543 ENGINE ASY CHART

2 001
RE

VENGINES MANUFACTURING & ENGINEERING

IL1F1E030002E0543F
ENGINE 3.0L4V TAU/SAB (D186)
VENGINE ILLUSTRATION

LET FR LET FR LET FR LET FR LET FR LTRS

N8 1

E9 2

P4 2A

P4 2B J8

F1 3

3A

3B E1

R1 3C N3 14 E8 35 N4 58 N11 74A

M1 4 J9 15

4A

5 J10

5A

6 P1 16 L5 39

N1 6A P1 16A

6B N4 17

J1 6C N17 18 E8 42 N14 65

N1 7 N5 19 43 L5 66

7A N6 20 E12 H2 67

7B E8 21

8 N10 22

8A L5 23 G4 47 N15 70

8B 24 N12

8C 25 N5

9 E8 26

J3 10 27

J11 11 K2 28 G3 49

J7 12 K2 28A

13 29

13A 13B 13C 13D 13E 13F 13G L5 30 N11 51 K3 31 P5 52 K3 31A 53 N5 32 E12 K2 34 E8 56 34A E8 57 P1 74

15A 15B 15C

N11 N11 N11 E12 36 E8 59 R1 1A 36A E8 59A N7 37 N11 60 P3 E8 61

N11 N11 40 41 P2 64

N11 N11 45 L5 68 46 N4 69

N11 N11 48 48A

N11 N11 50 50A

47A 47B D2 71 72

E19 N13 54 55

N11 N11 62 63

N15 N11 N15 N11 73 73A 73B 73C

ADDED FRAMES

N11 N11 N11 J14 47C 47D 47E 10A

20A 51A

REVISIONS CHECKER ENGR APP MATL / FSTN

ORIGINATOR

RELEASED FOR NE01E10854730000 JBELLOVA FDUDEK3

981118 MLESS

CAD: Y DLIRETTE NADAMOWI

H1 WAS BOLT TORQUE 30 Nm ON FR 13D H2 6X REVISED BRACKET ON FR 64, 67, 68, 73A & 73C H3 2X REVISED BACKGROUND ON FR 73A & 73C H4 4X REVISED TBODY ON FR 51, 52, 73 & 73B 990916 NE01I10880558017 JBELLOVA HBRENNE1 MLESS

CAD: Y

A1 ADDED END PLAY NOTE ON FR 7 A2 3X REVISED SINGLE WRENCH METHOD ON FR 58, 59 & 59A 981221 CAD: Y NE01E10913979000 MCONLON HBRENNE1 JYEAGER1 B1 REVISED INDEX ON FRAME 2A B2 WAS 9J472 BRKT ASY ON FRAME 46 990120 NE01I10476773077 JWILLI29 HBRENNE1 MLESS C1 ADDED VIEW C ON FRAME 16 C2 REVISED PULSE RING ON FRAME 16 990212 NE01E10931612000 JWILLI29 HBRENNE1 BMAZZELL

CAD: Y

CAD: Y

J1 REVISED FASTENER SPECIFICATIONS on FRAME 6C J2 3X REVISED BACKGROUND on FRAME 10,11,15B J3 REVISED BAFOIL PAN on FRAME 10 J4 WAS W701542 NUT AND TORQUE 5 Nm on FRAME 11 J5 REVISED SCRN & CVR ASY on FRAME 11 J6 REVISED ASSEMBLY PROCEDURE on FRAME 11 J7 REVISED SECTION B on FRAME 12 J8 2X WAS TORQUE 3743 Nm on FRAME 13D J9 REVISED GRCRKSHT on FRAME 15 J10 ADDED GRCRKSHT on FRAME 15B J11 REVISED VIEW A on FRAME 11 J12 ADDED VIEW A CODE on FRAME 64 J13 ENHANCED 6K817 ASY on FRAME 19 J14 ADDED FRAME 10A J15 REVISED INDEX on FRAME 2A 991213 CAD: Y NE01I10880558019 DROWAN HBRENNE1 MLESS K1 6X WAS STUD ON FRAME 28,28A,34,47B,73 & 73B K2 8X WAS BOLT ON FRAME 28,28A,32,34,47B,69,73 & 73B K3 2X REVISED CONNECTOR ON FRAME 31 & 31A K4 WAS TORQUE 24 Nm ON FRAME 32 K5 REVISED WIRE BRACKET ON FRAME 64 CAD: Y NE01E11029769000 000307 DKERR12 TSALUSKY MLESS L1 REVISED CONTD ON FR 73C L2 REVISED LAST FR ON FR 73C L3 2X ADDED FR 74 & 74A L4 2X REVISED FRONT COVER ON FR 16 & 16A L5 8X REVISED BACKGROUND ON FR 23,30,39,65,66,68,73A & 73C 000420 CAD: Y NE01I10880558020 FDUDEK3 HBRENNE1 MLESS M1 WAS W701228 DOWEL ON FR 4 M2 REVISED 9J447 INTAKE BACKGROUND ON FR 45 M3 REMOVED COIL ON PLUG BACKGROUND ON FR 46 000420 NE01I10880558020 JBELLOVA N1 N2 N3 N4 N5 N6 N7 N8 HBRENNE1 MLESS

D1 REVISED INDEX ON FRAME 2B D2 DELETED FRAME 71 D3 2X DELETED WATER PUMP PULLEY SHIELD ON FR 73 & 73B 990310 CAD: Y NE01I10880558006 JWILLI29 E1 E2 E3 E4 E5 E6 E7 E8 HBRENNE1 MLESS ADDED COLOR CODE ON FRAME 13G ADDED CHART ON FRAME 14 3X ADDED FRAMES 47C,47D,47E WAS STUD BOLT ON FRAME 16A ADDED STUD BOLT W701581 ON FRAME 16A REVISED WATER BYPASS TUBE ON FRAME 18 REVISED CRANKCASE HOSE ON FRAME 19 35X REVISED BACKGROUND ON FRAME 19,20,21,22,26,32,34, 35,36,40,41,42,47,47A,49,50,50A,51,52,54,55,56,57,58,59,59A, 60,61,62,63,64,66,68,69,70 E9 REVISED INDEX ON FRAME 2,2A,2B E10 2X REVISED FASTENER REQ ON FRAME 28,28A E11 2X REVISED WIREHARNESS ON FRAME 31,31A,45 E12 3X DELETED FRAME 33,38,44 E13 REVISED FUEL VAPOR TUBE ON FRAME 40 E14 MOVE VIEW A FRAME 47 TO 47D E15 ADDED IGNITION COIL & BRACKET ASY TO FRAME 47 E16 2X ADDED IGNITION WIRE LH ON FRAME 47A,47B E17 MOVED CONTENT FROM FRAME 47B TO 47D E18 REVISED OIL LEVEL INDICATOR ON FRAME 49 E19 REVISED A/C BRACKET ON FRAME 54 E20 REVISED A/C BRACE ON FRAME 65 E21 DELETED ENGINE ROLL BRACKET ON FRAME 66 E22 WAS N807985 BOLT ON FRAME 66 E23 REVISED CRANKSHAFT PULLEY ASY ON FRAME 67 E24 REVISED ASSEMBLY PROCEDURE ON FRAME 67 E25 DELETED TENSIONER ASY WATER PUMP BELT ON FRAME 69 E26 REVISED WATER PUMP BELT ON FRAME 70 E27 4X REVISED ENGINE MASTERS ON FRAME 73,73A,73B,73C E28 WAS TORQUE 57 ON FRAME 32 E29 REVISED EGR VALVE ASY ON FRAME 48 NE01I10880558010 990719 CAD: Y DFOLEY FDUDEK3 MLESS F1 REVISED SEALING AND LUBRICATING INDEX ON FR 3 F2 WAS 17mm ON FR 12 F3 WAS A7 SEALER ON FR 12 990719 CAD: Y NE01E10934485000 AJOHNSO4 HBRENNE1 MLESS

CAD: Y

2X WAS 0.1100.232mm END PLAY ON FR 6A & 7 REMOVED COLOR CHART ON FR 14 REVISED SPARK PLUGS ON FR 14 11X REVISED WATER PUMP ON FR 17,18,19,32,47B,58,69, 70,73,73B & 74 7X REVISED BYPASS TUBE ON FR 18,19,32,45,47B,73,73B & 74 WAS CONTD 21 ON FR 20 2X ADDED FR 20A & ON FR 2A REVISED INSTALLATION SEQUENCE ON FR 22 NOTE: FORD VEHICLE ROTATIONS: D186 V1 & V3

VENGINE ILLUSTRATION (543)

REFERENCE

MARK LESS (313) 8454498

X X

PART MUST COMPLY WITH MATERIAL SPECIFICATION WSSM99P9999A1 TO HELP SAFEGUARD HEALTH, SAFETY AND THE ENVIRONMENT. DRAFTED IN ACCORDANCE WITH FORD 3RD ANGLE PROJ ENGINEERING CAD AND DRAFTING DIMENSIONS IN STANDARDS CURRENT AT INITIAL RELEASE MILLIMETERS
CAD FILE

CAD TYPE CAD LOC G1 ADDED NOTE FOR TORQUE TIMING ON FR 28 XATROL EDM G2 REVISED SEALER NOTE ON FR 28 G3 10X REVISED VALVE ROCKER COVER ASY LH ON FR 28,28A,32 OPER. NO UNIT 34,47B,49,69,70,73,73B N460 G4 5X REVISED IGNITION COIL & BRACKET ASY ON FR 47,47A,47C, ILLUSTRATOR 47D,47E JBELLOVA G5 REMOVED W701539 NUT ON FR 52 CHECKED 990806 CAD: Y NE01E10924472000

il1f1e030002e0543f01.dg
DRAWING

DATA IS MASTER

IL1F1E030002E0543F
TITLE FRM 1 of

AJOHNSO4

HBRENNE1

MLESS

ENGINE ASSEMBLY PROCEDURE AND INSTRUCTION 2001 3.0L4V FDUDEK3 TAURUS / SABLE (D186) SCALE DATE DIVISION V ENGINE ENGINEERING 981111 PLANT CLEVELAND

74

RH/LH

LTRS ORIGINATOR

REVISIONS CHECKER ENGR APP MATL / FSTN

LTRS ORIGINATOR

REVISIONS CHECKER ENGR APP MATL / FSTN

N9 REVISED SECTION A ON FR 22 N10 REVISED VIEW B ON FR 22 N11 25X REVISED UPPER INTAKE ON FR 36,36A,37,40,41,45,46, 47A,47C,47D,47E,48,48A,50,50A,51,52,60,62,63,73,73A, 73B,73C & 74A N12 REVISED PLUG WIRE NOTE ON FR 47A N13 2X REVISED TORQUE NOTE ON FR 55 N14 WAS 2 BOLTS REQ ON FR 65 N15 4X REVISED DRIVE BELT ON FR 70,73,73B & 74 N16 ADDED FR 1A N17 ADDED STUD ON FR 18 000630 CAD: Y NE01I10880558021 JBELLOVA FDUDEK3 MLESS P1 3X FEAD TENSIONER WAS PIA TO FRONT COVER ON FR 16 & 16A & 74 P2 REVISED WIRING CONNECTION ON FR 64 P3 3X ADDED FRAME 51A ON FR 1,2A, & 51A P4 2X REVISED INDEX ON FR 2A & 2B P5 WAS CONTD 52 ON FR 51 000823 CAD: Y NE01I10880558022 DROWAN FDUDEK3 MLESS R1 ADDED VEHICLE DESIGNATIONS ON FRAMES 3C NE01E11183277048 010326 RWOLFFIS FDUDEK3 MLESS CAD: Y

NE01E11183277048

2001 3.0L4V D186

010402

74

IL1F1E030002E0543F

R1

1A

ITEM
GENERAL SPECIFICATIONS

INDEX

FRAME

ASSEMBLY AID BALANCING INSTRUCTIONS DIMENSIONING EMISSION CONTROL EQUIPMENT ENGAGEMENT SPECIFICATIONS FOR ALL VACUUM SYSTEM CONNECTIONS ENGINE APPLICATION CODES ENGINE ELECTRICAL EQUIPMENT ENGINE LUBRICATION REQUIREMENTS ENGINE PAINT INSTRUCTIONS NOTES BEFORE STARTING ENGINE OIL CLEANLINESS PERFORMANCE AND OIL ECONOMY TEST (DYNAMOMETER TEST) PRODUCTION HOT TEST SEALING AND LUBRICATING INDEX SHIPPING PLUGS AND DUNNAGE CAPS TORQUE VALUES FOR PARTS AS SUPPLIED CPSC: 030508 030505 030505 030505 030402 140301 030901 030901 031403 030202 030801 030901 030901 030101 031001 031101 030508 031001 031403 031101 031101 030801 030101 030101 031004 030102 030102 INSTALLATION: ACCESSORY DRIVE PULLEY A/C COMPRESSOR BRACE A/C COMPRESSOR & CLUTCH ASY A/C COMPRESSOR MOUNTING BRACKET ASY AIR INTAKE CHARGE THROTTLE BODY ASY ALTERNATOR ASY & WIRING BRACKET CAMSHAFT ASY, BEARING CAPS AND VALVE ROCKER ARM ASY CAMSHAFT ASY PREASSEMBLY TIMING MARK ALIGNMENT CAMSHAFT TIMING SENSOR ASY CRANKCASE OIL COOLER ASY AND OIL FILTER ASY CRANKCASE EMISSION VALVE TO INTAKE MANIFOLD HOSE CRANKSHAFT, CAMSHAFT ASY AND TIMING CHAIN PRE ASSEMBLY TIMING MARK ALIGNMENT (LH) CRANKSHAFT, CAMSHAFT ASY AND TIMING CHAIN TIMING MARK ALIGNMENT (LH & RH) CRANKSHAFT ENDPLAY CRANKSHAFT FRONT OIL SEAL ASY CRANKSHAFT, MAIN BEARING AND THRUST WASHER CRANKSHAFT PULLEY ASY CRANKSHAFT REAR OIL SEAL ASY CRANKSHAFT TIMING SENSOR ASY CRANKSHAFT TRANSMISSION SLEEVE CRANKSHAFT VIBRATION DAMPER ASY CRANKSHAFT VENT TUBE ASY CYLINDER BLOCK DOWELS, CUP PLUGS, PIPE PLUGS AND OIL FILTER INSERT CYLINDER BLOCK DOWELS AND PIPE PLUGS CYLINDER BLOCK OPENING COVER CYLINDER HEAD GASKETS CYLINDER HEAD ASY

3 3B 3 3B 3A 3C 3A 3B 3B 3A 3 3A 3A 3 3C 3

69 65 57 54 51 64

E9

13F,13G 13E 23 27 19,63 15A 15C 7 21 5A 67 7A 26 7B 22 41 4 4A, 55 24 13B 13C,13D

NE01I10880558010

2001 3.0L4V D186

990629

73C

IL1F1EINDEXE0543F

E9

2A

ITEM
CPSC: 031004 030904 030507 030804 031403 030804 030002 030002 030101 030101 030101 000103 031004 031004 030106 030104 030104 030104 030804 030804 030509 030105 030105 031302 030402 030702 030702 030103 030103 030103 030103 030202 030202 030203 030203 130501 030201 030201 030801 031102 031102 031102 INSTALLATION

INDEX

FRAME

CYLINDER HEAD ASY PIPE PLUGS AND DOWELS CYLINDER HEAD ASY VALVES AND SPRINGS DRIVE BELT EGR TRANSDUCER ASY EGR VACUUM REGULATOR CONTROL ASY EMISSION VACUUM CONTROL MAIN CONNECTOR ASY ENGINE ASYLEFT FRONT VIEW ENGINE ASYRIGHT REAR VIEW ENGINE BULKHEAD HOUSING ENGINE BULKHEAD HOUSING AND CRANKSHAFT MAIN BEARINGS ENGINE BULKHEAD HOUSING TO CYLINDER BLOCK ASY ENGINE CODE DECAL ENGINE FRONT COVER ASY ENGINE FRONT COVER ASY AND IGNITION PULSE CRANKSHAFT SENSOR RING ENGINE LIFTING EYE EXHAUST MANIFOLD EXHAUST MANIFOLD (RH) & CONVERTER ASY EXHAUST MANIFOLD STUDS EXHAUST RECIRCULATING VALVE ASY EXHAUST RECIRCULATING VALVE TO EXHAUST MANIFOLD TUBE ASY FEAD TENSIONER ASY FLYWHEEL ASY FLYWHEEL HOLE LOCATION FOR SHIPPING FUEL VAPOR RETURN TUBE ASY IDLE AIR CONTROL VALVE ASY IGNITION COIL & BRACKET ASY IGNITION WIRE ASY INTAKE MANIFOLD ASY (LOWER) INTAKE MANIFOLD ASY (UPPER) INTAKE MANIFOLD OPENING COVER ASY INTAKE MANIFOLD PORT PLUG OIL LEVEL INDICATOR ASY OIL LEVEL INDICATOR TUBE ASY OIL PAN ASY OIL PAN BAFFLE OIL PRESSURE SWITCH ASY OIL PUMP ASY OIL PUMP SCREEN & COVER ASY OIL SEPERATOR ASY, WATER INLET TUBE AND CUP PLUG PISTON ASY, PIN AND CONNECTING ROD ASY PISTON AND CONNECTING ROD ASY (CLEARANCES) PISTON & CONNECTING ROD ASY, BEARINGS AND CAP

13 13A 68 61 46 50 73, 73B 73A, 73C 6C 6B 6,6A 30 16A 16 43,56 58 59, 59A 42 48 60 51A 29 72 40 37 47

B1

P3

E9 E9

47A, 47B 34,34A 36,36A 48A 50A 49 25 20, 20A 10, 10A 53 9 11 12 8 8C 8B

N7 J15

P4

NE01I10880558022

2001 3.0L4V D186

000823

73C

IL1F1EINDEXE0543F

P4

2A

2B

ITEM
CPSC: INSTALLATION: PISTON ASY, PIN AND RINGS

INDEX

FRAME

031102 030503

8A 66

P4 E9 E9

POWER STEERING PUMP & PULLEY ASY

031101 030704 030901 031004 031004 030305 030305 030507

SELECTFIT MAIN BEARING GRADE CHART SPARK PLUG ASY TIMING CHAIN, GUIDE,TENSIONER, TENSIONER ARM AND CRANKSHAFT GEAR VALVE ROCKER ARM COVER ASY VALVE ROCKER ARM COVER ASY & CAMSHAFT SEAL REAR RETAINER WATER BYPASS TUBE ASY WATER PUMP ASY WATER PUMP DRIVE BELT

5 14 15, 15B 28A 28 18 17 70

D1
030403 030403 WIRING ASY CONNECTIONS WIRING ASYENGINE CONTROL SENSOR & FUEL CHARGING

35, 39, 45, 52, 62

31, 31A, 32

E9

NE01I10880558022

2001 3.0L4V D186

000823

73C

IL1F1EINDEXE0543F

P4

2B

GENERAL SPECIFICATIONS TORQUE VALUES FOR PARTS AS SUPPLIED

NOTE: REFER TO WERS TO VERIFY TORQUE VALUES. THREAD SIZE M5 X 0.8 M6 X 1 M8 X 1.25 M10 X 1.5 M12 X 1.75 M14 X 2 1/4 18 PIPE 3/8 18 PIPE 1/2 14 PIPE 3/4 14 PIPE 1 11.5 PIPE TORQUE 57 Nm 812 Nm 2030 Nm 4055 Nm 7095 Nm 110155 Nm 14 Nm THEN ROTATE 180 20 Nm THEN ROTATE 180 40 Nm THEN ROTATE 180 6075 Nm 90 Nm THEN ROTATE 180

DIMENSIONING
ALL DIMENSIONS ARE IN MILLIMETERS UNLESS OTHERWISE SPECIFIED.

SEALING AND LUBRICATING INDEX SEALER/ADHESIVE

WSEM4G323A6 WSKM2G349A7

DESCRIPTION
SILICONE RUBBER, OXIME SEALANT ANAEROBIC ADHESIVE ANAEROBIC ADHESIVE 12 12

FRAMES
6,6A,16,20,22,28

F1

WSKM2G349A10

LUBRICANT
ESEM99B176A ESEM99B144B CLEAR DIMETHYL SILOXANE SURFACTANT (MERPOL) 18 3,17

OIL
WSEM2C908A SAE 50 ASSEMBLY FLUID 3,6A,7A,8,8B,13A, 13F,13G,21,22,25, 27 3,3B 3B

WSSM2C914A ESEM99C103B1

5W20 GF3 FLUORESCENT DYE

FUEL
WSEM4C112A UNLEADED REGULAR 3A

CLEANER
WSEM5B392A ENGINE DEGREASER 6A

NOTE: ALL GASKETS AND SEALING SURFACES MUST BE CLEAN AND FREE OF ALL FOREIGN MATTER PRIOR TO ASSEMBLY.

ASSEMBLY AID
NOTE: ESEM99B144B HOSE ASSEMBLY SURFACTANT ONLY (DO NOT MIX). USE TO FACILITATE HOSE ASSEMBLY. ALL OTHER LUBRICANTS ARE NOT PERMITTED. MAY BE APPLIED TO ID AND OD OF HOSE. SPRAY NOT PERMITTED.

OIL CLEANLINESS
ASSEMBLY OIL (WSEM2C908A) BEING APPLIED TO ENGINE COMPONENTS AND THE INITIAL FILL OIL (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

NE01E10934485000

2001 3.0L4V D186

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73C

IL1F1E030002E0543F

F1

3A
X

GENERAL SPECIFICATIONS (Continued)

ENGAGEMENT SPECIFICATIONS FOR ALL VACUUM SYSTEM CONNECTIONS

HOSE/VACUUM CONNECTIONS: ALL HOSE, VACUUM TUBING CONNECTIONS, CONNECTOR BLOCKS AND CAPS MUST BE BOTTOMED OF 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".

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

PRODUCTION HOT TEST

THE PRODUCTION HOT TEST IS TO BE PERFORMED IN ACCORDANCE WITH SPECIFICATION ENGINE ASSEMBLY PRODUCTION HOT TESTING ESF7DE6007AA. USE 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 ESF7DE6007AA. USE WSEM4C112A FUEL.

NOTES BEFORE STARTING ENGINE

BEFORE STARTING AN ENGINE, CHECK TO SEE THAT VACUUM HOLES ARE PLUGGED OR CONNECTED AS REQUIRED. FOR INSTALLATION OF OIL LEVEL INDICATOR SEE FRAME 49. FOR INITIAL OIL FILL SEE FRAME 3B.

ENGINE ELECTRICAL EQUIPMENT

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

NE01E10854730000

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IL1F1E030002E0543F

3A

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 ESF7DE6007AA FOR ENGINE MASS BALANCE REQUIREMENTS.

ENGINE LUBRICATION REQUIREMENTS

ADD THE FOLLOWING AMOUNT OF WSSM2C914A OIL (5W20 GF3) FOR INITIAL OIL FILL AS SHOWN IN CHART BELOW: NOTE: 20 ml OF ESEM99C103B1 DYE MUST BE ADDED FOR IN PLANT OIL LEAK DETECTION. INITIAL OIL FILL: CUSTOMER OIL FILL: 6.0 quarts (5.7 liters) 5.0 qt WITHOUT OIL FILTER. 5.5 qt WITH OIL FILTER.

AFTER INITIAL OIL FILL, AND PRIOR TO HOT TEST, SPIN THE OIL PUMP IN THE NORMAL OPERATING DIRECTION, AT 1000 2000 RPM UNTIL 60 PSI IS ACHIEVED, 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

NOTE: RELEASED ENGINE OIL FILTER MUST BE USED ON FACTORY BREAKIN RUN.

ENGINE PAINT INSTRUCTIONS

ALL 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 RESPECTIVE DETAIL OR ASSEMBLY DRAWING.

NE01E10854730000

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73C

IL1F1E030002E0543F

3B

3C
X

GENERAL SPECIFICATIONS (Continued)

R1

ENGINE APPLICATION CODES

LEV
TRANSMISSION AUTO APPLICATION A/C CODE 1G850AA VEHICLE TAURUS/SABLE

LEADED FUEL
TRANSMISSION AUTO APPLICATION A/C CODE 1D856AA VEHICLE TAURUS/SABLE

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

CVR ASYVLV RKR ARM LH (6A505) COOL ASYCRKC OIL (6A642) PIA TUB ASYCRKC VEN (6758) PIA PMP & PLY ASYPWR STNG (3A696) PIA BDY ASYAIR INTK CHG THROT (9E926) PIA HOSWTR BYP (8548) HOSWTR PMP INLT (8A567)

FINAL (LEADED FUEL)FINAL FINAL FINAL FINAL FINAL FINAL

DRESS DRESS DRESS DRESS DRESS DRESS DRESS

NE01E11183277048

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IL1F1E030002E0543F

R1

3C

4
X

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

6890 INSERT OIL FLTR MTNG BOLT TORQUE 2740 Nm

6010 BLK ASY CYL

FOR 850 ONLY

M1 1 W706860
DOWEL (8 X 18.25) CVR ASY ENG FRT (2) REQ

W701516 [3/818] PIPE PLUG TORQUE 20 Nm THEN ROTATE 180

W701546 CUP PLUG (19.35)

1
FRONT OF ENGINE

(9.5 8.5)

(7.6 5.0)

1 (DOWEL)
(BLK ASY CYL)

(BLK ASY CYL) SECTION A TYPICAL (2) PLACES SECTION B

(CUP PLUG)

NE01I10880558020

2001 3.0L4V D186

000412

73C

IL1F1E030002E0543F

M1

4A
.5

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

W701517 1/214 PIPE PLUG TORQUE 40 Nm THEN ROTATE 180

FRONT OF ENGINE

1 W701202
DOWEL HOLLOW (16 X 19) TRANSMISSION 6010 BLK ASYCYL

1 W701202
DOWEL HOLLOW (16 X 19) TRANSMISSION

W701517 1/214 PIPE PLUG TORQUE 40 Nm THEN ROTATE 180

(9.5 8.5)

1 (DOWEL)

(BLK ASYCYL) SECTION A TYPICAL (2) PLACES

NE01E10854730000

2001 3.0L4V D186

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IL1F1E030002E0543F

4A

5
.5

SELECTFIT MAIN BEARING GRADE CHART

SELECTFIT 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 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.) (CRKSHFT) FRONT OF ENGINE

(HSGENG BLKHD)

SELECTFIT CODE

(BLK ASYCYL)

BLOCK CODE
98 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

NE01E10854730000

CRANKSHAFT CODE

2001 3.0L4V D186

981111

73C

IL1F1E030002E0543F

5A
.75

CRANKSHAFT, MAIN BEARING AND THRUST WASHER (UPPER)

6303 CRKSHT

W701528 KEY 4.76 X 53.5

6A341 WSHRCRKSHT MN CTR BRG THRS UPR

6333 BRGCRKSHT MN UPR (4) REQ

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

(BLK ASYCYL)

FRONT OF ENGINE

NE01E10854730000

2001 3.0L4V D186

981111

73C

IL1F1E030002E0543F

5A

6
.7

ENGINE BULKHEAD HOUSING TO CYLINDER BLOCK ASY (SEALANT)

SEALANT PATH WSEM4G323A6 SEALER 1mm DIA BEAD ( 3mm DIA BEAD AT GROOVES)

FRONT OF ENGINE

3mm BEAD AREA 1mm BEAD AREA

6010 BLK ASYCYL

NOTE: VIEW SIMPLIFIED FOR INSTALLATION CLARITY

6 A SEE FRAMES 6A & 6B

VIEW

ASSEMBLY PROCEDURE
1. 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)

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.

NE01E10854730000

2001 3.0L4V D186

981111

73C

IL1F1E030002E0543F

6A
.7

ENGINE BULKHEAD HOUSING TO CYLINDER BLOCK ASY (Continued)

ASSEMBLY PROCEDURE
A) B) ALL TRACES OF PREVIOUSLY APPLIED SEALANT MUST BE COMPLETELY REMOVED BY SCRAPING THE SURFACES (WITHOUT DAMAGING EITHER SURFACE). BOTH SURFACES MUST BE WIPED WITH A RAG SATURATED WITH WSEM5B392A 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. D) 2. 3. THE BULKHEAD SURFACE MUST BE CLEANED AFTER INSTALLATION OF CRANKSHAFT BEARINGS AND CRANKSHAFT TO REMOVE ANY RUNOFF OF BEARING PRELUBE OIL.

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 JOURNALS 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 OF APPLYING WSEM4G323A6 SEALER. 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 BLOCK SURFACE AS SHOWN ON FRAME 6. NOTE: THE SEALANT BEAD MUST TERMINATE 6mm FROM THE REAR CRANKSHAFT SEAL BORE ON BOTH SIDES (SEE ILLUSTRATION ON 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. INSTALL (7) M10 BOLTS,(5) M8 BOLTS, (1) M10 STUD, AND (4) M8 STUDS (DO NOT LUBRICATE FASTENERS). TORQUE TO 3.5 Nm. NOTE: DO NOT ROTATE CRANKSHAFT UNTIL ALL BULKHEAD MAIN BEARING BOLTS ARE TORQUED TO SPECIFICATION. INSTALL (5) PERIMETER BOLTS (DO NOT LUBRICATE FASTENERS). TORQUE TO 35 Nm. 13. 14. 15. 16. APPLY A REARWARD LOAD OF 1800 N THEN APPLY A FORWARD LOAD OF 1800 N 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 0.1350.255mm. CHECK CRANKSHAFT TORQUE TO TURN. NOTE: MAIN BEARING TO CRANKSHAFT JOURNAL SURFACE ASSEMBLED CLEARANCES IS 0.0250.050mm AT CROWN. (SEE FRAME 6D)

12.

N1

NE01I10880558021

2001 3.0L4V D186

000609

73C

IL1F1E030002E0543F

N1

6A

6B
X

ENGINE BULKHEAD HOUSING AND CRANKSHAFT MAIN BEARINGS (LOWER)

6F095 HSGENG BLKHD NOTE: TORQUE ALL BULKHEAD HOUSING TO CYLINDER BLOCK BOLTS/STUDS WITHIN (4) MINUTES OF INSTALLATION

(DOWELHOLLOW PART OF 6F095) (8) PLACES

(SEE FRAME 6) 6A339 BRGCRKSHT MN CTR LWR

A

6A338 BRGCRKSHT MN LWR (3) REQ

(CRKSHT)

(BLK ASYCYL)

FRONT OF ENGINE

NE01E10854730000

2001 3.0L4V D186

981111

73C

IL1F1E030002E0543F

6B

6C
.6

ENGINE BULKHEAD HOUSING (FASTENERS & TORQUE SEQUENCE)

19 17 21

J1
= BOLT = STUD

13

11

15

FRONT OF ENGINE

14

10

12

16

(HSGENG BLKHD)

20

18

22

HOLE NO.
181920 2122

FASTENER

DESCRIPTION
M8 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 95.3 STUD & WASHER PILOT M10 X 1.0 X M8 X 1.25 X 95.3 STUD & WASHER PILOT

J1

W701554

123417 F43E6345CB

131415 16

F43E6345DC

5678 YL8E6D311BA

9101112 YL8E6D311AA

FINAL TORQUE PROCEDURE

PRODUCTION METHOD (MULTISPINDLE) 1. 2. 3. 4. TORQUE FASTENERS TORQUE FASTENERS ROTATE FASTENERS TORQUE FASTENERS 1 THRU 9 1 8 TO 25 Nm

THRU 16 TO 40 Nm THRU 16 90 22 TO 2030 Nm

17 THRU

SINGLE WRENCH METHOD (SERVICEREPAIR) 1. 2. 3. 4. TORQUE FASTENERS TORQUE FASTENERS ROTATE FASTENERS TORQUE FASTENERS 1 THRU 9 8 TO 2228 Nm

THRU 16 TO 3743 Nm

1 THRU 16 AN ADDITIONAL 8595 17 THRU 22 TO 2030 Nm

NE01I10880558019

2001 3.0L4V D186

991213

73C

IL1F1E030002E0543F

J1

6C

7
.5

CRANKSHAFT ENDPLAY (LESS PISTON)

FRONT OF ENGINE

N1
1

CRANKSHAFT ENDPLAY 0.135 0.255mm FIM

(DIAL INDICATOR)

A1

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

NE01I10880558021

2001 3.0L4V D186

000609

73C

IL1F1E030002E0543F

N1

7A
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. 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)

(CRKSHT) 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. 0.50 FIM OF SEAL FACE REAR SURFACE IN RELATION TO REAR FACE OF CRANKSHAFT.

NE01E10854730000

2001 3.0L4V D186

981111

73C

IL1F1E030002E0543F

7A

7B
.5

CRANKSHAFT TRANSMISSION SLEEVE

FRONT OF ENGINE

(CRKSHT)

7G371 SLVTRANS CSHFT

(CRKSHT)

7G371 SLVTRANS CSHFT

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

NE01E10854730000

2001 3.0L4V D186

981111

73C

IL1F1E030002E0543F

7B

8
1

PISTON ASY, PIN AND CONNECTING ROD ASY

NOTE: PISTON MAY BE HEATED TO 60 F350 F TO ALLOW PIN TO SLIDE INTO PLACE IN ASSEMBLY PROCESS. NOTE: SEE FRAME 8A FOR VIEW A & B

6140 RETPST PIN (2) REQ

6110 PST ASY

A NOTE: ROD CAN BE INSTALLED INTO PISTON WITH IDENTIFICATION BUMPS IN EITHER DIRECTION. NOTE: PISTON & ROD AUTOMATED ASSEMBLY ALWAYS ASSEMBLES BUMPS REARWARD OF ENGINE B

1 6135 PINPST

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 CLEARANCE .009 CLEARANCE

6200 ROD ASYCONN NOTE: SEE FRAME 8B FOR ROD CAP INSTALLATION.

NE01E10854730000

2001 3.0L4V D186

981111

73C

IL1F1E030002E0543F

8A
.75

PISTON ASY, PIN AND RINGS

NOTE: PISTON RINGS ARE TO BE ASSEMBLED TO PISTONS WITH GAPS ORIENTATED AS SHOWN.

6150 RGPST COMPR UPR INSTALL EITHER DIRECTION NOTE: PISTON RING END GAP MEASURED AT 89.000 GAGE DIAMETER COMPRESSION RING END GAP UPPER 0.10 0.25 LOWER 0.27 0.42 OIL RING SEGMENT END GAP 0.150.65

.04.075 .04.085

6152 RGPST COMPR LWR ASSEMBLE WITH "0" MARK ON RING SIDE FACE UP TOWARDS TOP OF PISTON

6161 SPCRPST OIL CNTR RG SEG (ORIENT THE GAP SUCH THAT THE CUT ENDS ARE POINTED TOWARDS THE TOP OF PISTON) 6159 SEGPST UPR OIL CNTR RG UPR (2) PLACES NOTE: FOR INSTALLATION OF UPPER AND LOWER COMPRESSION RINGS UTILIZE RING EXPANDER TOOL.

VIEW A

RGPST COMPR UPR GAP LOCATION (RETPST PIN) 30 (PINPST) SEGPST UPR OIL CONTR RG UPR GAP LOCATION (UPPER) 30

CENTER LINE OF PISTON PARALLEL TO WRIST PIN BORE

SEGPST UPR OIL CONTR RG UPR GAP LOCATION (LOWER)

EXPANDER RING AND RGPST COMPR LWR GAP LOCATION VIEW B

NE01E10854730000

2001 3.0L4V D186

981111

73C

IL1F1E030002E0543F

8A

8B
.75

PISTON & CONNECTING ROD ASY, BEARINGS AND CAP

NOTE: 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. FRONT OF ENGINE VIEW A 6210 CAPCONN ROD (6) REQ

(GUIDE TOOL)

6211 BRGCONN ROD (6) REQ

6100 PST & CONN ROD ASY (6) REQ 6211 BRGCONN 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) (BLK ASYCYL)

F2LE6214BA (11mm HEX) MJ9 X 1 X 40 BOLT PILOT (2) PER CAP (PART OF 6200 ASY) TORQUE TO YIELD

PRODUCTION RUNDOWN METHOD

PRETORQUE 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 2025 Nm . THEN TORQUE BOTH FASTENERS 4045 Nm . THEN ROTATE 90 120 (BRGCONN ROD) (CAP)

1 4 2 5 3

(2 MAX)

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)

NE01E10854730000

2001 3.0L4V D186

981111

73C

IL1F1E030002E0543F

8B

8C
.35

PISTON & CONNECTING ROD ASY (CLEARANCES)

DIMENSION "Z"TWO READINGS FRONT AND REAR D DIMENSION "Z" TOP OF BLOCK (DECK) (BLK ASYCYL)

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

C L OF PISTON PARALLEL WITH C L OF CRANKSHAFT

ASSEMBLE WITH ARROW TOWARDS FRONT OF ENGINE VIEW C

(PST ASY)

BLOCK GRADE CYLINDER BORE DIAMETER

1 2 3 89.00089.010 89.01089.020 89.02089.030

PISTON DIAMETER UNCOATED

88.97088.980 88.97888.992 88.99089.000

PISTON DIAMETER COATED

88.99089.010 88.99889.022 89.01089.030

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 (BLK ASYCYL) (PST & CONN ROD ASY) (ROD ASYCONN) IDENTIFICATION ON CAP AND ROD MUST REMAIN ALIGNED AND RETAINED AS A MATCHED SET

(CRKSHT)

(BRGCONN ROD) (CRKSHT) 49.9550.05 (BLK ASYCYL GAGE LOCATION) A VERTICAL DIAMETRICAL BEARING ASSEMBLED CLEARANCE (0.0280.066) (BRGCONN ROD) C L OF CRKSHT (CAP) ROD ASYCONN TO CRKSHT SIDE CLEARANCE 0.100.30 VIEW A

SECTION D

NE01E10854730000

2001 3.0L4V D186

981111

73C

IL1F1E030002E0543F

8C

9
.50

OIL PUMP ASY (LESS SCREEN & COVER ASY)

6621 PMP ASYOIL LS SCRN & CVR

4 FRONT OF ENGINE

(BLK ASYCYL)

W500300 M6 X 1 X 33.25 BOLT HEX FLANGE HD TORQUE 812 Nm (4) REQ

ASSEMBLY PROCEDURE
1. 2. 3. ROTATE INNER ROTOR OF PMP ASYOIL LS SCRN & CVR (6621) TO ALIGN WITH FLATS ON CRANKSHAFT POST. ALIGN PMP ASYOIL LS SCRN & CVR WITH CRANKSHAFT AXIALLY AND CAREFULLY INSTALL ONTO CRANKSHAFT UNTIL SEATED AGAINST CYLINDER BLOCK ASY INSTALL (4) M6 BOLTS AND TORQUE TO SPECIFICATION.

NE01E10854730000

2001 3.0L4V D186

981111

73C

IL1F1E030002E0543F

10
.7

OIL PAN BAFFLE

J3

6687 BAFOIL PAN W701542 M6 X 1 NUT HEX FLANGE TORQUE 5 Nm THEN ROTATE 45 (4) REQ

(HSGENG BLKHD STUD (4) PLACES)

J2

FRONT OF ENGINE

NE01I10880558019

2001 3.0L4V D186

991213

73C

IL1F1E030002E0543F

J3

10

10A
.6

OIL PAN BAFFLE

W701582 (13 mm HEX) M8 X 1.25 NUT HEX FLANGE TORQUE 10 Nm THEN ROTATE 45 (3) REQ

J14

6687 BAFOIL PAN

(HSGENG BLKHD STUD (3) PLACES)

FRONT OF ENGINE

NE01I10880558019

2001 3.0L4V D186

991213

73C

IL1F1E030002E0543F

J14

10A

11
.6

OIL PUMP SCREEN & COVER ASY

6622 SCRN & CVR ASY OIL PUMP

J5

J4

W701582 M8 X 1 NUT HEX FLANGE TORQUE 10 Nm THEN ROTATE 45 W700005 M6 X 1 X 25.25 BOLT HEX FLANGE HD PILOT TORQUE 812 Nm (2) REQ

(HSGENG BLKHD STUD)

J2

(PMP ASYOIL)

FRONT OF ENGINE

J11
(SCRN & CVR ASY OIL PUMP) 1.

ASSEMBLY PROCEDURE
J6
2. INSERT SCRN & CVR ASYOIL PUMP (6622) TUBE END INTO OIL PUMP ASY AND SUPPORT BRACKET ONTO MAIN BEARING STUD. INSTALL (2) M6 BOLTS AND (1) M8 NUT AS SHOWN AND TORQUE TO SPECIFICATION.

(O" RING PART OF 6622 ASY)

VIEW A

NE01I10880558019

2001 3.0L4V D186

991213

73C

IL1F1E030002E0543F

J11

11

12
.6

OIL SEPARATOR ASY, WATER INLET TUBE AND CUP PLUG

(INSTALLATION TOOL) W701504 M6 X 1 X 23.25 BOLT & WASHER HEX HD PILOT TORQUE 812 Nm (2) REQ

8A505 TUBWTR INLT NOTE: INSTALL TO A HEIGHT OF 37.538.5

6B673 SEP ASYOIL APPLY 2mm BEAD OF WSKM2G349A7 SEALER

6B752 GSKTOIL SEP (BLK ASYCYL) W701923 35mm CUP PLUG F3 (APPLY 2mm BEAD OF WSKM2G349A10 SEALER TO CUP PLUG OR BORE) FRONT OF ENGINE

(TUBWTR INLT) (CYLINDER BLOCK ASY) (38.5 37.5)

J7

(CUP PLUG)

(11.0 9.0)

(BLK ASYCYL) VIEW A SECTION B

NE01I10880558019

2001 3.0L4V D186

991213

73C

IL1F1E030002E0543F

J7

12

13
.7

CYLINDER HEAD ASY PIPE PLUGS AND DOWELS

6050 HD ASYCYL LH W701515 1/418 INCHES PLUG HEADLESS SOCKET HEX TORQUE 14 Nm THEN ROTATE 180 (2) REQ

A
6049 HD ASYCYL FRONT OF ENGINE W701518 111.5 INCHES PIPE PLUG TORQUE 90 Nm THEN ROTATE 180 (2) REQ W701515 1/418 INCHES PLUG HEADLESS SOCKET HEX TORQUE 14 Nm THEN ROTATE 180 (2) REQ

(30.0 29.0)

W701501 DOWEL (10 X 49.25) (2) REQ

(DOWEL) (HD ASYCYL) SECTION A TYPICAL (2) PLACES 6049 HD ASYCYL

6050 HD ASYCYL LH

FRONT OF ENGINE W701515 1/418 INCHES PLUG HEADLESS SOCKET HEX TORQUE 14 Nm THEN ROTATE 180 (3) PLACES LH CYLINDER HEAD ASY (2) PLACES RH CYLINDER HEAD ASY

NE01E10854730000

2001 3.0L4V D186

981111

73C

IL1F1E030002E0543F

13

13A
.4

CYLINDER HEAD ASY VALVES AND SPRINGS

6518 KEYVLV SPG RET (24) REQ MUST BE PROPERLY SEATED 6513 6C501 SPECSPGVLV ADJ ASYVLV LSH (12) REQ (12) REQ NOTE: ADJ ASYVLV LSH MUST BE PUMPED UP PRIOR TO INSTALLATION.

6514 RETVLV SPG (12) REQ RIGHT SIDE LEFT SIDE (GARTER SPRING) 6A517 SE ASYVLV STM (12) REQ MUST BE INSTALLED BEFORE INSERTING VALVE (6507/6505) AND BOTTOMED ON VALVE GUIDE NOTE: GARTER SPRING MUST BE PRESENT SHOWN TYPICAL

FRONT OF ENGINE

6049 HD ASYCYL

6505 VLVEXH (6) REQ

NOTE: APPLY WSEM2C908A OIL TO ENTIRE ID 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 VLVINTK (6) REQ

VALVE SPRING INSTALLED HEIGHT (SERVICE/AUDIT)

TOP OF SPRING (HD ASYCYL) HEAD ASY)

INSTALLED SPRING HEIGHT (SEE CHART)

SPRING SEAT

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

GAGE LINE

VALVES
FOR 95% PRODUCTION FOR 100% PRODUCTION

INTAKE AND EXHAUST ALL

39.6940.29 39.4940.49

INSTALLED SPRING HEIGHT

NE01E10854730000 2001 3.0L4V D186

981111

73C

IL1F1E030002E0543F

13A

13B
.5

CYLINDER HEAD GASKETS

NOTE: GASKET MUST BE SNAPPED OVER DOWELS, BOTH HOLES AT ONCE. RIGHT SIDE LEFT SIDE SHOWN TYPICAL

6051 GSKCYL HD

W704688 DOWEL HOLLOW (16 X 19) (2) REQ AS SHOWN (EACH SIDE) NOTE: MUST BE BOTTOMED (SEE SECTION C )

(BLK ASYCYL)

FRONT OF ENGINE

(BLK ASYCYL) FRONT OF ENGINE

(9.0 8.0) DOWEL VIEW A (GSKTCYL HD) 6051 VIEW B (GSKTCYL HD LH) 6083 SECTION C

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.6

CYLINDER HEAD ASY

RIGHT SIDE LEFT SIDE SHOWN TYPICAL 6065 M10 X 1.5 X 154.8 BOLT & WASHER ASY HEX FLANGE HD PILOT (8) REQ PER HEAD REMOVE THRUST CAPS, SHIP ON PALLET AND NESTED OVER CAMSHAFTS NOTE: SEE FRAME 13D FOR ASSEMBLY PROCEDURE

6049 HD ASYCYL 6050 HD ASYCYL LH

(DOWEL 16 X 19) (2) PLACES

(GSKTCYL HD)

FRONT OF ENGINE

(BLK ASYCYL)

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13D
.52

CYLINDER HEAD ASY (TORQUE SEQUENCE)

SINGLE WRENCH CYLINDER HEAD TORQUE SEQUENCE

FRONT OF ENGINE

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.

J8

J8

MULTISPINDLE CYLINDER HEAD TORQUE SEQUENCE

FRONT OF ENGINE

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 )

H1

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13D

13E
.4

CAMSHAFT ASY PREASSEMBLY TIMING MARK ALIGNMENT (REFERENCE ONLY)

1.

SET CRANKSHAFT AT 43 +/ 5

B.T.D.C.

2. INSTALL CAMSHAFTS INTO CYLINDER HEADS WITH TIMING MARKS AS SHOWN. 3. ROTATE CRANKSHAFT TO 5 B.T.D.C.

93.28

96.18

4.02
RE F

RF

6.91

DA

MB
DAM B

RF F

DA

MB

DAM

RF

35 T.D.C.

CRKSHT KEY AT 35 ( 5 B.T.D.C.)

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13F
.35

CAMSHAFT ASY, BEARING CAPS AND VALVE ROCKER ARM ASY

QUALITY AUDIT ONLY RIGHT SIDE LEFT SIDE SHOWN TYPICAL 0.501.11 GAP MEASURED ON CAP BASE CIRCLE WITH ADJUSTER FULLY COLLAPSED. (ARM ASYVLV RKR) (C/SHT)

W705391 M6 X 1 X 43.75 BOLT HEX FLANGE HD PILOT TORQUE 812 Nm (16) REQ 6A258 CAPC/SHT BRG (6)REQ

VIEW FOR GAP

6B280 CAP ASYC/SHT BRG (2) REQ

6A266 C/SHT ASYINTK RH 6A267 C/SHT ASYINTK LH

(ARM ASYVLV RKR)

6529 ARM ASYVLV RKR (12) REQ NOTE: DIP ENTIRE FOLLOWER IN WSEM2C908A OIL PRIOR TO INSTALLATION.

FRONT OF ENGINE

(HD ASYCYL)

(ADJ ASYVLV LSH) (12) PLACES

1 NOTE:

CAP TO BE INSTALLED LAST & REMOVED FIRST

1
NOTE: LUBRICATE CAMSHAFT JOURNALS AND LOBES WITH WSEM2C908A OIL PRIOR TO INSTALLATION.

6A268 C/SHT ASYEXH RH 6A269 C/SHT ASYEXH LH

NOTE: SEE FRAME 13G FOR ASSEMBLY PROCEDURE & TORQUE SEQUENCE

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.5

CAMSHAFT ASY, BEARING CAPS AND VALVE ROCKER ARM ASY (Continued)
11 12 1L #1 #5 5L 1 1 2 2 5R #5 #1 1R 10 ORANGE STRIPE FRONT OF ENGINE 9

13 14 2L

(THRUST CAP) 6L

3 4

3 4 ORANGE STRIPE 6R

(THRUST CAP) 2R

11 12

E1

15 16 3L 7L

13 7R 3R 14

E1
6 6

ORANGE STRIPE 17 18 4L 8L 7 8 7 8 8R 4R 15 16

9L ORANGE STRIPE

10

E1

CAMSHAFT BEARING CAP TORQUE SEQUENCE ASSEMBLY PROCEDURE

1. 2. LOAD (12) ADJ ASYVLV LSH (6C501) IN CYLINDER HEADS. NOTE: REINSTALL CAMSHAFT BEARING CAPS AT THEIR CORRECT NUMBERED LOCATION

APPLY WSEM2C908A OIL TO CAMSHAFT JOURNALS, LOBES, VALVE TIP PADS, ROLLER FOLLOWER SURFACES, ADJUSTER SOCKETS AND #1 CAMSHAFT CAP THRUST GROOVE PRIOR TO INSTALLATION. LOAD (12) ARM ASYVLV RKR (6529), AND C/SHTS (6A266 INT RH 6A267 INT LH, 6A268 EXH RH & 6A269 EXH LH) 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 CAP ASYC/SHT BRG (6B280) LAST AND REMOVE IT FIRST. LOAD (12) ADJ ASYVLV LSH (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) ARM ASYVLV RKR (6529), AND C/SHTS (6A266 INT RH 6A267 INT LH, 6A268 EXH RH & 6A269 EXH LH) INTO CYLINDER HEADS WITH TIMING MARKS AS SHOWN FRAME 13E. POSITION CAMSHAFT CAPS OVER CAMSHAFTS, ENGAGING DOWELS IN CAM TOWERS. SNUG DOWN ALL CAPS BOLTS DIAGONALLY FROM THE 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 mm 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.

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13G

14
.35

SPARK PLUG ASY

RIGHT SIDE LEFT SIDE SHOWN TYPICAL

E2 N2

N3
12405 SP/PLG ASY TORQUE 920 Nm (6) REQ

(HD ASYCYL)

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)

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N3

14

15
.70

TIMING CHAIN, GUIDE, TENSIONER, TENSIONER ARM AND CRANKSHAFT GEAR

(C/SHT ASYINTK LH) (DOWEL) (2) PLACES (C/SHT ASYEXH LH)

6L253 ARMTM CHN TENS

6K297 GID TM CHN

6L266 TENSTM CHN

(CRKSHT)

J9
FRONT OF ENGINE

6306 GRCRKSHT

1 W701524
M8 X 1.25 X 49.3 BOLT & WASHER HEX FLANGE HD PILOT TORQUE 2030 Nm (4) REQ COLOR CODE: GOLD

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

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15

15A
.5

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

1. ROTATE CRANKSHAFT 120 CLOCKWISE TO 115 ATDC 2. INSTALL RH CAM DRIVE COMPONETS.

93.28

36.18

RE F
DAM

6.91

FFR

64.02

RE

DAM

TIMING MARK AT 115 CRKSHT KEY AT 85 (115 ATDC)

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RFF

DA MB

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15A

15B
.35

TIMING CHAIN, GUIDE, TENSIONER, TENSIONER ARM AND CRANKSHAFT GEAR

(C/SHT ASYEXH RH) (C/SHT ASYINT RH)

6K297 GIDTM CHN

6L253 ARMTM CHN TENS

W701232 M8 X 1.25 X 36.3 BOLT & WASHER HEX FLANGE HD PILOT TORQUE 2030 Nm (2) REQ

(DOWEL) (2) PLACES FRONT OF ENGINE

J2

(CRKSHT) 6L266 TENSTM CHN

J10

6306 GRCRKSHT W701524 M8 X 1.25 X 49.3 BOLT & WASHER HEX FLANGE HD PILOT TORQUE 2030 Nm (2) REQ COLOR CODE: GOLD

1
6268 CHNTM NOTE: ALIGN TIMING LINKS WITH TIMING MARKS ON SPROCKETS

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15B

15C
.5

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

NOTE: TYPICAL ALIGNMENT WHEN ROTATED BACK COUNTERCLOCKWISE TO TDC NOTE: AT TDC ALL (4) CAMSHAFT SPROCKETS ALIGN WITH ARROWS LOCATED ON THE BACK OF THE SPROCKETS.

35.78 93.68

A
6.52

BM AD

RE F

DA

MB

64.41

RE

TIMING MARK AT 130

BMA

FF

DA M

DA

MB

FF R

(T.D.C.)

DA

VIEW A REAR VIEW

RF

VIEW B REAR VIEW

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RF F

FF

RF F

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15C

16
.35

ENGINE FRONT COVER ASY AND IGNITION PULSE CRANKSHAFT SENSOR RING
(HD ASYCYL) (HD ASYCYL) WSEM4G323A6 SEALER

(BLK ASYCYL) VIEW A (TYPICAL) APPLY 6mm DIAMETER DOT (APPROX) OF WSEM4G323A6 SEALER ON CYLINDER HEAD & CYLINDER BLOCK INTERSECTION. A (4) PLACES A NOTE: USE ORANGE PAINT STRIP (BLK ASYCYL)

A A

WSEM4G323A6 SEALER

C B

(HSGENG BLKHD) VIEW B (TYPICAL) APPLY 6mm DIAMETER DOT (APPROX) OF WSEM4G323A6 SEALER TO CYLINDER BLOCK & BULKHEAD HOUSING INTERSECTION. (2) PLACES B B NOTE: TORQUE FASTENERS WITHIN (6) MINUTES OF APPLYING WSEM4G323A6 SEALER.

C2

(CRKSHT) (HSGENG BLKHD) 12A227 IGNITION PULSE RING

(BLK ASYCYL) IGNITION PULSE RING NOTE: THE PULSE RING TEETH MUST FACE FORWARD

6C086 CVR ASYENG FRT

FRONT OF ENGINE VIEW C

L4 P1

C1

FRONT OF ENGINE

FOR FASTENER LOCATION AND TORQUE SEQUENCE SEE FRAME 16A.

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P1

16

16A
.45

ENGINE FRONT COVER ASY (FASTENERS & TORQUE SEQUENCE)

NOTE: TORQUE IN THIS SEQUENCE 116.

14

P1

15 10

4 11 3 16

13

E4

9 12

1 2

L4
6 5

E5

VIEW FRONT OF COVER

HOLE NO.
E4
1

FASTENER

DESCRIPTION
M8 X 1.25 X 47.5 / M6 X 1 X 20 STUD HEX SHOULDER PILOT M8 X 1.25 X 51.8 BOLT & WASHER ASY HEX FLANGE HD PILOT M8 X 1.25 X 68 / M8 X 1.25 X 26 STUD HEX SHOULDER PILOT M8 X 1.25 X 34.3 BOLT & WASHER ASY HEX FLANGE HD PILOT

W701712 234 5810 111213 141516

W701525

E5

6 W701581

79 W701240 NOTE: TORQUE ALL FASTENERS (2030 Nm)

= STUD = BOLT

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P1

16A

17
.45

WATER PUMP ASY

FRONT OF ENGINE

(TUBWTR INLT)

(HD ASYCYL LH)

N4
W701544 M6 X 1 X 69.25 BOLT & WASHER ASY HEX FLANGE HD PILOT TORQUE 10 Nm THEN ROTATE 85 95 (3) REQ

8501 PMP ASYWTR NOTE: FOR ASSEMBLY AID SEE FRAME 3

ASSEMBLY PROCEDURE
1 1. INSTALL PMP ASYWTR (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.

VIEW A

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

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

NOTE: ENGAGEMENT SPECIFICATIONS FOR 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.

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N4

17

18
.5

WATER BYPASS TUBE ASY

NOTE: PARTS MARKED 1 ARE PIA TO WATER BYPASS TUBE ASY

(HD ASYCYL)

FRONT OF ENGINE

N4

1 (12A648
SNS ASYENG ELETR CONTR COOL TEMP)

N17
(HD ASYCYL LH) W701632 M6 X 1 X 32.5 / M5 X 0.8 X 17.5 STUD HEX FLANGE TORQUE 812 Nm

N5 1 "O" RING (2) REQ

APPLY ESEM99B176A LUBRICANT NOTE: VISUALLY INSPECT "O" RINGS AND SURFACES FOR CONTAMINATION PRIOR TO INSTALLATION.

E6

8548 TUB ASYWTR BYP

W701669 M6 X 1 X 33.25 BOLT HEX FLANGE HD TORQUE 812 Nm

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N17

18

19
.6

CRANKCASE EMISSION VALVE TO INTAKE MANIFOLD HOSE

NOTE: REFER TO FRAME 63 FOR INSTALLATION OF THIS END

J13

6K817 HOSCRKC EMS VLV TO INTK MANF NOTE: ASSEMBLY AID SEE FRAME 3

E7

FRONT OF ENGINE

(SEP ASYOIL)

N4

E8 N5

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N5

19

20
.9

OIL PAN ASY

NOTE: PARTS MARKED 1 TO OIL PAN ASY

ARE PIA

NOTE: ALIGN TRANSMISSION MOUNTING FACE OF OIL PAN WITH REAR FACE OF CYLINDER BLOCK. IT SHOULD HAVE A MAXIMUM MISMATCH OF 0.25mm UNDERFLUSH. IF STEP IS GREATER THAN ABOVE IT WILL REQUIRE SHIMMING. (SEE FRAME 20A)

= BOLT = STUD

E8

(HSGENG BLKHD)

(CVR ASYENG FRT)

1 (6710
GSKTOIL PAN) 7 6

5 4 3 2 1 FRONT OF ENGINE

A
8 9 10 11 14 15

6675 PAN ASYOIL

A
12

1 (W701605
M8 X 1.25 X 33 BOLT HEX FLANGE HD) TORQUE 2030 Nm (13) REQ

1 (DRAIN PLUG)
TORQUE 2230 Nm

13

1 (W701606
M8 X 1.25 X 33 / M6 X 1 X 22.5 STUD HEX SHOULDER PILOT) TORQUE 2030 Nm (2) REQ

2 WSEM4G323A6
SEALER

2 NOTE:
APPLY A 10mm DIAMETER DOT (APPROX) OF WSEM4G323A6 SEALER TO THE GSKTOIL PAN (6710) IN (2) LOCATIONS. SEE VIEW A

1 (6710
GSKTOIL PAN) VIEW A TYPICAL (2) PLACES

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

N6

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20

20A
.45

OIL PAN ASY (Continued)

ASSEMBLY PROCEDURE
1. ENSURE THAT GSKTOIL PAN (6710) IS CORRECTLY ASSEMBLED TO PAN ASYOIL (6675). 2. APPLY SEALER TO OIL PAN GASKET AS INDICATED ON FRAME 20. 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. 7. ACCEPT ALL ASSEMBLIES THAT GAGE 0.00 TO 0.25mm . 8. ASSEMBLIES THAT GAGE BETWEEN 0.26 AND 0.50mm UNDERFLUSH TO THE REAR FACE OF BLOCK MAY BE REPAIRED BY USING (1) OR (2) 0.25mm SHIMS (SILVER) ON EACH AFFECTED SIDE OF THE OIL PAN. 9. ASSEMBLIES THAT GAGE BETWEEN 0.51 AND 0.75mm UNDERFLUSH TO THE REAR FACE OF BLOCK MAY BE REPAIRED BY USING (1) OR (2) 0.50mm SHIMS (GOLD) ON EACH AFFECTED SIDE OF THE OIL PAN. 10. IF THE STEP GAGES GREATER THAN 0.75mm UNDERFLUCH OR IF TRANSMISSION MOUNTING FACE PROTRUDES OVERFLUSH TO REAR FACE OF CYLINDER BLOCK, THEN THE OIL PAN MUST BE REMOVED AND REPLACED AND THE ENTIRE ASSEMBLY PROCEDURE REPEATED.

SERVICE AUDIT
1. INSTALL OIL PAN TO TRANSMISSION RETAINING FASTENERS FINGER TIGHT. THIS WILL ALIGN THE TWO FACES PRIOR TO TORQUING OIL PAN. 2. TIGHTEN OIL PAN FASTENERS TO SPECIFICATION, THEN TIGHTEN TRANSMISSION TO OIL PAN FASTENERS.

FRONT OF ENGINE

(PAN ASYOIL) NOTE: IF LH SIDE IS SHIMMED, (2) SHIMS MUST BE USED ONE IN EACH LOCATION. 6C629 SPCRENG OIL PAN (SILVER) 6C629 SPCRENG OIL PAN (GOLD)

N7

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20A

21
1

CRANKSHAFT FRONT OIL SEAL ASY

(CRKSHT) 6700 SE ASYCRKSHT FRT OIL NOTE: LUBRICATE SEAL BORE IN COVER BEFORE INSTALLING. (STEP 2)

(INSTALLATION TOOL)

SURFACE "S"

E8

FRONT OF ENGINE

ASSEMBLY PROCEDURE
1. CHECK RELATIONSHIP OF SEAL BORE TO CENTERLINE OF CRANKSHAFT. 2. APPLY WSEM2C908A OIL TO THE ID OF THE CRANKSHAFT SEAL BORE (IN FRONT COVER ASY). 3. INSTALL SE ASYCRKSHT FRT OIL (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). 4. CHECK SEAL SQUARENESS.

CRANKSHAFT FRONT OIL SEAL ASY (SQUARENESS AND CONCENTRICITY SERVICE AUDIT)
(DAMPER SEALING SURFACE) C L OF CRANKSHAFT (CRKSHT)

(CRKSHT)

0.50 FIM

0.50 FIM (CVR ASYENG FRT) FRONT OF ENGINE SECTION A (DIAL INDICATOR) FRONT OF ENGINE

DO NOT EXCEED THE FOLLOWING SPECIFICATIONS:

1. 0.50 FIM OF FRONT COVER SEAL BORE IN RELATION TO FRONT FACE OF CRANKSHAFT (SEAL MUST NOT BE INSTALLED) SEE SECTION A. 2. 0.50 FIM OF SEAL FRONT FACE SURFACE IN RELATION TO SEALING SURFACE OF DAMPER.

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21

22
.45

CRANKSHAFT VIBRATION DAMPER ASY

(CRKSHT) 6316 DMPR ASYCRKSHT VIB NOTE: COAT SEAL SURFACE ON O.D. OF DAMPER WITH WSEM2C908A OIL PRIOR TO INSTALLATION. NOTE: INSTALL AT A MAXIMUM PRESS FORCE OF 19,125 N.

W701511 FLAT WASHER

E8
FRONT OF ENGINE

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

INSTALLATION SEQUENCE
N8
1. 2. 3. 4. SEAL SURFACE MUST BE FREE OF DIRT AND OIL. APPLY WSEM4G323A6 SEALER TO CRANKSHAFT DAMPER. SEE VIEW INSTALL DMPR ASYCRKSHT VIB (6316) AS SHOWN. TORQUE M12 BOLT TO SPECIFICATION.

(KEYWAY)

(DMPR ASYCRKSHT VIB)

(DMPR ASYCRKSHT VIB)

B

N9

N10

NOTE: APPLY WSEM4G323A6 SEALER TO KEYWAY SLOT PRIOR TO DAMPER AND BOLT INSTALLATION. SEAL SURFACE MUST BE FREE OF DIRT AND OIL. (CRKSHT) VIEW B SECTION A

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N10

22

23
.6

CAMSHAFT TIMING SENSOR ASY

(CVR ASYENG FRT)

6B288 SNS ASYC/SHT TIM

L5

FRONT OF ENGINE

W500214 M6 X 1 X 23.25 BOLT HEX FLANGE HD PILOT TORQUE 812 Nm

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L5

23

24
1

CYLINDER BLOCK OPENING COVER

FRONT OF ENGINE

6C070 CVRCYL BLK OPG

(HSGENG BLKHD)

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24

25
1

OIL LEVEL INDICATOR TUBE ASY

FRONT OF ENGINE

(HD ASYCYL LH)

6754 TUB ASYOIL LVL IND

W701822 M6 X 1 X 12.35 M6 X 1 X 20.42 STUD & WASHER HEX FLANGE HD PILOT TORQUE 812 Nm

(HSGENG BLKHD)

6754 TUB ASYOIL LVL IND NOTE: LUBRICATE "0" RING WITH WSEM2C908A OIL PRIOR TO INSTALLATION. NOTE: MUST BE BOTTOMED OUT AS SHOWN (HSGENG BLKHD)

SECTION A

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26
.6

CRANKSHAFT TIMING SENSOR ASY

(CVR ASYENG FRT)

6C315 SNS ASYCRKSHT TIM

E8
FRONT OF ENGINE W500214 M6 X 1 X 23.25 BOLT HEX FLANGE HD. PILOT TORQUE 812 Nm

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E8

26

27
1

CRANKCASE OIL COOLER ASY AND OIL FILTER ASY

(INSERTOIL FLTR)

FOR 850 ONLY

FRONT OF ENGINE

(LOCATING PIN)

6A642 COOL ASYCRKC OIL NOTE: POSITION TUBES AS SHOWN

FOR 856 ONLY

A

(GASKET PART OF 6A642 ASY) NOTE: LUBRICATE GASKETS OR SEALING SURFACES WITH WSEM2C908A OIL PRIOR TO INSTALLATION

(INSERTOIL COOL PART OF 6A642 ASY) TORQUE 5560 Nm

(COOL ASYCRKC OIL)

FOR 856 ONLY

(GASKET PART OF 6714 ASY) NOTE: LUBRICATE GASKETS OR SEALING SURFACES WITH WSEM2C908A OIL PRIOR TO INSTALLATION 6714 FLTR ASYOIL TORQUE 1417 Nm (LOCATING PIN)

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

NE01E10854730000

2001 3.0L4V D186

981111

73C

IL1F1E030002E0543F

27

28
.75

VALVE ROCKER ARM COVER ASY & CAMSHAFT SEAL REAR RETAINER ASY
LEFT SIDE RIGHT SIDE SHOWN TYPICAL (BLK ASYCYL) (PILOT TOOL) 6B293 RET ASYC/SHT SE RR NOTE: INSTALL PRIOR TO CAMSHAFT COVER ASY NOTE: USE A PILOT TOOL TO PROTECT "LIP" FROM DAMAGE. W701242 M6 X 1 X 43.25 BOLT & WSHR HEX FLNG HD PILOT TORQUE 812 Nm (2) REQ

2 6766
CAP ASYOIL FILL (PART OF 6A505 ASY)

6A505 CVR ASYVLV RKR ARM LH 6582 CVR ASYVLV RKR ARM

G3

VIEW A

2 M5 X 0.8 X 21
M6 X 1 X 34 STUD HEX FLNG PILOT TORQUE 812 Nm (8) REQ (LH) (9) REQ (RH)

E10

1 2 M6 X 1 X 34 BOLT
HEX FLNG PILOT TORQUE 812 Nm (3) REQ (LH) (1) REQ (RH)

FRONT OF ENGINE

E10
NOTE: SEE FRAME 28A FOR TORQUE SEQUENCE.

1
(RET ASYC/SHT SE RR) (HD ASYCYL LH)

G1

NOTE: DO NOT EXCEED 45 MINUTE MIN DURATION BEFORE FINAL TORQUE SPEC IS ACHEIVED 1 NOTE: APPLY 8mm DIAMETER DROP OF WSEM4G323A6 SEALER. TO FRONT COVER GASKET INTERSECTION (6) PLACES (2 PER RH VALVE COVER ASY). (4 PER LH VALVE COVER ASY).

1 (CVR ASYENG FRT) NOTE: PARTS MARK 2 ARE PIA TO VALVE ROCKER ARM COVER ASY

NOTE: TORQUE ALL VALVE COVER FASTENERS WITHIN (6) MINUTES OF APPLYING G2 WSEM4G323A6 SEALER WHEN (6) MINUTE CRITERIA CANNOT BE MET: PRETORQUE ALL FASTENERS TO 3 Nm.

NE01E10924472000

2001 3.0L4V D186

990719

73C

IL1F1E030002E0543F

G3

28

28A
.5

VALVE ROCKER ARM COVER ASY (Continued) TORQUE SEQUENCE

= STUD = BOLT

8 4

10 2

K2

1 10 7

11

K1
1

E10

6 6582 CVR ASYVLV RKR ARM

5 7 FRONT OF ENGINE 6A505 CVR ASYVLV RKR ARM LH

G3

NE01E11029769000

2001 3.04V D186

000225

73C

IL1F1E030002E0543F

K2

28A

29
.35

FLYWHEEL ASY

(BLK ASYCYL) FRONT OF ENGINE

6375 FL/WHL ASY

(CRKSHT)

W701559 M10 X 1 X 20 BOLT HEX LOCK HD PILOT TORQUE 7387 Nm (8) REQ

NE01E10854730000

2001 3.0L4V D186

981111

73C

IL1F1E030002E0543F

29

30
.6

ENGINE CODE DECAL

(CVR ASYVLV RKR ARM LH)

ENGINE CODE DECAL LOCATE IN THIS AREA

L5

FRONT OF ENGINE

NOTE: DECAL INSTALLATION PROCEDURES 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 MISPOSITIONED) OR IF IT HAS DESTROYED ITSELF IN ANY WAY, IT MUST BE REMOVED AND REPLACED WITH A NEW DECAL.

NE01I10880558020

2001 3.0L4V D186

000418

73C

IL1F1E030002E0543F

L5

30

31
1

1. TO E/G/R VAC REG (FR 47C) WIRING ASYENGINE 2. TO ALT ASY (FR 64) 3. TO SNS ASYCRKSHT TIM (FR 47C) 4. TO CAP ASYRADO IGN INTFER (FR 47C) 5. TO IGN COIL ASY FRONT OF ENGINE (FR 47D) 6. TO VLV ASYIDL AIR CONTR (FR 45) 7. TO BDY ASYAIR INTK CHG THROT (FR 52) 8. TO TRNSDC ASYE/G/R (FR 62) 9. TO SNS ASYENG ELETR CONTR COOL TEMP (FR 45) 10. TO INJ ASYFUL (6) PLACES (FR 35) 11. TO SNS ASYC/SHT TIM (FR 39)

CONTROL SENSOR & FUEL CHARGING FOR 850 ONLY

1

ALL CONNECTORS MARKED 12 ARE B & A INSTALLED

NE01E11029769000

12 12

12

12

IL1F1E030002E0543F K3 31 31A
.45

E11
10

2001 3.0L4V D186

12

11

12 12 12

12 12
12 3

12 12 12 12

K3

000225 73C

12 12 12
12B637 WIR ASYENG CONTR SNS & FUL CHG

WIRING ASYENGINE CONTROL SENSOR & FUEL CHARGING FOR 856 ONLY
1. TO SNS ASYC/SHT TIM (FR 39) 2. TO ALT ASY (FR 64) 3. TO SNS ASYCRKSHT TIM (FR 47C) 4. TO CAP ASYRADO IGN INTFER (FR 47C) 5. TO IGN COIL ASY (FR 47D) 6. TO VLV ASYIDL AIR CONTR (FR 45) 7. TO BDY ASYAIR INTK CHG THROT (FR 52) 8. TO SNS ASYENG ELETR CONTR COOL TEMP (FR 45) 9. TO INJ ASYFUL (6) PLACES (FR 35)

ALL CONNECTORS MARKED 10 ARE B & A INSTALLED

NE01E11029769000

10
FRONT OF ENGINE

10

10
7

IL1F1E030002E0543F K3 31A 32
.45

E11

4
9

2001 3.0L4V D186

14

10

10

10

10 10
3

10

K3

000228
10 10
12B637 WIR ASYENG CONTR SNS & FUL CHG

10 10

73C

WIRING ASYENGINE CONTROL SENSOR & FUEL CHARGING

E28 K4

W701539 M5 X 1 NUT (TORQUE 23 Nm)

12B637 WIR ASYENG CONTR SNS & FUL CHG

FRONT OF ENGINE

(CVR ASYVLV RKR ARM)

G3

N5

K2

N4 E8
(TUB ASYWTR BYP)

NE01I10880558021

2001 3.0L4V D186

000612

73C

IL1F1E030002E0543F

N5

32

33
.45

IGNITION COIL & BOOT ASY

W701663 M5 X 26 SCREW & WASHER HEX FLANGE PILOT TORQUE 57 Nm (6) REQ

12A366 CIL & BT ASYIGN (6) REQ

FRONT OF ENGINE

(CVR ASYVLV RKR ARM LH)

E12
LEFT SIDE RIGHT SIDE SHOWN TYPICAL

NOTE: FOR CONNECTION TO WIRE HARNESS SEE FRAMES 47 & 47A

NE01I10880558010

2001 3.0L4V D186

990619

73C

IL1F1E030002E0543F

E12

33

34
.65

INTAKE MANIFOLD ASY (LOWER)

W706155 M6 X 1 X 81 BOLT HEX FLANGE PILOT (TORQUE 812 Nm) (8) REQ

9J447 MANF ASYINTK LWR

FRONT OF ENGINE

(HD ASYCYL)

K1

K2

G3
(HD ASYCYL LH)

NOTE: SEE FRAME 34A FOR TORQUE SEQUENCE

NE01E11029769000

2001 3.0L4V D186

000225

73C

IL1F1E030002E0543F

K2

34

34A
.55

INTAKE MANIFOLD ASY (LOWER) (TORQUE SEQUENCE)

FRONT OF ENGINE

9J447 MANF ASYINTK LWR

NE01E10854730000

2001 3.0L4V D186

981111

73C

IL1F1E030002E0543F

34A

35
.75

WIRING ASY CONNECTIONS FUEL INJECTOR ASY

TO INJ ASYFUL (6) PLACES

12B637 WIR ASYENG CONTR SNS & FUL CHG

1 4 2 5 3 6 (MANF ASYINTK LWR) RETAINER (2) PLACES

E8
5 3

RETAINER

(CAMSHAFT COVER ASY LH STUD)

FRONT OF ENGINE

NE01I10880558010

2001 3.0L4V D186

990619

73C

IL1F1E030002E0543F

E8

35

36
.8

INTAKE MANIFOLD ASY (UPPER)

9424 MANF ASYINTK

N11
(M6 X 1 X 49.5 BOLT HEX FLNG HD PILOT) TORQUE 812 Nm (8) REQ

(MANF ASYINTK LWR)

FRONT OF ENGINE

NOTE: SEE FRAME 36A FOR TORQUE SEQUENCE

E8

NE01I10880558021

2001 3.0L4V D186

000612

73C

IL1F1E030002E0543F

N11

36

36A
.55

INTAKE MANIFOLD ASY (UPPER) (TORQUE SEQUENCE)

FRONT OF ENGINE

(MANF ASYINTK)

N11

NE01I10880558021

2001 3.0L4V D186

000612

73C

IL1F1E030002E0543F

N11

36A

37
.65

IDLE AIR CONTROL VALVE ASY

W500214 M6 X 1 X 23.25 SCREW HEX FLNG HD PILOT TORQUE 812 Nm (2) REQ

FRONT OF ENGINE

9F715 VLV ASYIDL AIR CONTR

N11

(MANF ASYINTK)

NE01I10880558021

2001 3.0L4V D186

000612

73C

IL1F1E030002E0543F

N11

37

38
1

RADIO IGNITION INTERFERENCE CAPACITOR ASY

18801 CAP ASYRADO IGN INTFER

(CVR ASYENG FRT STUD) FRONT OF ENGINE W701542 M6 X 1 NUT HEX FLANGE FREE RUNNER TORQUE 812 Nm

E12

NE01I10880558010

2001 3.0L4V D186

990619

73C

IL1F1E030002E0543F

E12

38

39
1

WIRING ASY CONNECTIONS CAMSHAFT TIMING SENSOR ASY

(SNS ASYC/SHT TIM)

12B637 WIR ASYENG CONTR SNS & FUL CHG

L5

TO SNS ASYC/SHT TIM

FRONT OF ENGINE

NE01I10880558020

2001 3.0L4V D186

000419

73C

IL1F1E030002E0543F

L5

39

40
1

FUEL VAPOR RETURN TUBE ASY

N11

E8

(MANF ASYINTK)

E13
9G271 TUB ASY FU/VPR RTN NOTE: FOR ASSEMBLY AID SEE FR 3 (CVR ASYVLV RKR ARM STUD) (2) PLACES

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

FRONT OF ENGINE

NE01I10880558021

2001 3.0L4V D186

000612

73C

IL1F1E030002E0543F

N11

40

41
.9

CRANKCASE VENT TUBE ASY

6758 TUB ASYCRKC VEN NOTE: FOR ASSEMBLY AID SEE FRAME 3

N11

E8

(CAMSHAFT COVER ASY RH) FRONT OF ENGINE

NE01I10880558021

2001 3.0L4V D186

000612

73C

IL1F1E030002E0543F

N11

41

42
1

EXHAUST MANIFOLD STUDS

E8

(HD ASYCYL)

W701732 M8 X 1.25 X 58.1 STUD TORQUE 1013 Nm (6) REQ

FRONT OF ENGINE

NOTE: INSTALL SHORT END OF STUD INTO CYLINDER HEAD ASY

FRONT OF ENGINE

W701732 M8 X 1.25 X 58.1 STUD TORQUE 1013 Nm (6) REQ

(HD ASYCYL LH)

NE01I10880558010

2001 3.0L4V D186

990619

73C

IL1F1E030002E0543F

E8

42

43
.8

ENGINE LIFTING EYE (REAR)

FRONT OF ENGINE

(HD ASYCYL LH)

17A084 EYEENG LFT RR

W701627 M12 X 1.75 X 39.3 BOLT HEX FLNG HD PILOT TORQUE 100125 Nm

NE01E10854730000

2001 3.0L4V D186

981111

73C

IL1F1E030002E0543F

43

44
1

RADIO IGNITION INTERFERENCE CAPACITOR ASY

W701539 M5 X 0.8 NUT TORQUE 57 Nm

E12

18801 CAP ASY RADO IGN INTFER

FRONT OF ENGINE

(CVR ASYVLV RKR ARM LH STUD)

NE01I10880550010

2001 3.0L4V D186

990619

73C

IL1F1E030002E0543F

E12

44

45
1

WIRING ASY CONNECTIONS ENGINE ELECTRICAL CONTROL TEMP SENSOR ASY, IDLE AIR CONTROL VALVE AND COOLANT TEMP INDICATOR SENDER ASY

FRONT OF ENGINE

(VLV ASYIDL AIR CONTR)

N11

TO VLV ASYIDL AIR CONTR

M2

E11

TO SNS ASYENG ELETR CONTR COOL TEMP

N5

(SNS ASYENG ELETR CONTR COOL TEMP)

(B & A CONNECTION)

12B637 WIR ASYENG CONTR SNS & FUL CHG

NE01I10880558021

2001 3.0L4V D186

000626

73C

IL1F1E030002E0543F

N11

45

46
.75

EGR VACUUM REGULATOR CONTROL ASY FOR 850 ONLY

(MANF ASYINTK)

N11

M3

B2

9J459 CONTR ASYE/G/R VAC REG

FRONT OF ENGINE

W500204 M5 X 0.8 X 18.75 SCREW HEX FLANGE HD PILOT TORQUE 57 Nm (2) REQ

NE01I10880558021

2001 3.0L4V D186

000612

73C

IL1F1E030002E0543F

N11

46

47
.8

IGNITION COIL & BRACKET ASY

12A310 IGNITION COIL & BRACKET ASY

W701539 M5 X 0.8 NUT HEX FLANGE HD TORQUE 57Nm (2) REQ

(18801 RADIO CAPACITOR PART OF 12A310 ASY)

G4

E15

W701619 (13mm HEX) M6 X 20/M6 X 15 STUD & WASHER HEX FLNG PILOT TORQUE 812Nm

(CAMSHAFT COVER ASY RH)

FRONT OF ENGINE

(CYL HD ASYRH)

E8

NE01E10924472000

2001 3.0L4V D186

990802

73C

IL1F1E030002E0543F

G4

47

47A
.8

IGNITION WIRE ASY (LH) & FIRING ORDER

E16

6 5

N11

12281 IGNITION WIRE ASY (LH) NOTE; INSTALLED ON FRAME 47B 4

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

(CAMSHAFT COVER ASY RH)

E8

G4
(IGNITION COIL & BRACKET ASY) FRONT OF ENGINE

12280 IGNITION WIRE ASY (RH) 3 2 1

FIRING ORDER:

(IGNITION COIL ASY)

N12 1
NOTE: ASSURE SPARK PLUG WIRES ARE FULLY ENGAGED ON COIL TOWERS.

2 6

3
6

4
4

FRONT OF ENGINE

12281 IGINITION WIRE ASY (LH)

NE01I10880558021

2001 3.0L4V D186

000612

73

IL1F1E030002E0543F

N12

47A

47B
.6

IGNITION WIRE ASY (LH) (Continued)

12281 IGNITION WIRE ASY (LH)

FRONT OF ENGINE

(CVR ASYVLV RKR ARM) G3

E16

N5 K1 K2

N4

NE01I10880558021

2001 3.0L4V D186

000626

73

IL1F1E030002E0543F

N5

47B

47C
.6

IGNITION WIRE ASY (RH)

3
NOTE: SPARK PLUG BOOT MUST BE FULLY SEATED ON SPARK PLUG TO ASSURE BOOT UMBRELLA SEAL ON CAMSHAFT COVER ASY

12280 IGNITION WIRE ASY (RH)

3 2 1

N11

FRONT OF ENGINE

G4 (IGNITION COIL &

BRACKET ASY)

(CVR ASYVLV RKR ARM)

E3

NE01I10880558021

2001 3.0L4V D186

000612

73

IL1F1E030002E0543F

N11

47C

47D
.7

WIRING ASY CONNECTIONS

(WIR ASYENG CONTR SNS & FUL CHG)

N11
FRONT OF ENGINE (STUDVLV RKR ARM CVR ASY LH) (2) PLACES VIEW A

(BRKT ASYE/G/R VAC REG)

E14

(IGNITION COIL & BRACKET ASY)

RE

TO E/G/R VAC REG

(CAP ASYIGN RAD INTFER)

G4
12B637 WIR ASYENG CONTR SNS & FUL CHG TO COIL RADIO CAP

E17

E3

FRONT OF ENGINE

(SNS ASY CRKSHT TIM)

TO SNS ASY CRKSHT TIM

NE01I10880558021

2001 3.0L4V D186

000612

73

IL1F1E030002E0543F

N11

47D

47E
.7

WIRING ASY CONNECTIONS

N11

HEGO CONNECTOR 12B637 WIR ASYENG CONTR SNS & FUL CHG

(IGNITION COIL & BRACKET ASY)

G4

(CAMSHAFT COVER ASY RH)

FRONT OF ENGINE

E3

NE01I10880558021

2001 3.0L4V D186

000612

73C

IL1F1E030002E0543F

N11

47E

48
1

EXHAUST RECIRCULATING VALVE ASY FOR 850 ONLY

N11
FRONT OF ENGINE

(TUB ASYE/G/R OLET)

W701625 M8 X 1.25 X 39 BOLT & WASHER HEX FLANGE HD PILOT (PART OF 9D460 ASY) TORQUE 2030 Nm (2) REQ

E29

(9D476 GSKTE/G/R VLV PART OF 9D460 ASY)

9D460 VLV ASYEXH RECU

NE01E10880558021

2001 3.0L4V D186

000612

73C

IL1F1E030002E0543F

N11

48

48A
1

INTAKE MANIFOLD OPENING COVER ASY FOR 856 ONLY

FRONT OF ENGINE

N11

(TUB ASYE/G/R OLET)

W701625 M8 X 1.25 X 39 BOLT & WASHER HEX FLANGE HD PILOT (PART OF 9D440 ASY) TORQUE 2030 Nm (2) REQ

(9D476 GSKTCVR ASY PART OF 9D440 ASY) 9D440 CVR ASYINTK MANF OPG

NE01I10880558021

2001 3.0L4V D186

000612

73C

IL1F1E030002E0543F

N11

48A

49
1

OIL LEVEL INDICATOR ASY

6750 IND ASY OIL LVL NOTE: ORIENT AS SHOWN

G3

H11

FRONT OF ENGINE

(TUB ASYOIL LVL IND)

NE01E10924472000

2001 3.0L4V D186

990802

73C

IL1F1E030002E0543F

G3

49

50
1

EMISSION VACUUM CONTROL MAIN CONNECTOR ASY FOR 850 ONLY

NOTE: CRANKCASE VENT TUBE ASY MUST BE OUTBOARD OF VACUUM CONNECTOR ASY

9E498 CONN ASYEMS VAC CONTR MN NOTE: FOR ASSEMBLY AID SEE FRAME 3A

(VLV ASYEXH RECU)

1 N11
(BRKT ASYE/G/R VAC REG)

(MANF ASYINTK)

E8
FRONT OF ENGINE

NE01I10880558021

2001 3.0L4V D186

000612

73C

IL1F1E030002E0543F

N11

50

50A
.6

INTAKE MANIFOLD PORT PLUG FOR 856 ONLY

N11

(MANF ASYINTK)

PLUG

FRONT OF ENGINE

E8

NE01I10880558021

2001 3.0L4V D186

000612

73C

IL1F1E030002E0543F

N11

50A

51
.6

AIR INTAKE CHARGE THROTTLE BODY ASY

FRONT OF ENGINE

N11

E8
(MANF ASYINTK)

9E926 BDY ASYAIR INTK CHG THROT

W701632 M5 X 0.8 X 15 M6 X 1 X 30 STUD & WSHR HEX FLNG HD PILOT (TORQUE 812 Nm)

H4
W701669 M6 X 1 X 33.25 BOLT & WASHER HEX FLNG HD PILOT (TORQUE 812 Nm)

P5

NE01I10880558022

2001 3.0L4V D186

000823

73C

IL1F1E030002E0543F

P5

51

51A
1

FEAD TENSIONER ASY

(8mm HEX) HEX FLANGE HD PIA TO TENSIONER (TORQUE 2030 Nm)

6B209 TENSFEAD

(CVR ASYENG FRT)

FRONT OF ENGINE

P3

NE01I10880558022
VENGINE ILLUSTRATION

2001 3.0L4V D186

000823

73C

IL1F1E030002E0543F

P3

51A

52
.5

WIRING ASY CONNECTIONS AIR INTAKE CHARGE THROTTLE BODY ASY

FRONT OF ENGINE

TO BDY ASYAIR INTK CHG THROT

E8 N11

12B637 WIR ASYENG CONTR SNS & FUL CHG

H4

G5

(BDY ASYAIR INTK CHG THROT)

NE01E10880558021

2001 3.0L4V D186

000612

73C

IL1F1E030002E0543F

N11

52

53
1

OIL PRESSURE SWITCH ASY

FRONT OF ENGINE

9278 SW ASYOIL PRESS TORQUE 1216 Nm

(BLK ASYCYL)

NE01E10854730000

2001 3.0L4V D186

981111

73C

IL1F1E030002E0543F

53

54
1

A/C COMPRESSOR MOUNTING BRACKET ASY

FRONT OF ENGINE

(HD ASYCYL LH)

E8

2 2

E19

2
W701524 M8 X 1.25 X 49.3 BOLT HEX FLANGE HD PILOT TORQUE 25 Nm THEN ROTATE 90

(BLK ASYCYL)

19N586 BRKT ASYA/C COMP MTG

2
W701526 M8 X 1.25 X 74.3 BOLT HEX FLANGE HD PILOT TORQUE 25 Nm THEN ROTATE 90 (3) REQ

850 856

SHOWN TYPICAL

NE01I10880558010

2001 3.0L4V D186

990622

73C

IL1F1E030002E0543F

E19

54

55
.9

CYLINDER BLOCK ASY PIPE PLUGS

FRONT OF ENGINE

E8

N13

W701548 [3/414] PIPE PLUG TORQUE 6075 Nm OR 10 Nm THEN ROTATE CLOCKWISE 720 (BLK ASYCYL)

(BLK ASYCYL)

N13

W701548 [3/414] PIPE PLUG TORQUE 6075 Nm OR 10 Nm THEN ROTATE CLOCKWISE 720

FRONT OF ENGINE

NE01I10880558021

2001 3.0L4V D186

000612

73C

IL1F1E030002E0543F

N13

55

56
V1 .7 V3 .8

ENGINE LIFTING EYE (FRONT)

H8

(HD ASYCYL)

17A084 EYEENG LFT FRT

FRONT OF ENGINE

W701627 M12 X 1.75 X 39.3 BOLT HEX FLANGE HD PILOT TORQUE 100125 Nm

NE01I10880558010

2001 3.0L4V D186

990630

73C

IL1F1E030002E0543F

E8

56

57
1

A/C COMPRESSOR & CLUTCH ASY

FRONT OF ENGINE

(BRKT ASYA/C COMP MTG)

19D629 COMPR & CL ASYA/C

E8

(COMPR & CL ASYA/C) 1 3

W701626 M8 X 1.25 X 111.3 BOLT HEX FLNG HD PILOT TORQUE 2030 Nm (4) REQ

2 FRONT OF ENGINE NOTE: TORQUE ALL BOLTS SIMULTANEOUSLY OR FOR SINGLE WRENCH TORQUE IN SEQUENCE AS SHOWN. VIEW A

NE01I10880558010

2001 3.0L4V D186

990629

73C

IL1F1E030002E0543F

E8

57

58
.7

EXHAUST MANIFOLD (LH)

(HD ASYCYL LH STUDS (6) PLACES

N4

E8

FRONT OF ENGINE

9431 MANF ASYEXH LH W701706 M8 X 1.25 NUT HEX FLANGE HD TORQUE 1822 Nm (6) REQ

9448 GSKTEXH MANF

A2
SINGLE WRENCH METHOD TORQUE SEQUENCE 16 PERFORM TORQUE SEQUENCE TWICE

9431 MANF ASYEXH LH 3 2

FRONT OF ENGINE

VIEW A

NE01I10880558021

2001 3.0L4V D186

000612

73C

IL1F1E030002E0543F

N4

58

59
.55

EXHAUST MANIFOLD (RH) & CONVERTER ASY FOR 850 ONLY

(HD ASYCYL STUDS (6) PLACES

E8
9448 GSKTEXH MANF (HEGO SHIPPING CAP PIA 5G236)

5G236 MANF & CONV ASYEXH RH

FRONT OF ENGINE

W701706 M8 X 1.25 NUT HEX FLANGE HD TORQUE 1822 Nm (6) REQ

6
A

FRONT OF ENGINE

A2
SINGLE WRENCH METHOD TORQUE SEQUENCE 16 PERFORM TORQUE SEQUENCE TWICE 5G236 MANF & CONV ASYEXH RH VIEW A

NE01I10880558010

2001 3.0L4V D186

990622

73C

IL1F1E030002E0543F

E8

59

59A
.7

EXHAUST MANIFOLD (RH) & CONVERTER ASY FOR 856 ONLY

(HD ASYCYL STUDS (6) PLACES

E8

9448 GSKTEXH MANF (9G458 PLG ASYEXH MANF PART OF 5G236) TORQUE 4045 Nm

(N807040 CAP M22 X 1.5 HEX PART OF 5G236) TORQUE 5060 Nm FRONT OF ENGINE

W701706 M8 X 1.25 NUT HEX FLANGE HD TORQUE 1822 Nm (6) REQ

6
A

FRONT OF ENGINE 5G236 MANF & CONV ASYEXH RH

A2
SINGLE WRENCH METHOD TORQUE SEQUENCE 16 PERFORM TORQUE SEQUENCE TWICE

5G236 MANF & CONV ASYEXH RH VIEW A

NE01I10880558010

2001 3.0L4V D186

990629

73C

IL1F1E030002E0543F

E8

59A

60
.7

EXHAUST RECIRCULATING VALVE TO EXHAUST MANIFOLD TUBE ASY FOR 850 ONLY
W701542 M6 X 1 NUT HEX FLANGE HD TORQUE 10 Nm AND ROTATE AN ADDITIONAL 90 (2) REQ

N11

(9D476 GSKTTUB ASY PART OF 9D477 ASY)

E8

9D477 TUB ASYEXH RECU VLV TO EXH MANF TORQUE TO 3545 Nm (LOWER END)

(MANF & CONV ASYEXH RH)

FINAL TORQUE PROCEDURE

FRONT OF ENGINE PRODUCTION METHOD (MULTISPINDLE) TORQUE TO 10 Nm AND ROTATE AND ADDITIONAL 90 SINGLE WRENCH METHOD (SERVICEREPAIR) SNUG LOWER NUT TO 5 Nm RUN NUT TO 10 Nm AND ROTATE AND ADDITIONAL 90

NE01I10880558021

2001 3.0L4V D186

000612

73C

IL1F1E030002E0543F

N11

60

61
.70

EGR TRANSDUCER ASY FOR 850 ONLY

9J433 TRNSDC ASYE/G/R

(EGR TUBE ASY)

FRONT OF ENGINE

NE01E10854730000

2001 3.0L4V D186

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73C

IL1F1E030002E0543F

61

62
1

WIRING ASY CONNECTIONS EGR TRANSDUCER ASY FOR 850 ONLY

TO TRNSDCR ASYE/G/R

N11

E8

12B637 WIR ASYENG CONTR SNS &FUL CHG

(TRNSDCR ASYE/G/R)

FRONT OF ENGINE

NE01I10880558021

2001 3.0L4V D186

000612

73C

IL1F1E030002E0543F

N11

62

63
1

CRANKCASE EMISSION VALVE TO INTAKE MANIFOLD HOSE

N11
FRONT OF ENGINE

E8

(MANF ASYINTK)

(HOSCRKC EMS VLV TO INTK MANF) NOTE: FOR ASSEMBLY AID SEE FRAME 3

NE01I10880558021

2001 3.0L4V D186

000612

73C

IL1F1E030002E0543F

N11

63

64
1

ALTERNATOR ASY & WIRING BRACKET

(HD ASYCYL) 12B637 WIR ASYENG CONTR SNS & FUL CHG

(WIR ASYENG CONTR SNS & FUL CHG)

(BLK ASYCYL) (CVR ASYENG FRT)

P2

H2

FRONT OF ENGINE (BRKTWIR)

E8
VIEW A

J12

FOR 850 ONLY

FRONT OF ENGINE

W701581 M8 X 1.25 X 23 M8 X 1.25 X 65 STUD HEX SHLDR HD PILOT (TORQUE 2030 Nm)
A

TO ALT ASY TO CMS SENSOR (B & A RESP)

W705707 M8 X 1.25 X 23 M8 X 1.25 X 135 STUD HEX SHLDR PILOT (TORQUE 2030 Nm) 10300 ALT ASY

K5

W701629 M8 X 1.25 X 137 BOLT HEX FLANGE HD PILOT (TORQUE 2030 Nm)

H2
14536 BRKTWIR

NE01I10880558022

2001 3.0L4V D186

000823

73C

IL1F1E030002E0543F

P2

64

65
.7

A/C COMPRESSOR BRACE

L5

19D896 BRAA/C COMP

E20

(BRKT ASYA/C COMP MTG)

FRONT OF ENGINE

N14

W701759 M8 X 1 X 26.3 BOLT HEX FLANGE HD TORQUE 2030 Nm (3) REQ

NE01I10880558021

2001 3.0L4V D186

000612

73C

IL1F1E030002E0543F

N14

65

66
1

POWER STEERING PUMP & PULLEY ASY

(CVR ASYENG FRT)

PULLEY ALIGNMENT FOR FASTENERS LOCATIONS VIEW A

E8

FRONT OF ENGINE

L5

E21

(PLY ASYPWR STG NOTE: PART OF 3A696 ASY SHOWN EXPLODED FOR INSTALLATION CLARITY

3A696 PMP & PLY ASY PWR STG

E22

W5000319S309 M8 X 1.25 X 80 BOLT HEX FLANGE PILOT 10 TORQUE 2030 Nm (3) REQ

NE01I10880558020

2001 3.0L4V D186

000419

73C

IL1F1E030002E0543F

L5

66

67
.8

CRANKSHAFT PULLEY ASY

H2

FRONT OF ENGINE

NOTE: CRANKSHAFT PULLEY HAS LEFTHAND THREADS 6312 PLY ASYCRKSHT

E23

ASSEMBLY PROCEDURE
E24
1. ROTATE CRANKSHAFT PULLEY ASY (6312) COUNTER CLOCKWISE. 2. TORQUE 95105 Nm .

NE01I10880558017

2001 3.0L4V D186

990903

73C

IL1F1E030002E0543F

H2

67

68
1

DRIVE BELT (FEAD)

(PMP & PLY ASY PWR STG)

(TENS ASYENG DRV BEL)

(COMP & CL ASYA/C)

L5 E8

8620 BELDRV

H2

(ALT ASY) (PLY ASYCRKSHT) FRONT OF ENGINE

P/S (BELDRV)

ALT TEN A/C

C/S NOTE: PULL DOWN ON BELT BETWEEN C/S AND A/C TO RELEASE THE SPRING CLIP. BELT WILL BE NOMINAL POSITION.

VIEW A

NE01I10880558020

2001 3.0L4V D186

000419

73C

IL1F1E030002E0543F

L5

68

69
.4

ACCESSORY DRIVE PULLEY

FRONT OF ENGINE

G3

(C/SHT ASYINTK LH)

K2
6A359 PLYACC DRV NOTE: MAX PRESS 15 KN

N4

E25

NE01I10880558021

2001 3.0L4V D186

000612

73C

IL1F1E030002E0543F

N4

69

70
.5

WATER PUMP DRIVE BELT

FRONT OF ENGINE

(PLYACC DRV)

8K543 BELWTR PMP DRV

G3

E26

N4

(PMP ASYWTR)

N15
ACC

TENS

(BELWTR PMP DRV)

W/P

VIEW A

NE01I10880558021

2001 3.0L4V D186

000613

73C

IL1F1E030002E0543F

N15

70

71
.75

WATER PUMP PULLEY SHIELD

W701539 M5 X 0.8 NUT TORQUE 57 Nm (2) REQ 8A590 SHLDWTR PMP PLY

D2

(STUDVLV RKR ARM CVR ASY LH) (2) PLACES

FRONT OF ENGINE

NE01I10880558006

2001 3.0L4V D186

990305

73C

IL1F1E030002E0543F

D2

71

72
1

FLYWHEEL HOLE LOCATION FOR SHIPPING

FRONT OF ENGINE

(FL/WHL ASY)

NOTE: FLYWHEEL HOLE TO BE LOCATED AT BDC +/ 12 THIS ALLOWS THE HOLE AT BDC +/ ONE INCH .

(FL/WHL ASY) POSITION ONE OF THE FOUR HOLES AT BOTTOM DEAD CENTER VIEW A

NE01E10854730000

2001 3.0L4V D186

981111

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IL1F1E030002E0543F

72

73
.6

ENGINE ASY LEFT FRONT VIEW (VEHICLE) FOR 850 ONLY

N11

FRONT OF ENGINE

G3 H4

N5

E27

K1 K2 N4 N15

NE01I10880558021

2001 3.0L4V D186

000626

73C

IL1F1E030002E0543F

N15

73

73A
.4

ENGINE ASY RIGHT REAR VIEW (VEHICLE) FOR 850 ONLY

N11

L5

H3

FRONT OF ENGINE

H2 E27

NE01I10880558021

2001 3.0L4V D186

000613

73C

IL1F1E030002E0543F

N11

73A

73B
.4

ENGINE ASY LEFT FRONT VIEW (VEHICLE) FOR 856 ONLY

N11

FRONT OF ENGINE

H4

G3

N5

E27 K1 K2 N4 N15

NE01I10880558021

2001 3.0L4V D186

000626

73C

IL1F1E030002E0543F

N15

73B

73C
.4

ENGINE ASY RIGHT REAR VIEW (VEHICLE) FOR 856 ONLY

N11

L5 H3

H2 E27
FRONT OF ENGINE

L1

L2

NE01I10880558021

2001 3.0L4V D186

000613

74

IL1F1E030002E0543F

N11

73C

74
.4

2001 3.0L4V D186

8K543
N15

6A359

6582 ASY

8501 W701544 (3 REQ)

N4

6A505 ASY

6A258 (13 REQ) W705391 (34 REQ) 6065 (16 REQ) 6C501 (24 REQ) 6529 (24 REQ) 12405 (6 REQ) 6K817 8A505 6514 (24 REQ) 6513 (24 REQ) 6A517 (24 REQ) W701732 (12 REQ) 6A268 W704688 (4 REQ) 6B280 (4 REQ) 6A266 W701632

W701242 6050 8548 6A269 W701669 6750 W701504 (2 REQ) W701585 6B673 6083 6B752 W701923 W701524 (4 REQ) 6K255 6L266 6B297 6268 9431 6754 9448 6A267

N5

6518 (48 REQ)

6049

9278 6505 (12 REQ)

9448

6K255 5G236 6507 (12 REQ) 6621 6333 (4 REQ) W701542 6051 6701 W500300 (4 REQ) 6622 W700005 (2 REQ) 6A339 6303 6306 6150 (6 REQ) 6A338 (3 REQ) 6L266 W701524 (2 REQ) W701232 (2 REQ) 6306

6M256 6268 6C086

W701525 (12 REQ)

6A341 W701706 (12 REQ)

6B209

P1

W701240 (2 REQ) 12A227 6700

6316

W701511 W701512 W701581

6F095 6152 (6 REQ) 6159 (12 REQ) 6140 (12 REQ) 6110 (6 REQ) 6687 6200 ASY (6 REQ) 6214 (16 REQ) W701582 (4 REQ) 6121 (6 REQ) 6135 (6 REQ) 6C070 6345 (5 REQ) W701554 (5 REQ) 6D311 (4 REQ) 6D311 (4 REQ) 6345 (4 REQ) 6A642 ASY (GCC ONLY) 6890 6714

W701712

6100 ASY (6 REQ)

6211 (12 REQ)

6710

W701542 (4 REQ)

6675 ASY
L3

NE01I10880558022

2001 3.0L4V D186

000823

74

IL1F1E030002E0543F

P1

74

74A
.375

2001 3.0L4V D186

W701669 W701632

9E926 ASY

W500214 (2 REQ) 9F715 9424 9E470 9D476

W500213 (2 REQ) 9D460 W500224 (2 REQ)

9D476 W701539 (2 REQ) 12280

N11

9S479 (8 REQ)

9E498 9J472 ASY W500204 (2 REQ)

9G271 W701539 (2 REQ) 12A310 6758 9J447 ASY

gc

W706155 (8 REQ) 12281 17A084 W701627

W701619

9J433

W701559 (8 REQ)

6B288 W500214 3A696 ASY

12B637 9D477 6375

3A696 ASY 17A084 W701581 W701627 6C315 W500214 10300 ASY 14536 19D896 W701759 (3 REQ) W701629 W705707 (2 REQ) 6312 ASY 8620 W500319 (3 REQ)

19N586

W701524 (1 REQ) W701526 (3 REQ) 19D629 ASY

W701626 (4 REQ)

L3

NE01I10880558020

2001 3.0L4V D186

000613

74

IL1F1E030002E0543F

N11

74A

END
.375