 1 X 43.25 BOLT HEX FLANGE HD PILOT (TORQUE 812 Nm) (16) REQ RIGHT SIDE LEFT SIDE 6A258 CAP CAMSHAFT BEARING (6) REQ SHOWN TYPICAL

1 6B280CAP ASY CAMSHAFT BEARING (2) REQ

2 6A267CAMSHAFT ASY INTAKE LH FRONT OF ENGINE NOTE: CAMSHAFT SPROCKETS DETAIL MAY NOT BE PICTORALLY ACCURATE.

6529 ARM ASY VALVE ROCKER (12) REQ

(HEAD ASY CYLINDER)

(ADJUSTER ASY VALVE LASH) (12) REQ

2 6A269CAMSHAFT 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 WSEM2C908A OIL PRIOR TO INSTALLATION.

QUALITY AUDIT ONLY(0.501.11) GAP MEASURED ON CAP BASE CIRCLE WITH ADJUSTER FULLY COLLAPSED.


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IL1S7E030002E0543D

14E

14F.5

CAMSHAFT PREASSEMBLY 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: YELLOW11 12 1L #1 #5 2 13 14 2L (THRUST CAP) 6L 3 3 4 4 6R (THRUST CAP) 2R 11 12 5R #5 #1 1R 10 5L 1 2 1

FOR H/O ONLY9

1BLUE STRIPE

1 BLUESTRIPE 15 16 3L 7L 5 5 6 6 7R 3R 14 13

1 ORANGESTRIPE 17 18 4L 8L 7 7 8 8 8R 4R 16 15

9L

10

1 BLUESTRIPE

9

FRONT OF ENGINE NOTE: REINSTALL CAMSHAFT BEARING CAPS AT THEIR CORRECT NUMBERED LOCATION.

CAMSHAFT BEARING CAP TORQUE SEQUENCE ASSEMBLY PROCEDURE1. 2. LOAD (12) LASH ADJUSTERS (6C501) IN CYLINDER HEADS.

APPLY WSEM2C908A OIL TO CAMSHAFT JOURNALS, LOBES, VALVE TIP PADS, ROLLER FOLLOWER SURFACES, ADJUSTER SOCKETS AND #1 CAM CAP THRUST GROOVE PRIOR TO INSTALLATION. LOAD (12) ROLLER FOLLOWER (6529), AND CAMSHAFT (6250) INTO CYLINDER HEAD THEN POSITION CAMSHAFT CAPS OVER CAMSHAFT, ENGAGING DOWELS IN CAM TOWERS. DEPRESS CAMSHAFT AND CAMSHAFT CLUSTER CAPS. (INSURE ALL COMPONENTS ARE PROPERLY ALIGNED) AND TORQUE ALL BOLTS SIMULTANEOUSLY TO (812 Nm). CAMSHAFT END PLAY (0.0250.165 FIM) CHECK AT TORQUE (4168 Nm).

3.

4. 5.

ASSEMBLY PROCEDURE (SINGLE WRENCH METHOD)1. 2. 3. INSTALL THRUST CAM CAP (6B280) LAST AND REMOVE IT FIRST. LOAD (12) LASH ADJUSTERS (6C501) IN CYLINDER HEADS. APPLY WSEM2C908A OIL (OR EQUIVALENT) TO CAMSHAFT JOURNALS, LOBES, VALVE TIP PADS, ROLLER FOLLOWER SURFACES, ADJUSTER SOCKETS AND #1 CAM CAP THRUST GROOVE PRIOR TO INSTALLATION. LOAD (12) ROLLER FOLLOWER (6529), AND CAMSHAFTS (6A266 R.H. INT. 6A267 LH INT, 6A269 RH EXH & 6A269LH EXH) INTO CYLINDER HEADS WITH TIMING MARKS AS SHOWN FRAME 14F. POSITION CAMSHAFT CAPS OVER CAMSHAFTS, ENGAGING DOWELS IN CAM TOWERS. SNUG DOWN ALL CAPS BOLTS DIAGONALLY FROM CENTER OUT. TORQUE ALL BOLTS (812 Nm) IN SEQUENCE SHOWN. CAMSHAFT END PLAY (0.0250.165 FIM) CHECK AT TORQUE (4168 Nm). NOTE: CAMSHAFT END PLAY (0.0250.165 Nm) FORCE OF 133222 N (3050 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.

4.

5.

6.

030901


2001 2.5L4V CD132/SW164/MPV

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IL1S7E030002E0543D

14G

15.35

SPARK PLUG ASYRIGHT SIDE LEFT SIDE SHOWN TYPICAL NOTE: CAMSHAFT SPROCKETS DETAIL MAY NOT BE PICTORALLY ACCURATE.

12405 SPARK PLUG ASY (TORQUE 920 Nm) (6) REQ

FOR CD132,SW164 & MPVCOLOR CODE: BLACK (AWSF32F)

FOR HOCOLOR CODE: PURPLE (AWSF22F)

(HEAD ASY CYLINDER)

FRONT OF ENGINE

PRODUCTION METHOD (MULTISPINDLE)1. PRETORQUE TO SEAT PLUGS 2. RETORQUE PLUGS TO SPECIFICATION (920 Nm)

SINGLE WRENCH METHOD (SERVICE AND REPAIR)1. INSTALL PLUGS AND SEAT 2. TIGHTEN PLUGS TO SPECIFICATION (920 Nm)


2001 2.5L4V CD132/SW164/MPV

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52

IL1S7E030002E0543D

15

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

2

6L266 TENSIONER TIMING CHAIN

2

(CRANKSHAFT) 6306 GEAR CRANKSHAFT

FRONT OF ENGINE

2 W701524 (10mm HEX)M8 X 1.25 X 49.3 BOLT & WSHR HEX FLANGE HD PILOT (TORQUE 2030 Nm) (4) REQ COLOR CODE: GOLD


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


2001 2.5L4V CD132/SW164/MPV

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IL1S7E030002E0543D

16

16A.5

CRANKSHAFT, CAMSHAFT SPROCKETS AND DRIVE CHAIN, PREASSEMBLY 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



2001 2.5L4V CD132/SW164/MPV

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IL1S7E030002E0543D

16A

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 2030 Nm) (2) REQ COLOR CODE: BLACK 2

1 6M256GUIDE ASY TIMING CHAIN (RH)

1 6K2552 TENSIONER ARM ASY (RH)

(DOWEL)

(CRANKSHAFT) 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 2030 Nm) (2) REQ COLOR CODE: GOLD

2

26268 CHAIN TIMING NOTE: ALIGN TIMING LINKS WITH TIMING MARKS ON SPROCKETS



2001 2.5L4V CD132/SW164/MPV

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IL1S7E030002E0543D

16B

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



2001 2.5L4V CD132/SW164/MPV

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IL1S7E030002E0543D

16C

17.35

FRONT COVER ASY, TENSIONER AND IGNITION PULSE RING(HEAD ASY CYLINDER) NOTE: TORQUE FASTENERS WITHIN (6) MINUTES OF APPLYING WSEM4G323A6 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: BLUE PAINT STRIPE

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

W704920 M8 X 60 BOLT & WSHR HEX FLANGE HD PILOT 6C086 COVER ASY ENGINE FRONT 6B209 TENSIONER ASY ENGINE DRIVE BELT


C

WSEM4G323A6 SEALER

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

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

(HOUSING ENGINE BULKHEAD) VIEW B WSEM4G323A6 SEALER

TYPICALAPPLY (6mm) DIAMETER DOT (APPROX) OF WSEM4G323A6 SEALER ON CYLINDER BLOCK & BULKHEAD HOUSING INTERSECTION. (2) PLACES B (BLOCK ASY CYLINDER) VIEW A FRONT OF ENGINE VIEW C NOTE: CAMSHAFT SPROCKETS DETAIL MAY NOT BE PICTORALLY ACCURATE.

TYPICAL

031403 031004NE01I10872796025VENGINE ILLUSTRATION

APPLY (6mm) DIAMETER DOT (APPROX) OF WSEM4G323A6 SEALER ON CYLINDER HEAD & CYLINDER BLOCK INTERSECTION. (4) PLACES A

2001 2.5L4V CD132/SW164/MPV

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IL1S7E030002E0543D

17

17A.45

FRONT COVER ASY FASTENERS= STUD = BOLT

14 6C086 COVER ASY ENGINE FRONT

15

10 11 4 3 13 16

9 12

7

8

1 2 6 MPV CDW/SW SHOWN TYPICAL 5

VIEW FRONT OF COVER HOLE NO. FASTENER DESCRIPTIONM8 X 1.25 X 40 M6 X 1 X 20 STUD & WASHER ASY HD SHLDR PILOT

34810 11141516

W706961 (13mm HEX)

256 791213

W701525 (10mm HEX)

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

1 W701712 (13mm HEX)

M8 X 47.5 M6 X 20 STUD & WSHRHEX FLNG HD PILOT

NOTE: TORQUE ALL FASTENERS (2030 Nm) IN SEQUENCE: 116


2001 2.5L4V CD132/SW164/MPV

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52

IL1S7E030002E0543D

17A

18.4

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

(HOUSING ENGINE BULKHEAD) 5 7 6 4 3 2 1

(COVER ASY ENGINE FRONT)

FRONT OF ENGINE

1 GASKET OIL PAN

8 9 15 1 DRAIN PLUG (TORQUE 2230 Nm) 10 11 12 = BOLT = STUD 13 A 14 1 W701605 M8 X 1.25 X 34.3 BOLT & WASHER HEX FLANGE HD PILOT (TORQUE 2030 Nm) (11) PLACES 6675 PAN ASY OIL

1 W701606 M8 X 1.25 X 33 + M6 X 1 X 22.5 STUD & WASHER HEX CONL SHLDR PILOT (TORQUE 2030 Nm) (4) PLACES

NOTE: ALIGN TRANSMISSION MOUNTING FACE OF OIL PAN WITH REAR FACE OF CYLINDER BLOCK. IT SHOULD HAVE MAXIMUM MISMATCH OF (0.25mm)UNDERFLUSH. IF STEP IS GREATER THAN ABOVE SPECIFICATION SHIMMING WILL BE REQUIRED. (SEE FRAME 18A)

2

WSEM4G323A6 SEALER

2

NOTE: APPLY (10mm) DIAMETER DOT (APPROX) OF WSEM4G323A6 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.


2001 2.5L4V CD132/SW164/MPV

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IL1S7E030002E0543D

18

18A.5

OIL PAN ASY (Continued) FOR CD132/SW164 (MANUAL TRANS) & MPVASSEMBLY PROCEDURE1. 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 115 SIMULTANEOUSLY (TORQUE 2030 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 AUDIT1. 2. INSTALL OIL PAN TO TRANSMISSION RETAINING FASTENERS FINGER TIGHT. THIS WILL ALIGN TWO FACES PRIOR TO TORQUING OIL PAN. TIGHTEN OIL PAN FASTENERS TO SPECIFICATION, THEN TIGHTEN TRANSMISSION TO OIL PAN FASTENERS.

FRONT OF ENGINE

A

6C629 SPACE ENGINE OIL PAN

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

FOR AUTO & MANUAL TRANS

FOR AUTO TRANS ONLYVIEW A


2001 2.5L4V CD132/SW164/MPV

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52

IL1S7E030002E0543D

18A

191

CRANKSHAFT FRONT SEAL ASY, CRANKSHAFT TIMING SENSOR AND CAMSHAFT TIMING SENSORMPV CDW/SW SHOWN TYPICAL

6B288 SENSOR ASY CANSHAFT TIMING

W500214 (8mm HEX) M6 X 1 X 23.25 SCREW HEX FLANGE HD PILOT (TORQUE 812 Nm) (1) REQ EACH SENSOR 6C315 SENSOR ASY CRANKSHAFT TIMING (INSTALLATION TOOL)

FRONT OF ENGINE (CRANKSHAFT) SURFACE "S" (COVER ASY ENGINE FRONT) 6700 SEAL ASYCRANKSHAFT FRONT NOTE: LUBRICATE SEAL BORE IN COVER BEFORE INSTALLING

ASSEMBLY PROCEDURE1. CHECK RELATIONSHIP OF SEAL BORE TO CENTERLINE OF CRANKSHAFT (SEE SECTION A ON FRAME 19A FOR SPECIFICATION). 2. APPLY WSEM2C908A 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.


2001 2.5L4V CD132/SW164/MPV

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52

IL1S7E030002E0543D

19

19A.55

CRANKSHAFT FRONT SEAL SQUARENESS AND CONCENTRICITY (SERVICE/AUDIT)

C OF CRANKSHAFT L (CRANKSHAFT)

(0.50 FIM)

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

CHECKING CONCENTRICITYDO 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 SQUARENESS030203NE01I10872796025VENGINE ILLUSTRATION

2001 2.5L4V CD132/SW164/MPV

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52

IL1S7E030002E0543D

19A

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(COVER ASY ENGINE FRONT) (CRANKSHAFT)

W701512 M12 X 1.5 X 52.5 BOLT HEX FLANGE HD PILOT 1. PRETORQUE TO (120 Nm) 2. BACKOUT A MINIMUM OF ONE FULL TURN (360 ) 3. TORQUE (4753 Nm) 4. ROTATE (85 95 )

W701511 FLAT WASHER

ASSEMBLY PROCEDURE1. 2. 3. 4. SEAL SURFACE MUST BE FREE OF DIRT AND OIL. APPLY WSEM4G323A6 SEALER TO CRANKSHAFT DAMPER. (SEE VIEW B). INSTALL CRANKSHAFT DAMPER ASY (6316) AS SHOWN TORQUE M12 BOLT TO SPECIFICATION. (DAMPER ASY CRANKSHAFT VIBRATION)

(DAMPER ASY CRANKSHAFT VIBRATION)

B

NOTE: APPLY WSEM4G323A6 SEALER TO KEYWAY SLOT PRIOR TO DAMPER AND BOLT INSTALLATION. SEAL SURFACE MUST BE FREE OF DIRT AND OIL. VIEW

(CRANKSHAFT) SECTION A


B

2001 2.5L4V CD132/SW164/MPV

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52

IL1S7E030002E0543D

20

21.6

CAMSHAFT COVER ASY & CAMSHAFT REAR SEAL RETAINER ASYNOTE: SEE FRAME 21A FOR TORQUE SEQUENCE. LEFT SIDE RIGHT SIDE SHOWN TYPICAL 6A505 COVER ASY VALVE ROCKER ARM LH 6582 COVER ASY VALVE ROCKER ARM NOTE: H/O BLACK COVERS VIEW A

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

NOTE: PARTS MARKED 2 ARE PART OF CAMSHAFT COVER ASY

2 6766CAP ASY OIL FILL (PART OF 6A505 ASY ONLY)

W701242 M6 X 1 X 43.25 BOLT & WSHR HEX FLANGE HD PILOT (TORQUE 812 Nm) (2) REQ

2 M6 X 1 X 34 BOLTHEX FLANGE PILOT (TORQUE 812 Nm) (6) REQ (LH) (3) REQ (RH)

1

2 M6 X 1 X 34/M5 X 0.8 X 21 STUD HEX FLANGE PILOT (TORQUE 812 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.

1

A


1

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


1 APPLY (8mm) DIAMETER DROP OF WSEM4G323A6 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 WSEM4G323A6 SEALER. WHEN (6) MINUTE CRITERIA CANNOT BE MET: PRETORQUE ALL FASTENERS TO (3 Nm).

2001 2.5L4V CD132/SW164/MPV

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52

IL1S7E030002E0543D

21

21A.5

CAMSHAFT COVER ASY (Continued)

= STUD = BOLT

6

8 4

3

5

2

10

2

1 10 7

11

1 8 3 9 9

6 6582 CAMSHAFT COVER ASY (RH)

4

5 7 6A505 CAMSHAFT COVER ASY (LH)

FRONT OF ENGINE

CAMSHAFT COVER TORQUE SEQUENCE


2001 2.5L4V CD132/SW164/MPV

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52

IL1S7E030002E0543D

21A

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 57 Nm) (3) REQ 18B960 BRACKET & CAPACITOR ASY RADIO IGNITION INTERFERENCE

FOR EAO CD132/SW16419A095 GROUND STRAP NOTE: SEE FRAME 44 FOR INSTALLATION OF OTHER END 12029 COIL ASYIGNITION FRONT OF ENGINE

ORIENT CAPACITOR AS SHOWN

(COVER ASYVALVE ROCKER ASY)

VIEW A

A

W706995 M5 X 0.8 X 29 BOLT HEX FLANGE HD (TORQUE 57 Nm) (3) REQ 18B960 BRACKET & CAPACITOR ASY RADIO IGNITION INTERFERENCE 19A095 GROUND STRAP NOTE: SEE FRAME 44 FOR INSTALLATION OF OTHER END

FOR NAAO SW164 AND MPV

12029 COIL ASYIGNITION FRONT OF ENGINE

(COVER ASYVALVE ROCKER ASY)


2001 2.5L4V CD132/SW164/MPV

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52

IL1S7E030002E0543D

22

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 ASYVALVE ROCKER ARM RH)

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



2001 2.5L4V CD132/SW164/MPV

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52

IL1S7E030002E0543D

22A

23.57

ELECTRIC IMRC ASY & BRIDGE

W701669 M6 X 1 X 33.25 BOLT & WSHR HEX FLNG HD PILOT (TORQUE 812 Nm)

9J559 CONTROL ASYENGINE AIR SHUT OFF

NOTE: SEE FRAME 30 FOR CABLE INSTALLATION

(COVER ASYVALVE ROCKER ARM LH)

9C836 BRACKET ASY THROTTLE CONTROL LINKAGE LH

FOR CD/SW ONLY

FRONT OF ENGINE


2001 2.5L4V CD132/SW164/MPV

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52

IL1S7E030002E0543D

23

24.5

WATER PUMP ASY

FRONT OF ENGINE

(TUBEWATER INLET) (HEAD ASY CYLINDER LH)

2

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 8501PUMP ASYWATER

ASSEMBLY PROCEDURE1 1. INSTALL WATER PUMP ASY (8501) AND POSITION TO REAR FACEOF CYLINDER HEAD ASY (LH) 2. ALIGN HOLES. INSERT M6 BOLTS AND TORQUE TO SPECIFICATION. 3. CLAMP HOSE TO WATER INLET TUBE.

2 ENGAGEMENT SPECIFICATIONS FORCLAMP 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.

VIEW A

1 NOTE:LUBRICATE WATER PUMP ASY HOSE OR WATER INLET TUBE WITH ESEM99B144B SURFACTANT PRIOR TO INSTALLATION.


2001 2.5L4V CD132/SW164/MPV

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IL1S7E030002E0543D

24

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 812 Nm)

110884 SENDER ASY COOLANT TEMPERATURE

8548 HOSEWATER BYPASS

(HEAD ASY CYLINDER LH)


"O" RING (2) REQ (PART OF 8548 ASY) APPLY ESEM99B176A 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 812 Nm)

1 NOTE:

FOR MPV ONLY(HEAD ASYCYLINDER RH)

SEE FRAME 30 FOR INSTALLATION OF IMRC CABLE TO THIS STUD

FRONT OF ENGINE

FOR CD132 ONLY

18548 HOSEWATER BYPASS 10884 SENDER ASY COOLANT TEMPERATURE

(HEAD ASY CYLINDER LH)

"O" RING (2) REQ (PART OF 8548 ASY) APPLY ESEM99B176A 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 812 Nm)

W701669 M6 X 1 X 33.25 BOLT & WASHER HEX FLANGE PILOT (TORQUE 812 Nm)


FOR SW164 ONLY 2001 2.5L4V CD132/SW164/MPV 001019 52

IL1S7E030002E0543D

25

25A.60

CRANKCASE EMISSION HOSE

FRONT OF ENGINE

6K817 HOSECRANKCASE EMISSION VALVE TO INTAKE MANIFOLD

(SEPARATOR ASYOIL)



2001 2.5L4V CD132/SW164/MPV

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52

IL1S7E030002E0543D

25A

26.6

INTAKE MANIFOLD ASY (LOWER) AND EMISSION VACUUM CONTROL CONNECTOR FOR NAAO SW164W701592 M6 X 1 X 66.25 BOLT & WASHER HEX FLANGE HD (TORQUE 812 Nm) (8) REQ

NOTE: SEE FRAME 26C FOR TORQUE SEQUENCE

FRONT OF ENGINE 9J447 MANIFOLD ASY INTAKE LOWER

9J447 MANIFOLD ASY INTAKE LOWER

FOR NAAO H/O ONLY

B

FOR ALL NAAO EXCEPT H/O

VIEW B

A9439 GASKET INTAKE MANIFOLD TO CYLINDER HEAD (2) REQ

(HEAD ASY CYLINDER)

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

1 LOCATING PIN(2) PLACES PER GASKET SECTION A (TYPICAL)

(GASKETINTAKE MANIFOLD TO CYLINDER HEAD)

030109


2001 2.5L4V CD132/SW164/MPV

001019

52

IL1S7E030002E0543D

26

26A.5

INTAKE MANIFOLD ASY (LOWER) AND EMISSION VACUUM CONTROL CONNECTOR FOR MPV AND EAO SW164W701592 M6 X 1 X 66.25 BOLT & WASHER HEX FLANGE HD (TORQUE 812 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


FOR CD132/SW164 AND MPV

2


A

FOR EAO SW164 H/O ONLYNOTE: GREEN INJECTORS FRONT OF ENGINE


A9439 GASKETINTAKE MANIFOLD TO CYLINDER HEAD (2) REQ


VIEW A

(HEAD ASY CYLINDER)



030103


2001 2.5L4V CD132/SW164/MPV

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52

IL1S7E030002E0543D

26A

26B.5

INTAKE MANIFOLD ASY (LOWER) FOR CD132 ONLY


W701592 M6 X 1 X 66.25 BOLT & WASHER HEX FLANGE HD (TORQUE 812 Nm) (8) REQ

FRONT OF ENGINE 9J447 MANIFOLD ASY INTAKE LOWER

9439 GASKETINTAKE MANIFOLD TO CYLINDER HEAD (2) REQ

A(HEAD ASY CYLINDER)



030103


2001 2.5L4V CD132/SW164/MPV

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52

IL1S7E030002E0543D

26B

26C.5

INTAKE MANIFOLD ASY (LOWER) (Continued)

7

8

3

4

1

2

FRONT OF ENGINE

5

6

(MANIFOLD ASY INTAKE LOWER)

MANUAL TORQUE SEQUENCE


NAAO EAO/MPV

SHOWN TYPICAL

2001 2.5L4V CD132/SW164/MPV

001019

52

IL1S7E030002E0543D

26C

27.5

030403ALL CONNECTORS MARKED ARE B & A INSTALLED 12A581 WIRING ASY ENGINE CONTROL SENSOR FRONT OF ENGINE

WIRING HARNESS ASY FOR SW164 AND CD132

NE01I10872796025 2001 2.5L4V CD132/SW164/MPV 001019 52

11

VENGINE ILLUSTRATION

12

VIEW A

FOR EAO SW AND CD12

IL1S7E030002E0543D 27 27AX

8

11

FOR NAAO ONLY

5

1

6 4

7

10 2

FOR NAAO SW ONLY13 7 8 9 10 11 12 6 TO BODY ASY AIR INTAKE CHARGE THROTTLE (SEE FRAME 37B) 13 1 2 3 4 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 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)

3

5

030403ALL CONNECTORS MARKED ARE B & A INSTALLED 12A581 WIRING ASY ENGINE CONTROL SENSOR FRONT OF ENGINE

WIRING HARNESS ASY FOR MPV ONLY

NE01I10872796025 2001 2.5L4V CD132/SW164/MPV 001019 52

VENGINE ILLUSTRATION

11

IL1S7E030002E0543D 27A 28X

11

8

10 9

5

1

4

6

7

2

1 2 3 4

3

5 6

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

7 8 9 11 12

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

INTAKE MANIFOLD ASY (UPPER)W701520 (10mm HEX) M6 X 1 X 49.5 BOLT HEX FLANGE HD PILOT (TORQUE 812 Nm) (6) REQ 9S479 ISOLATOR INTAKE MANIFOLD (6) REQ

9424 MANIFOLD ASY INTAKE

BACKGROUND DETAIL MAY NOT BE PICTORALLY ACCURATE FOR ALL APPLICATIONS NOTE: SEE FRAME 28A TORQUE SEQUENCE NOTE: INTAKE MANIFOLD IS BLACK FOR H/O APPLICATIONS

9H486 GASKET INTAKE MANIFOLD UPPER

1 1 1AFRONT OF ENGINE

1

(MANIFOLD ASY INTAKE LOWER)

1 LOCATING PIN(2) PLACES PER GASKET

SECTION A (TYPICAL)


(GASKET INTAKE MANIFOLD UPPER)

2001 2.5L4V CD132/SW164/MPV

001019

52

IL1S7E030002E0543D

28

28A.5

INTAKE MANIFOLD ASY (UPPER) (Continued)

(MANIFOLD ASY INTAKE)

5

1

3

6

2

4

FRONT OF ENGINE

MANUAL TORQUE SEQUENCE


2001 2.5L4V CD132/SW164/MPV

001019

52

IL1S7E030002E0543D

28A

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: 142536BACKGROUND DETAIL MAY NOT BE PICTORALLY ACCURATE FOR ALL APPLICATIONS

1

NOTE: INSTALLED AFTER ENGINE MOUNT BRACKET AT B & A

3

2

1

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

2

3

5

6

4

VIEW A


2001 2.5L4V CD132/SW164/MPV

001019

52

IL1S7E030002E0543D

29

30.4

ELECTRIC IMRC ASY CABLE ROUTINGBACKGROUND 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 812 Nm) (2) REQ

1 1 TO HOSE WATERBYPASS 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 2001 2.5L4V CD132/SW164/MPV 001019 52

IL1S7E030002E0543D

30

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 7387 Nm) (8) REQ

(DOWEL)

STAKE LOCATION (PLATE ENGINE REAR COVER)



2001 2.5L4V CD132/SW164/MPV

001019

52

IL1S7E030002E0543D

31

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 ONLYW701559 (17mm HEX) M10 X 1 X 20 BOLT HEX LOCK HD (TORQUE 7387 Nm) (8) REQ

(DOWEL)

STAKE LOCATION (PLATE ENGINE REAR COVER)



2001 2.5L4V CD132/SW164/MPV

001019

52

IL1S7E030002E0543D

31A

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 812 Nm) W701632 (10mm HEX) M6 X 1 X 32.5 + M5 X 0.8 X 17.5 STUD & WSHR HEX FLANGE HD PILOT (TORQUE 812 Nm)

9F670 GASKET AIR BYPASS VALVE



2001 2.5L4V CD132/SW164/MPV

001019

52

IL1S7E030002E0543D

32

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 57 Nm) WITH INSERTS (2) REQ

9J459 CONTROL ASY EGR VACUUM REGULATOR



2001 2.5L4V CD132/SW164/MPV

001019

52

IL1S7E030002E0543D

32A

33.65

INLINE CONNECTOR BRACKET

W701539 (8mm HEX) M5 X 0.8 NUT (TORQUE 57 Nm) (2) REQ

14A206 BRACKET WIRING CONNECTOR

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

FRONT OF ENGINE



2001 2.5L4V CD132/SW164/MPV

001019

52

IL1S7E030002E0543D

33

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 2030 Nm) (2) REQ


48ZE3209 3/4 PLUG

FOR MPV ONLY

FRONT OF ENGINE



2001 2.5L4V CD132/SW164/MPV

001019

52

IL1S7E030002E0543D

33A

33BX

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 2030 Nm (2) REQ



2001 2.5L4V CD132/SW164/MPV

001019

52

IL1S7E030002E0543D

33B

34X

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 100125 Nm) 17A084 EYE ENGINE LIFTING LH

A

(HEAD ASY CYLINDER LH) (EYE ENGINE LIFTING)

17A084 EYE ENGINE LIFTING RH

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

VIEW A

FRONT OF ENGINE

(HEAD ASY CYLINDER) W701627 (18mm HEX) M12 X 1.75 X 39.3 BOLT HEX FLANGE HD PILOT (TORQUE 100125 Nm)


2001 2.5L4V CD132/SW164/MPV

001019

52

IL1S7E030002E0543D

34

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 13 4

1 NOTE:

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

(VALVE ASY EXHAUST RECIRULATING) (MANIFOLD ASY INTAKE) 2 1 FRONT OF ENGINE

3

(CONTROL ASY EGR VACUUM REGULATOR)

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


2001 2.5L4V CD132/SW164/MPV

001019

52

IL1S7E030002E0543D

35

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 22

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


2001 2.5L4V CD132/SW164/MPV

001019

52

IL1S7E030002E0543D

35A

35B.5

EMISSION VACUUM CONTROL SEAL FOR CD132 ONLY

9H490 SEAL VACUUM OUTLET MANIFOLD

(MANIFOLD ASY INTAKE) FRONT OF ENGINE


2001 2.5L4V CD132/SW164/MPV

001019

52

IL1S7E030002E0543D

35B

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

3

FRONT OF ENGINE

2(MANIFOLD ASY INTAKE) 1

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


2001 2.5L4V CD132/SW164/MPV

001019

52

IL1S7E030002E0543D

35C

35D.5

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

1 2 3 4

TO MANIFOLD ASY INTAKE TO VALVE EXHAUST RECIRCULATING CONTROL ASY EGR VACUUM REGULATION 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


2001 2.5L4V CD132/SW164/MPV

001019

52

IL1S7E030002E0543D

35D

35E.5

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

1 2

TO MANIFOLD ASY INTAKE TO FUEL PRESSURE REGULATOR

1

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

2

FRONT OF ENGINE


2001 2.5L4V CD132/SW164/MPV

001019

52

IL1S7E030002E0543D

35E

35F.5

EMISSION VACUUM CONTROL CONNECTOR ASY (Continued) FOR MPV ONLY

1 2 3 4

TO MANIFOLD ASY INTAKE TO SPEED CONTROL TO FUEL PRESSURE REGULATOR 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


2001 2.5L4V CD132/SW164/MPV

001019

52

IL1S7E030002E0543D

35F

36.5

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


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

NOTE: WSEM99C45A2 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 030803NE01I10872796025VENGINE ILLUSTRATION

2001 2.5L4V CD132/SW164/MPV

001019

52

IL1S7E030002E0543D

36

37.7

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

(FRONT COVER STUD) (2) PLACES

BACKGROUND DETAIL MAY NOT BE PICTORALLY ACCURATE FOR ALL APPLICATIONS SHOWN OUT OF SEQUENCE FOR CHART CONGRUITY

ALL CONNECTORS MARKED ARE B & A INSTALLED

TO SWITCH ASY OIL PRESSURE (SEE VIEW A)

A

TO SENSOR ASY CAMSHAFT TIMING WIRING RETAINER (5) PLACES

TO SENSOR ASY CRANKSHAFT TIMING (SENSOR ASY CRANKSHAFT TIMING) (COVER ASYVALVE ROCKER ARM STUD)

TO SWITCH ASY OIL PRESSURE

(SWITCH ASY OIL PRESSURE)

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

(WIRING ASY ENGINE CONTROL SENSOR) FRONT OF ENGINE

030403


2001 2.5L4V CD132/SW164/MPV

001019

52

IL1S7E030002E0543D

37

37A.6

WIRING HARNESS ASY TO IGNITION COILTO COIL ASY IGNITION

(CAPACITOR ASYRADIO IGNITION INTERFERENCE)

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

(COIL ASY IGNITION)

(WIRING ASY ENGINE CONTROL SENSOR)

FOR NAAO & MPV ONLYSEE FRAMES 27 & 27A FOR INITIAL INSTALLATION SHOWN OUT OF SEQUENCE FOR CHART CONGRUITY

ALL CONNECTIONS SHOWN ARE FOR 9H589 WIRING HARNESS ASY TO COIL ASY IGNITION



FRONT OF ENGINE (COIL ASY IGNITION)

TO CAPACITOR ASY RADIO IGNITION INTERFERENCE

(COVER ASYVALVE ROCKER ARM STUD)

FOR EAO ONLY


2001 2.5L4V CD132/SW164/MPV

001019

52

IL1S7E030002E0543D

37A

37B.5

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

A

(VALVE ASYIDLE AIR CONTROL)

TO VALVE ASYIDLE AIR CONTROL


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

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


(CONTROL ASYENGINE AIR SHUT OFF) TO CONTROL ASYENGINE AIT SHUT OFF

SHOWN OUT OF SEQUENCE FOR CHART CONGRUITY BACKGROUND DETAIL MAY NOT BE PICTORALLY ACCURATE FOR ALL APPLICATIONS

FRONT OF ENGINE

FRONT OF ENGINE


(VALVE ASYIDLE AIR CONTROL STUD) (HEGO SENSOR)

VIEW A


2001 2.5L4V CD132/SW164/MPV

001019

52

IL1S7E030002E0543D

37B

38.6

OIL LEVEL INDICATOR TUBE ASY AND OIL LEVEL INDICATOR ASY

(TUBE ASYOIL 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 812 Nm)

A

6754 TUBE ASYOIL LEVEL INDICATOR

FOR CD132/SW164 ONLY

XU3E6754AD TUBE ASY

FRONT OF ENGINE


FOR MPV ONLY

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


2001 2.5L4V CD132/SW164/MPV

001019

52

IL1S7E030002E0543D

38

39.6

THROTTLE BODY ASY

FRONT OF ENGINE


W701519 (8mm HEX) M6 X 1 X 33.25 BOLT & WSHR HEX FLANGE HD PILOT (TORQUE 812 Nm) (3) REQ

9E936 GASKETAIR CHARGE CONTROL TO INTAKE MANIFOLD

1 9E926

BODY ASYAIR INTAKE CHARGE THROTTLE

FOR AUTO TRANS ONLY

W701632 (10mm HEX) M6 X 1 X 32.5 + M5 X 0.8 X 17.5 STUD & WSHR HEX FLANGE HD PILOT (TORQUE 812 Nm)

1

NOTE: SEE FRAME 39A FOR MAN TRANS AND H/O THROTTLE BODY ASYS

AUTO TRANS MAN TRANS & H/O

SHOWN TYPICAL



2001 2.5L4V CD132/SW164/MPV

001019

52

IL1S7E030002E0543D

39

39A.65

THROTTLE BODY ASY (Continued)9E926 BODY ASYAIR 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 812 Nm) (3) REQ

SV T

9E936 GASKETAIR CHARGE CONTROL TO INTAKE MANIFOLD

FOR H/O ONLY

W701519 (8mm HEX) M6 X 1 X 32.5 + M5 X 0.8 X 17.5 STUD & WSHR HEX FLANGE HD PILOT (TORQUE 812 Nm) (3) REQ

9E926 BODY ASYAIR INTAKE CHARGE THROTTLE W701519 (8mm HEX) M6 X 1 X 33.25 BOLT & WSHR HEX FLANGE HD PILOT (TORQUE 812 Nm) (3) REQ

9E936 GASKETAIR CHARGE CONTROL TO INTAKE MANIFOLD W701632 (10mm HEX) M6 X 1 X 33.25 BOLT & WSHR HEX FLANGE HD PILOT (TORQUE 812 Nm)


FOR MANUAL TRANS ONLY 2001 2.5L4V CD132/SW164/MPV 001019 52

IL1S7E030002E0543D

39A

39B1

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

FRONT OF ENGINE

(BODY ASYAIR INTAKE CHARGE THROTTLE)

TO BODY ASY AIR INTAKE CHARGE THROTTLE

(WIRINGENGINE CONTROL SENSOR) (MANIFOLD ASY INTAKE LOWER)

TO INJECTOR PRESSURE SENSOR

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


2001 2.5L4V CD132/SW164/MPV

001019

52

IL1S7E030002E0543D

39B

40.8

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

FRONT OF ENGINE

9278 SWITCH ASY OIL PRESSURE Nm (TORQUE 1216 Nm)

1 GASKET(PART OF 6A642 ASY) NOTE: LUBRICATE WITH WSEM2C908A OIL PRIOR TO INSTALLATION


2 LOCATING PIN(INSERT)

FOR CD132 & NAAO SW1646A642 COOLER ASYCRANKCASE OIL NOTE: POSITION TUBES AS SHOWN

2

FOR ALL EAO SW164 , H/O & MPV

1

OIL COOLER INSERT (PART OF 6A642 ASY) (TORQUE 5560 Nm)

GASKET (PART OF 6714 ASY) NOTE: LUBRICATE WITH WSEM2C908A OIL PRIOR TO INSTALLATION

6714 FILTER ASYOIL TORQUE 1417 NmA

ASSEMBLY PROCEDURE(LOCATING PIN) 1. INSTALL LOCATING PIN ON OIL IT INTO CAST SLOT IN CYLINDER BLOCK. 2. ROTATE OIL COOLER CLOCKWISE UNTIL IT STOPS. 3. TORQUE AS SPECIFIED. VIEW A (CAST SLOT IN CYLINDER BLOCK)


2001 2.5L4V CD132/SW164/MPV

001019

52

IL1S7E030002E0543D

40

41.65

LINKSHAFT BRACKET ASY AND CYLINDER BLOCK PLUGS


W701548 (14.30mm HEX) 3/414 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 ONLYW500233 (13mm HEX) M10 X 1.5 X 25 BOLT HEX FLANGE HD (TORQUE 4055 Nm) (3) REQ


2001 2.5L4V CD132/SW164/MPV

001019

52

IL1S7E030002E0543D

41

42.75

A/C COMPRESSOR & CLUTCH ASY FOR NAAO SW164 ONLY

FRONT OF ENGINE

(BLOCK ASY CYLINDER

1

1


19D629 COMPRESSOR & CLUTCH ASYA/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 2030 Nm) (3) REQ

BACKGROUND DETAIL MAY NOT BE PICTORIALLY ACCURATE FOR ALL APPLICATIONS

2001 2.5L4V CD132/SW164/MPV

001019

52

IL1S7E030002E0543D

42

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 ASYEGR

FOR NAAO SW ONLY

(HEAD ASY CYLINDER)

9D477 TUBE ASYEGR (TORQUE 3545 Nm) BOTH ENDS

FOR NAAO SW ONLY9448 GASKET EXAUST MANIFOLD

W705609 (27mm HEX) CAP (TORQUE 3545 Nm)

W701732 (5mm HEX) M8 X 1.25 X 15 X M8 X 1.25 X 23 STUD (TORQUE 1013 Nm) (6) PLACES PER SIDE NOTE: INSTALL SHORT END OF STUD INTO CYLINDER HEAD ASY

FOR EAO SW AND CD ONLY

W701706 (13mm HEX) M8 X 1.25 NUT HEX FLANGE HEAD (TORQUE 1822 Nm) (6) REQ 5G236 MANIFOLD & CONVERTER ASY EXHAUST RH BACKGROUND DETAIL MAY NOT BE PICTORIALLY ACCURATE FOR ALL APPLICATIONS

SINGLE WRENCH METHODTORQUE SEQUENCE 16 PERFORM TORQUE SEQUENCE TWICE


2001 2.5L4V CD132/SW164/MPV

001019

52

IL1S7E030002E0543D

43

44.6

GROUND STRAP

FRONT OF ENGINE

(HEAD ASY CYLINDER)

1 GROUND STRAP

W701539 (8mm HEX) M5 X 0.8 NUT (TORQUE 57 Nm)

A

W701643 (13mm HEX) M5 X .8 X 15 / M6 X 1 X 19.25 STUD & WASHER HEX FLANGE HD PILOT (TORQUE 812 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


2001 2.5L4V CD132/SW164/MPV

001019

52

IL1S7E030002E0543D

44

45.65

ALTERNATOR ASY AND ALTERNATOR MOUNTING BRACKET ASY FOR SW164 ONLY


1

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

FRONT OF ENGINE

W705832 (6mm HEX) M10 X 1.5 X 21/ M10 X 1.5 X 29 STUD STUD (TORQUE 1015 Nm) W701524 (10mm HEX) M8 X 1.25 X 49.3 BOLT & WASHER HEX FLANGE HD PILOT (TORQUE 2030 Nm) (3) REQ

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

10239 BRACKET ASY ALTERNATOR MOUNTING

W705831 (15mm HEX) M10 X 1.5 NUT (TORQUE 4055 Nm) W701521 (13mm HEX) M10 X 1.5 X 85.3 BOLT HEX FLANGE HD PILOT (TORQUE 4055 Nm) (2) REQ

10300 ALTERNATOR ASY

UNIQUE FOR EAO 2001 2.5L4V CD132/SW164/MPV 001019 52


IL1S7E030002E0543D

45

45A.5

ALTERNATOR MOUNTING BRACKET ASY FOR MPV ONLY


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 2030 Nm) (3)REQ


2001 2.5L4V CD132/SW164/MPV

001019

52

IL1S7E030002E0543D

45A

46X

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

(BRACKET POWER STEERING)

(COVER ASYENGINE FRONT STUD) (6) PLACES CAP COLOR: CD132 ORANGE SW164 YELLOW 3D639 PUMP PULLEY & BRACKET ASYPOWER STEERING

UNIQUE FOR CD2 W707172 (13mm HEX)M8 X 21.5 BOLT & WSHR HEX FLNG CONCL 8 (TORQUE 2030 Nm) (2) REQ 3A733 PULLYPOWER STEERING PUMP

A

2 3

1

FRONT OF ENGINE

W701542 (10mm HEX) M6 X 1 NUT HEX FLANGE HD (TORQUE 812 Nm) (6) REQ

3 W500319 (10mm HEX)(COVER ASY ENGINE FRONT)

M8 X 1.25 X 84.3 BOLT HEX FLANGE PILOT (TORQUE 2030 Nm) (2) REQ NOTE: MUST BE RUN DOWN FIRST W701522 (10mm HEX) M8 X 1.25 X 19 BOLT & WASHER ASY HEX FLANGE HD PILOT (TORQUE 2030 Nm) (4) REQ

14 15

10 4

11

1

NOTE: "DIMPLE" ON PULLEY MUST FACE FORWARD

3

VIEW A (FRONT) STUD LOCATION (6) PLACES

0305

duratech 2.5l engine v6

Documents

eao flexplate asy

egr tube asy

naao sw164 electric

pistons crankshaft

crankshaft timing sensor

drive chain

engine assembly procedure

upper main bearings