Yale GLP050LX Parts Manual

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Page 1

GLP050LX

(A974)

PARTS MANUAL

Yale Materials Handling Corporation

1400 Sullivan Drive Caller No. 12011 Greenville, NC 27834-2011

550013968

©Yale Corp.

09/2010

Page 2

MODEL NOMENCLATURE

NOTE: This parts manual contains alternate pages for certain assemblies. The truck model code can be used to

determine many of the assemblies on your lift truck (power, tire type, mast type). The complete truck model and serial number are stamped into the nameplate. See for further information.

Page 3

SECTIONS

1 GENERAL TRUCK

2 ENGINE ASSEMBLY

3 EXHAUST SYSTEM

4 COOLING SYSTEM

5 FUEL SYSTEM

6 ELECTRICAL SYSTEM

7 TRANSMISSION

8 DRIVE AXLE

9 STEERING SYSTEM

10 BRAKE SYSTEM

11 HYDRAULIC SYSTEM

12 MAST-THREE STAGE FULL FREE-LIFT

13 OPTIONS

14 NUMERICAL INDEX

15 USER SUPPORT INFORMATION

This Parts Manual is divided into 15 major sections which are listed above. Quick reference to these sections can be made by placing the right thumb on the tab of the desired section, bending the book back and thumbing the pages to the corresponding tab.

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Page 5

GENERAL INFORMATION

TABLE OF CONTENTS

DESCRIPTION PAGE

AIR FILTER ASSEMBLY ................................................................................................................................. 5-4

AIR INTAKE SYSTEM ..................................................................................................................................... 5-2

ASSEMBLED ENGINE

MAZDA 2.0L, LPG - 2010 EMISSION COMPLIANT ENGINES .................................................................. 2-6

AUDIBLE BACKUP ALARM ............................................................................................................................ 13-3

BATTERY AND CABLES ................................................................................................................................ 6-4

BRAKE ASSEMBLY ........................................................................................................................................ 10-2

BRAKE PEDAL LINKAGE ............................................................................................................................... 10-4

CARRIAGE

THREE STAGE FULL FREE-LIFT .............................................................................................................. 12-20

CENTER SECTION ......................................................................................................................................... 8-4

COOLING SYSTEM ........................................................................................................................................ 4-2

COUNTER/REVERSE CLUTCH

SINGLE SPEED TRANSMISSION .............................................................................................................. 7-14

COUNTERWEIGHT ........................................................................................................................................ 1-6

COWL MOUNT ................................................................................................................................................ 1-10

CRANKSHAFT AND PISTONS

MAZDA 2.0L, LPG - 2010 EMISSION COMPLIANT ENGINES .................................................................. 2-14

CYLINDER BLOCK

MAZDA 2.0L LPG - 2010 EMISSION COMPLIANT ENGINES ................................................................... 2-10

CYLINDER HEAD AND COVER

MAZDA 2.0L LPG - 2010 EMISSION COMPLIANT ENGINES ................................................................... 2-8

DISPLAY CLUSTER ........................................................................................................................................ 6-8

DRIVE AXLE AND ATTACHING PARTS ........................................................................................................ 8-2

DRIVE TIRE AND WHEEL .............................................................................................................................. 8-6

ELECTRICAL ARRANGEMENT ..................................................................................................................... 6-2

ELECTRONIC PRESSURE REGULATOR ASSEMBLY

MAZDA 2.0L LPG - 2010 EMISSION COMPLIANT ENGINES ................................................................... 5-14

ELECTRONIC PRESSURE REGULATOR KIT

(MAZDA 2.0L LPG) ..................................................................................................................................... 5-16

EMISSION CONTROL SYSTEM

MAZDA 2.0L, LPG - 2010 EMISSION COMPLIANT ENGINES .................................................................. 2-22

ENGINE CONTROL MODULE

MAZDA 2.0L LPG ........................................................................................................................................ 6-9

ENGINE COOLING SYSTEM

MAZDA 2.0L, LPG - 2010 EMISSION COMPLIANT ENGINES .................................................................. 2-20

ENGINE MOUNTING ...................................................................................................................................... 2-4

EXHAUST MANIFOLD

MAZDA 2.0L, LPG - 2010 EMISSION COMPLIANT ENGINES .................................................................. 2-18

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GENERAL INFORMATION

TABLE OF CONTENTS (continued)

DESCRIPTION PAGE

EXHAUST SYSTEM WITH CATALYTIC CONVERTER

MAZDA 2.0L, LPG ....................................................................................................................................... 3-2

MAZDA 2.0L, LPG - LATIN AMERICAN SERIES ....................................................................................... 3-4

FIRE EXTINGUISHER .................................................................................................................................... 13-4

FLOORPLATES AND COVERS ...................................................................................................................... 1-12

FLYWHEEL AND HOUSING ASSEMBLY

MAZDA 2.0L ................................................................................................................................................ 2-2

FORKS ............................................................................................................................................................ 1-2

OPTIONAL .................................................................................................................................................. 1-3

FREE LIFT CYLINDER ASSEMBLY

THREE STAGE FULL FREE LIFT .............................................................................................................. 12-16

FUEL SYSTEM

MAZDA 2.0L LPG - 2010 EMISSION COMPLIANT ENGINES ................................................................... 5-8

FUEL SYSTEM HOSES AND ATTACHING PARTS

MAZDA 2.0L LPG - 2010 EMISSION COMPLIANT ENGINES ................................................................... 5-10

FUEL TANK COVERS

LATIN AMERICAN SERIES ........................................................................................................................ 5-5

FULL SUSPENSION SEAT

MANUAL HYDRAULIC - NON-SWIVEL ...................................................................................................... 1-20

SHEET 2 OF 2 ............................................................................................................................................ 1-24

GEAR PUMP ASSEMBLY ............................................................................................................................... 11-4

HAND LEVERS

2 AND 3 FUNCTION ................................................................................................................................... 11-14

HEADER HOSE AND ATTACHING PARTS

3 FUNCTION ............................................................................................................................................... 12-18

HOOD .............................................................................................................................................................. 1-16

HYDRAULIC CONTROL VALVE

MANUAL - 3 FUNCTION ............................................................................................................................. 11-16

HYDRAULIC FILTER HOUSING ..................................................................................................................... 11-10

HYDRAULIC HOSES

STEERING .................................................................................................................................................. 11-6

HYDRAULIC SUPPLY AND RETURN ............................................................................................................ 11-2

INPUT/FORWARD CLUTCH

SINGLE SPEED TRANSMISSION .............................................................................................................. 7-12

INTAKE MANIFOLD

MAZDA 2.0L, LPG - 2010 EMISSION COMPLIANT ENGINES .................................................................. 2-16

INTEGRAL SIDE-SHIFT CARRIAGE

THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-6

INTEGRAL SIDE-SHIFT CYLINDER .............................................................................................................. 13-10

INTEGRAL SIDE-SHIFT HYDRAULIC HOSES

THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-8

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GENERAL INFORMATION

TABLE OF CONTENTS (continued)

DESCRIPTION PAGE

LABELS

SHEET 1 OF 2 ............................................................................................................................................ 1-26

SHEET 2 OF 2 ............................................................................................................................................ 1-28

LIGHTS

STOP, TAIL, TURN, BACKUP, AND STROBE - WITH OVERHEAD GUARD ........................................... 6-6

LOAD BACKREST EXTENSION ..................................................................................................................... 1-4

LPG FUEL TANK AND MOUNTING ............................................................................................................... 5-6

MAIN LIFT CYLINDER ASSEMBLY

THREE STAGE FULL FREE LIFT .............................................................................................................. 12-12

MAST ASSEMBLY

INNER MAST AND FREE-LIFT .................................................................................................................. 12-8

INTERMEDIATE MAST AND MAIN LIFT .................................................................................................... 12-4

OUTER MAST ............................................................................................................................................. 12-2

MIRRORS ........................................................................................................................................................ 13-2

MIXER AND THROTTLE BODY ASSEMBLY

MAZDA 2.0L - 2010 EMISSION COMPLIANT ENGINES ........................................................................... 5-12

NON SUSPENSION SEAT

WITHOUT ELECTRONIC CONTROLS ...................................................................................................... 1-18

OIL PUMP AND FILTER

MAZDA 2.0L, LPG - 2010 EMISSION COMPLIANT ENGINES .................................................................. 2-24

OVERHEAD GUARD ...................................................................................................................................... 1-8

PARK BRAKE .................................................................................................................................................. 10-6

STEER TIRE AND WHEEL ............................................................................................................................. 9-10

STEERING AXLE AND ATTACHING PARTS ................................................................................................. 9-6

STEERING COLUMN ASSEMBLY ................................................................................................................. 9-4

STEERING CYLINDER ................................................................................................................................... 9-8

STEERING WHEEL AND COLUMN ............................................................................................................... 9-2

THROTTLE PEDAL AND ATTACHING PARTS ............................................................................................. 5-18

TILT AND AUXILIARY HOSES ....................................................................................................................... 11-8

TILT CYLINDER AND MAST INSTALLATION ................................................................................................ 11-11

TILT CYLINDER ASSEMBLY .......................................................................................................................... 11-12

TIMING GEAR COVER AND OIL PAN

MAZDA 2.0L, LPG - 2010 EMISSION COMPLIANT ENGINES .................................................................. 2-12

TORQUE CONVERTER .................................................................................................................................. 7-8

TORQUE CONVERTER HOUSING AND ATTACHING PARTS .................................................................... 7-6

TRANSMISSION COOLING

MAZDA 2.0L LPG ........................................................................................................................................ 7-2

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GENERAL INFORMATION

TABLE OF CONTENTS (continued)

DESCRIPTION PAGE

TRANSMISSION HOUSING AND ASSEMBLY

SINGLE SPEED .......................................................................................................................................... 7-10

TRANSMISSION MOUNT

SINGLE SPEED .......................................................................................................................................... 7-4

VALVE ASSEMBLY, AUXILIARY

MANUAL CONTROL VALVE - THREE FUNCTION ................................................................................... 11-20

VALVE ASSEMBLY, LIFT AND TILT

MANUAL CONTROL VALVE - THREE FUNCTION ................................................................................... 11-18

VALVE ASSEMBLY, OUTLET SECTION

MANUAL CONTROL VALVE - THREE FUNCTION ................................................................................... 11-22

WIRE HARNESS

MAZDA 2.0L LPG - POWERTRAIN ............................................................................................................ 6-10

RH CHASSIS - SHEET 1 OF 2 ................................................................................................................... 6-14

RH CHASSIS - SHEET 2 OF 2 ................................................................................................................... 6-16

WIRE HARNESS ADAPTER

LOW FUEL PRESSURE ............................................................................................................................. 6-18

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GENERAL INFORMATION

ABBREVIATIONS QUICK REFERENCE SHEET

Listed below are abbreviations used in parts manuals to denote the following expressions:

spacer

TERM DEFINITION

Amp Amperes

AR As Required

BDI Battery Discharge Indicators

BWI Brush Wear Indicator

CE Communicator End

CRE Corrosive Environment

D/B Date Break

dbA Decibel "A" Scale

DE Drive End

ECH Empty Container Handler

ECH-3 Empty Container Handler - 3 High

Stacking

ECH-4 Empty Container Handler - 4 High

Stacking

ECH-5 Empty Container Handler - 5 High

Stacking

ECH-6 Empty Container Handler - 6 High

Stacking

ECH-7 Empty Container Handler - 7 High

Stacking

ECM Electronic Control Module

ECN Engineering Change Notice

EEPROM Electrically Erasable Programmable

Read Only Memory

EPA US Environmental Protection Agency

EPROM Electrically Programmable Read Only

Memory

FRE Freezer Environment

in. inches

LPG Liquefied Petroleum Gas

MAP Manifold Absolute Pressure

mm millimeters

MSTS Microprocessor Spark Timing System

NPT National Pipe Threads

O/S Oversize

PTO Power Take Off

RPM Revolutions per Minute

S/N Serial Number

TMM Truck Management Module

UL Type D Diesel-Powered Safety Rating

UL Type DS Diesel-Powered Safety Rating

UL Type E Battery-Powered Safety Rating

UL Type EE Battery-Powered Safety Rating

UL Type ES Battery-Powered Safety Rating

UL Type G Gasoline-Powered Safety Rating

UL Type GS Gasoline-Powered Safety Rating

UL Type LP Gas-Powered Safety Rating

UL Type LPS LP Gas-Powered Safety Rating

U/S Undersize

UL Underwriters Laboratory

V Volts

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GENERAL INFORMATION

HOW TO USE THE ILLUSTRATED PARTS MANUAL

This parts manual describes and illustrates assemblies, subassemblies, and detail parts needed for service replacement.

The different constructions are indicated by keys and footnotes. The callouts correspond to descriptions found on the next page.

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HOW TO FIND THE DESIRED PART NUMBER

GENERAL INFORMATION

WHEN THE PART NUMBER AND THE NEXT HIGHER ASSEMBLY IS NOT KNOWN:

1. Determine the function and application of the part

required. Turn to the Sections Page. Choose the general area of reference most likely to include the part.

2. Turn to the section you chose. Use the Section

Table of Contents to determine the assembly which would normally contain the part required. Then locate the part on the assembly breakdown page.

WHEN THE PART NUMBER IS NOT KNOWN AND THE NEXT HIGHER ASSEMBLY IS KNOWN:

3. Determine the assembly the required part is used

on. Turn to the Table of Contents (Page i).

4. Locate the assembly the required part is used on

and turn to the page indicated for that assembly. Then locate the part on the assembly breakdown page.

WHEN THE PART NUMBER IS KNOWN:

5. Use the Numerical Index (Page 14-1) to find the

part number. Turn to the page listed and locate the part as indicated by the item number.

GENERAL:

The assembly breakdowns include part numbers, descriptions, quantities required, keys and footnotes to help in selecting correct parts.

6. Parts Supersession Information. Part numbers that

have this history will be displayed in the parts list in the order that they were superseded (from oldest to newest). The superseded part numbers will be shown with a line through them.

Five periods in the PART NO. column (. . . . .)

indicate that the part is either Not Serviced Separately or there is a reference to another figure. A figure reference is denoted by a pointing hand followed by a parts page number in the DESCRIPTION column (F7A56)

7. Keys are used to show two or more similar

assemblies, RH and LH assembly parts, etc. Select the appropriate key, "A", "B", "C", "D", or "E" and the corresponding quantity column to find the required parts. Two periods in the QTY column (..) indicate that the part is not used for that assembly.

8. Indented descriptions under the DESCRIPTION

column are used to indicate assemblies and

subparts of assemblies. In the example on the previous page, BEARING CAP (Item 2) is a subpart of the major assembly CASE.

9. Quantities shown are for one assembly. The quantities of the subpart BEARING CAP are indicated as two and two. This means two per CASE assembly.

10. Serial number breaks identify the most current parts information and are shown as follows:

→ S/N A810N2639

Indicates last serial number affected.

S/N A810N2640 →

Indicates the first serial number affected.

S/N A810N1553 ↔ S/N A810N3291

Indicates a range of serial numbers affected.

ECN numbers for pending serial numbers are shown to allow for the inclusion of the most current parts information and are identified as follows:

→ S/N Pending Per ECN 63243

Indicates a pending serial number for last unit affected.

S/N Pending Per ECN 63243 →

Indicates a pending serial number for first unit affected.

Date breaks are used to indicate when a change occurred but a subsequent serial number break was not recorded. This is an arbitrary date usually based on the ECN release and are identified as follows:

→ D/B 3/00

Indicates that a change occurred sometime within that month for the item affected.

D/B 3/00 →

Indicates that a change occurred sometime within that month for the item affected.

D/B 3/00 ↔ D/B 4/00

Indicates a range of production dates of the item affected.

Contact your local dealer for Yale lift trucks for serial number information for items with a ECN or a date break.

ORDERING PARTS:

When ordering replacement parts, give the unit serial number, part number, name of part and quantity required.

For any further information on parts, service, or ordering, consult your local dealer for Yale lift trucks.

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Page 12

GENERAL INFORMATION

IDENTIFICATION OF TRUCK SERIAL NUMBERS

NOTE: Serial Number breakdown is only for trucks built after 1994.

(1) and (2) The first letter and three numbers indicate the truck unit code.

(3) The second letter indicates the plant of manufacture.

(4) The four or five digit number indicates the production sequence number of the truck.

(5) The final letter indicates the year of manufacture starting with "A" in 1957, 1980, and 2003.

The letters "I", "O", and "Q" will not be used.

For pending serial numbers contact your local dealer for Yale lift trucks.

Parts referred to in this book as right or left hand parts are in accordance with the illustration above.

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GENERAL INFORMATION

IDENTIFICATION OF MAST SERIAL NUMBERS

(1) and (2) The first letter and number indicates the mast unit code.

(3) The second letter indicates the plant of manufacture.

(4) The four or five digit number indicates the production sequence number of the mast.

(5) Carriage travel in millimeters stamped just below the serial number.

Mast Group identification consists of mast unit code (1) and (2) plus carriage travel (5).

For pending production sequence numbers contact your local dealer for Yale lift trucks.

LIFT EQUIPMENT IDENTIFICATION

1. Fork part number, capacity rating, plant code letter, and date of manufacture are stamped approximately six inches below the top of most forks.

2. The carriage group number is stamped on the right hand side of the top crossmember (pin type) or on the back of the right hand end of the bottom crossmember (hook type). A date code has two letters in line with or below the carriage group number.

3. The mast identification number has a unit code, a letter indicating the plant of manufacture, and a serial number. Underneath the production sequence number is a four digit number that indicates the carriage travel in millimeters.

4. Tilt and lift cylinder group numbers are stamped on the cylinder shell.

Always refer to the group, serial, or part number when ordering service parts.

Modification of masts and carriages by SPED (Special Products Engineering Department) are identified by a model prefix code beginning with the letter "S". contact your dealer for Yale lift trucks for information on these assemblies.

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GENERAL INFORMATION

IDENTIFICATION OF ATTACHMENT AND SIDE-

SHIFT CARRIAGE SERIAL NUMBERS

(1) and (2) The first letter and three numbers indicate the attachment unit code.

(3) The second letter indicates the plant of manufacture.

(4) The four or five digit number indicates the production sequence number.

For pending production sequence numbers contact your local dealer for Yale lift trucks.

Side-shift carriages and attachments have nameplates. Use the serial number found on the nameplate to identify the attachment.

Always refer to the group, serial, or part number when ordering service parts.

Modifications of attachments and side-shift carriages by SPED (Special Products Engineering Department) are identified by a model prefix code beginning with the letter "S". Contact your dealer for Yale lift trucks for information on these assemblies.

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PUBLICATIONS

GENERAL INFORMATION

Every new lift truck is provided with an OPERATING MANUAL. This manual has information that the operator must know for inspection and operation of the lift truck.

MANUALS with complete replacement part identification, are available at a nominal fee from your Yale dealer to assist users in effectively maintaining Yale lift trucks in a safe, useful condition. See the list below for information on ordering specific publications

SERVICE MAINTENANCE MANUALS, which provide

for this model lift truck.

service and overhaul procedures, and PARTS

PUBLICATION YALE PART NUMBER

Operating Manual.................................................................................................................... 550013965

Service Manual (Complete)..................................................................................................... 550013971

Parts Manual........................................................................................................................... 550013968

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GENERAL INFORMATION

MASTER PART SHEET CROSS-REFERENCE

NOTE: Throughout this manual are references to Part Sheet Numbers. These references are usually found after

the description of a part or assembly. The Part Sheet Number is found on the upper left- or righthand corner of the parts pages.

EXAMPLE:

ITEM PART NO. DESCRIPTION QTY

31 505965530 Steering Cylinder (F6E67 [Figure 4-3]) ..............................................................

32 504224261 Pin........................................................................................................................ 4

Below is a numerical listing of Part Sheet Numbers found in this parts book and what page number they are on.

PART SHEET PAGE

P21596..................................1-18

P21895..................................1-10

P21896....................................1-6

P21897..................................1-12

P21898....................................1-8

P21899..................................1-16

P21900..................................1-26

P21901..................................1-28

P21902....................................1-4

P21903....................................2-4

P21904....................................3-2

P21905....................................3-4

P21906....................................2-2

P21907....................................2-8

P21908..................................2-10

P21909..................................2-12

P21910..................................2-14

P21911..................................2-16

P21912..................................2-18

P21913..................................2-20

P21914..................................2-22

P21916..................................2-24

P21917....................................2-6

P21918....................................4-2

P21949....................................5-5

P21950....................................5-6

P21951....................................5-2

P21952....................................5-8

P21953..................................5-10

P21954..................................5-12

PART SHEET PAGE

P21955..................................5-14

P21956..................................5-16

P21957....................................7-8

P21958..................................7-10

P21959....................................7-6

P21960..................................7-12

P21961..................................7-14

P21962....................................7-4

P21963....................................7-2

P21976..................................11-2

P21977..................................11-6

P21978..................................11-8

P21979................................11-10

P21980................................11-11

P21981................................11-12

P21982................................11-14

P21983................................11-16

P21984................................11-18

P21985................................11-20

P21986................................11-22

P22004..................................12-2

P22005..................................12-4

P22006..................................12-8

P22007................................12-12

P22008................................12-16

P22009................................12-18

P22010....................................6-6

P22011....................................6-8

P22012....................................6-9

P22013..................................6-14

PART SHEET PAGE

P22014..................................6-16

P22015..................................6-10

P22028....................................8-2

P22029....................................8-4

P22030....................................8-6

P22031....................................9-6

P22032....................................9-2

P22033....................................9-4

P22034..................................13-2

P22035..................................13-3

P22036..................................13-4

P22041..................................5-18

P22042....................................6-2

P22043....................................6-4

P22050................................12-20

P22051..................................13-6

P22052..................................13-8

P22053................................13-10

P22054..................................10-2

P22055..................................10-4

P22056..................................10-6

P22060..................................9-10

P22063....................................5-4

P22063....................................1-2

P22064....................................1-3

P22064....................................9-8

P22068..................................1-20

P22075..................................6-18

P22082..................................1-24

P22083..................................11-4

xii

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SECTION 1

1 GENERAL TRUCK

Page 18

Page 19

CONTENTS

SECTION 1

GENERAL TRUCK

DESCRIPTION PAGE

COUNTERWEIGHT ........................................................................................................................................ 1-6

COWL MOUNT ................................................................................................................................................ 1-10

FLOORPLATES AND COVERS ...................................................................................................................... 1-12

FORKS ............................................................................................................................................................ 1-2

OPTIONAL .................................................................................................................................................. 1-3

FULL SUSPENSION SEAT

MANUAL HYDRAULIC - NON-SWIVEL ...................................................................................................... 1-20

SHEET 2 OF 2 ............................................................................................................................................ 1-24

HOOD .............................................................................................................................................................. 1-16

LABELS

SHEET 1 OF 2 ............................................................................................................................................ 1-26

SHEET 2 OF 2 ............................................................................................................................................ 1-28

LOAD BACKREST EXTENSION ..................................................................................................................... 1-4

NON SUSPENSION SEAT

WITHOUT ELECTRONIC CONTROLS ...................................................................................................... 1-18

OVERHEAD GUARD ...................................................................................................................................... 1-8

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1-1

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P22063 05-10

FORKS (FIGURE 1-1)

ITEM PART NO. DESCRIPTION QTY

1 504111202 Fork (42 in.) ........................................................................................................ 2

1 504111203 Fork (48 in.) ........................................................................................................ 2

2 580034999 Knob ................................................................................................................... 2

3 580035001 Pin ....................................................................................................................... 2

4 580026749 Spring ................................................................................................................. 2

5 580035000 Pin ....................................................................................................................... 2

580035002 Kit-Latch .............................................................................................................. 2

1-2

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FORKS (FIGURE 1-2)

OPTIONAL

05-10 P22064

ITEM PART NO. DESCRIPTION QTY

1 524199303 Fork (42 in.) ........................................................................................................ 2

2 580006844 Roll Pin ............................................................................................................... 2

3 580006843 Latch ................................................................................................................... 2

4 580006842 Spring ................................................................................................................. 2

5 580049861 Pin ....................................................................................................................... 2

580049860 Kit-Latch (Class II) .............................................................................................. 1

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1-3

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P21902 04-10

LOAD BACKREST EXTENSION (FIGURE 1-3)

1-4

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04-10 P21902

KEY: A: For Use With Standard Carriage Only B: For Use With Integral Side-Shift Carriage Only

QTY

ITEM PART NO. DESCRIPTION A B

1 524310196 Load Backrest (38.5 in.) ............................................................................. 1 ..

1 524310197 Load Backrest (42 in.) (1067 mm) .............................................................. .. 1

2 501749901 Capscrew ................................................................................................... .. 4

2 505960578 Capscrew ................................................................................................... 4 ..

3 504233271 Washer ....................................................................................................... 4 4

4 061278200 Washer ....................................................................................................... 4 4

5 909882405 Nut .............................................................................................................. 4 4

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Page 24

P21896 11-09

COUNTERWEIGHT (FIGURE 1-4)

1-6

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11-09 P21896

COUNTERWEIGHT

ITEM PART NO. DESCRIPTION QTY

1 580051185 Seal ..................................................................................................................... 1

2 550005006 Counterweight ..................................................................................................... 1

3 580080171 Tow Pin ............................................................................................................... 1

4 580002019 Washer ............................................................................................................... 1

5 955400911 Washer ............................................................................................................... 1

6 449001406 Capscrew ............................................................................................................ 1

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P21898 03-10

OVERHEAD GUARD (FIGURE 1-5)

1-8

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03-10 P21898

OVERHEAD GUARD

ITEM PART NO. DESCRIPTION QTY

1 524240422 Overhead Guard ................................................................................................. 1

2 580056667 Capscrew ............................................................................................................ 8

2 580051941 Capscrew (Optional) ........................................................................................... 8

3 580056528 Nut (Shoulder) .................................................................................................... 2

4 580056526 Handle (Grab) ..................................................................................................... 1

5 580056815 Capscrew ............................................................................................................ 2

6 580044861 Insert ................................................................................................................... 4

7 580090887 Grommet ............................................................................................................. 2

8 524208883 Grommet ............................................................................................................. 1

9 258979300 Plug ..................................................................................................................... 4

10 524240692 Plug ..................................................................................................................... 1

11 580058212 Capscrew ............................................................................................................ 2

12 580041704 Insert ................................................................................................................... 2

13 580063390 Grommet ............................................................................................................. 1

14 500136904 Grommet ............................................................................................................. 1

15 580026812 Clip ...................................................................................................................... 1

16 580056613 Fastener .............................................................................................................. 1

17 580051747 Handle Assembly ................................................................................................ 1

17 580050959 Handle ............................................................................................................ 1

17 580058447 Push Button Switch ........................................................................................ 1

17 580022893 Connector ....................................................................................................... 1

17 505968540 Connector (Secondary Lock) .......................................................................... 1

17 505968514 Terminal (Pin) ................................................................................................. 1

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P21895 03-10

COWL MOUNT (FIGURE 1-6)

ITEM PART NO. DESCRIPTION QTY

1 580056815 Capscrew ............................................................................................................ 2

1 580030966 Capscrew (Optional) ........................................................................................... 2

2 550007449 Cowl .................................................................................................................... 1

3 580074879 Insert ................................................................................................................... 7

3 580055652 Nut (Optional) ..................................................................................................... 7

3 504071785 Washer (Optional) ............................................................................................... 7

4 580064483 Capscrew ............................................................................................................ 7

1-10

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NOTES

03-10 P21895

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1-11

Page 30

P21897 03-10

FLOORPLATES AND COVERS (FIGURE 1-7)

1-12

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03-10 P21897

FLOORPLATES AND COVERS

ITEM PART NO. DESCRIPTION QTY

1 582001890 Capscrew ............................................................................................................ 2

2 582001885 Washer ............................................................................................................... 2

3 580041704 Insert ................................................................................................................... 6

4 524195752 Cover (Radiator) ................................................................................................. 1

4 580061815 Seal (LH) ........................................................................................................ 1

4 580061814 Seal (RH) ........................................................................................................ 1

4 580058734 Screw ............................................................................................................. 2

4 449021001 Washer ........................................................................................................... 2

4 507353800 Retaining Ring ................................................................................................ 2

5 925776402 Cap ..................................................................................................................... 4

6 580092936 Tail Light Base (RH) ........................................................................................... 1

7 580058212 Capscrew ............................................................................................................ 4

8 580048561 Cover (Rear) ....................................................................................................... 1

9 580041711 Capscrew ............................................................................................................ 3

10 580092937 Tail Light Base (LH) ............................................................................................ 1

11 580044859 Insert ................................................................................................................... 3

12 580046138 Cover (Steering Column Lower) ......................................................................... 1

13 580083020 Cover (Steering Column Upper) ......................................................................... 1

14 909904403 Screw .................................................................................................................. 2

15 580046139 Clip ...................................................................................................................... 6

16 582001891 Capscrew ............................................................................................................ 5

17 580044859 Insert ................................................................................................................... 5

18 580053146 Panel (Kick) ........................................................................................................ 1

19 580046139 Clip ...................................................................................................................... 6

20 580052910 Dash Panel ......................................................................................................... 1

20 580052409 Cup Holder ..................................................................................................... 1

21 580026621 Nut ...................................................................................................................... 17

22 580055698 Seal ..................................................................................................................... 1

23 580038033 Grommet ............................................................................................................. 1

24 580056531 Cover Plate Assembly ........................................................................................ 1

24 580052974 Cover .............................................................................................................. 1

25 580045192 Seal ................................................................................................................ 1

26 580056815 Capscrew ............................................................................................................ 17

27 524188740 Panel (Front) ....................................................................................................... 1

28 580087185 Step Panel (LH) .................................................................................................. 1

29 582010050 Plate .................................................................................................................... 1

30 580050478 Mud Flap ............................................................................................................. 2

31 580042963 Locknut ............................................................................................................... 4

32 580096406 Plate .................................................................................................................... 1

33 582004500 Capscrew ............................................................................................................ 6

34 580056003 Washer ............................................................................................................... 6

35 580012987 Nut ...................................................................................................................... 6

36 580054070 Floormat .............................................................................................................. 1

37 524188745 Panel (Front) ....................................................................................................... 1

38 580087184 Step Panel (RH) .................................................................................................. 1

39 580056224 Trim Seal ............................................................................................................ 2

40 524177726 Panel (Rear) ....................................................................................................... 1

41 580050773 Seal ..................................................................................................................... 2

42 580038024 Floorplate ............................................................................................................ 1

43 524177725 Panel (Rear) ....................................................................................................... 1

44 580054710 Seal (LH) ............................................................................................................. 1

A974

1-13

Page 32

P21897 03-10

FLOORPLATES AND COVERS

ITEM PART NO. DESCRIPTION QTY

45 580052993 Seal (RH) ............................................................................................................ 1

1-14

A974

Page 33

NOTES

03-10 P21897

A974

1-15

Page 34

P21899 12-09

HOOD (FIGURE 1-8)

1-16

A974

Page 35

12-09 P21899

HOOD

ITEM PART NO. DESCRIPTION QTY

550015595 Hood ................................................................................................................... 1

1 550015378 Hood ............................................................................................................... 1

2 580084480 Boot ................................................................................................................ 1

3 580054201 Seal ................................................................................................................ 1

4 524255979 Plug (Gold) ..................................................................................................... 2

5 580054196 Hinge .............................................................................................................. 2

6 580049231 Capscrew ....................................................................................................... 10

7 580084478 Latch ............................................................................................................... 1

8 580004592 Nut .................................................................................................................. 2

9 580058383 Bumper (Hood) ............................................................................................... 2

10 580039900 Capscrew ....................................................................................................... 6

11 580087164 Seat Pan ......................................................................................................... 1

12 580065405 Hood Reinforcement .................................................................................. 1

13 580065388 Bracket ....................................................................................................... 2

14 518805632 Nut .............................................................................................................. 10

15 580058135 Bracket ....................................................................................................... 1

16 580064907 Bracket ....................................................................................................... 1

17 580065386 Capscrew ................................................................................................... 6

18 580049011 Capscrew ................................................................................................... 4

19 580091885 Nut .............................................................................................................. 4

20 580085970 Plate ........................................................................................................... 1

21 580023008 Capscrew ............................................................................................................ 4

22 580027572 Nut ...................................................................................................................... 4

23 580051832 Grommet ............................................................................................................. 1

24 580084483 Striker Bolt .......................................................................................................... 1

25 580049229 Capscrew ............................................................................................................ 2

26 580044860 Insert ................................................................................................................... 2

27 580056664 Gas Spring (RH) ................................................................................................. 1

27 580056664 Gas Spring (LH) .................................................................................................. 1

27 a 582004571 Gas Spring (LH) .................................................................................................. 1

28 580049915 Ball Stud (RH) ..................................................................................................... 2

28 580049915 Ball Stud (LH) ..................................................................................................... 2

28 a 582004516 Ball Stud (LH) ..................................................................................................... 2

29 580004592 Nut ...................................................................................................................... 2

30 580086342 Hood Support ...................................................................................................... 1

31 580056815 Capscrew ............................................................................................................ 2

32 580044860 Insert ................................................................................................................... 2

33 580049758 Fastener .............................................................................................................. 8

34 580058137 Plug ..................................................................................................................... 1

FOOTNOTES:

a With lift and latch option

A974

1-17

Page 36

P21596 11-09

NON SUSPENSION SEAT (FIGURE 1-9)

WITHOUT ELECTRONIC CONTROLS

1-18

A974

Page 37

11-09 P21596

NON SUSPENSION SEAT

WITHOUT ELECTRONIC CONTROLS

ITEM PART NO. DESCRIPTION QTY

582003574 Seat-Non Suspension ......................................................................................... 1

1 580049906 Kit-Seat Cushion (Vinyl) ................................................................................. 1

2 580049892 Hip Restraint (LH) ........................................................................................... 1

3 580090679 Kit-Seat Rail ................................................................................................... 1

4 580097531 Sensor (Operator Presence) .......................................................................... 1

5 582000813 Bracket (Operator Presence Sensor) ............................................................. 1

6 582005028 Wire Harness .................................................................................................. 1

7 580049893 Hip Restraint (RH) .......................................................................................... 1

8 580056926 Storage Box .................................................................................................... 1

9 580018614 Cover .............................................................................................................. 1

10 580086211 Seat Belt ............................................................................................................. 1

10 580062078 Kit-Seat Belt (Black) ............................................................................................ 1

10 524281279 Kit-Seat Belt (Red) .............................................................................................. 1

11 449015098 Nut ...................................................................................................................... 4

12 580087659 Stud .................................................................................................................... 4

13 520082877 Capscrew ............................................................................................................ 2

14 580056005 Washer ............................................................................................................... 6

15 502097909 Locknut ............................................................................................................... 2

16 580092987 Cover (Seat Side Electrical) ................................................................................ 1

17 582002621 Cover Plate ......................................................................................................... 1

18 940400905 Washer ............................................................................................................... 2

19 580092732 Capscrew ............................................................................................................ 2

20 449001412 Capscrew ............................................................................................................ 2

21 016103500 Washer ............................................................................................................... 1

22 580046396 Clamp ................................................................................................................. 1

23 580060018 Nut ...................................................................................................................... 2

24 023021000 Roll Pin ............................................................................................................... 1

A974

1-19

Page 38

P22068 05-10

FULL SUSPENSION SEAT (FIGURE 1-10)

MANUAL HYDRAULIC — NON-SWIVEL

1-20

A974

Page 39

05-10 P22068

FULL SUSPENSION SEAT

MANUAL HYDRAULIC – NON-SWIVEL

ITEM PART NO. DESCRIPTION QTY

582003582 Seat-Full Suspension (Vinyl) (Non-Swivel) ......................................................... 1

1 580095476 Kit-Cushion (Seat and Back, Vinyl) ................................................................ 1

2 580095474 Kit-Cushion (Back Cushion, Vinyl) ............................................................. 1

2 . . . . . Back Cushion ......................................................................................... 1

2 . . . . . Screw ..................................................................................................... 2

3 580095475 Kit-Seat Cushion (Vinyl) ............................................................................. 1

3 . . . . . Seat Cushion ......................................................................................... 1

3 . . . . . Spring .................................................................................................... 2

3 . . . . . Cotter Pin ............................................................................................... 2

4 580095462 Kit-Weight Adjuster ......................................................................................... 1

4 . . . . . Knob ........................................................................................................... 1

4 . . . . . Bushing ...................................................................................................... 1

4 . . . . . Washer ....................................................................................................... 1

4 . . . . . Pin .............................................................................................................. 1

5 580095463 Kit-Service (Front Panel) (Non Swivel) ........................................................... 1

5 . . . . . Front Panel ................................................................................................. 1

5 . . . . . Socket Head Capscrew .............................................................................. 2

5 . . . . . Roll Pin ....................................................................................................... 1

6 580095477 Kit-Seat Rail ................................................................................................... 1

6 . . . . . Locking Rail ................................................................................................ 1

6 . . . . . Slave Rail ................................................................................................... 1

6 . . . . . Bolt ............................................................................................................. 4

6 . . . . . Nut .............................................................................................................. 4

7 582005028 Wire Harness .................................................................................................. 1

7 580049884 Sensor (Operator Presence) ...................................................................... 1

8 582004126 Armrest (Left-Hand Side) .................................................................................... 1

9 311207098 Screw .................................................................................................................. 2

10 580057451 Washer ............................................................................................................... 2

11 502097909 Locknut ............................................................................................................... 2

12 580056005 Washer ............................................................................................................... 6

13 520082877 Capscrew ............................................................................................................ 2

14 582002534 Cover Plate ......................................................................................................... 1

15 023021000 Roll Pin ............................................................................................................... 1

16 . . . . . Seat Belt ............................................................................................................. 1

17 580084956 Armrest (Right-Hand Side) ................................................................................. 1

18 582002535 Spacer ................................................................................................................ 2

19 518803677 Nut ...................................................................................................................... 4

20 203142800 Capscrew ............................................................................................................ 2

21 062151600 Capscrew ............................................................................................................ 2

22 580092732 Capscrew ............................................................................................................ 2

23 940400905 Washer ............................................................................................................... 2

24 580092987 Cover (Seat Side Electrical) ................................................................................ 1

25 504230271 Nut ...................................................................................................................... 4

26 580087659 Stud .................................................................................................................... 4

a 580014465 Information Case (Kit) ......................................................................................... 1

580095465 Kit-Service Internal Tether-80 MM Travel ........................................................... 1

580095460 Kit-Damper Service ............................................................................................. 1

580095461 Kit-Recliner (Back Seat Adjustment) .................................................................. 1

A974

1-21

Page 40

P22068 05-10

FOOTNOTES:

a Not Illustrated

1-22

A974

Page 41

NOTES

05-10 P22068

A974

1-23

Page 42

P22082 06-10

FULL SUSPENSION SEAT (FIGURE 1-11)

SHEET 2 OF 2

1-24

A974

Page 43

06-10 P22082

FULL SUSPENSION SEAT

SHEET 2 OF 2

ITEM PART NO. DESCRIPTION QTY

1 580095461 Kit-Recliner (Back Seat Adjustment) .................................................................. 1

2 . . . . . Knob ............................................................................................................... 1

3 . . . . . Lever .............................................................................................................. 1

4 580018642 Plate ............................................................................................................... 1

5 . . . . . Spring ............................................................................................................. 1

6 580018643 Latch ............................................................................................................... 1

7 580057307 Nut .................................................................................................................. 2

8 580095460 Kit-Damper Service ............................................................................................. 1

9 580057260 Damper ........................................................................................................... 1

10 580057307 Nut .................................................................................................................. 2

11 580057266 Bolt ................................................................................................................. 2

A974

1-25

Page 44

P21900 03-10

LABELS (FIGURE 1-12)

SHEET 1 OF 2

1-26

A974

Page 45

03-10 P21900

LABELS

SHEET 1 OF 2

ITEM PART NO. DESCRIPTION QTY

1 504231215 Label (Mast Warning) ......................................................................................... 1

2 504231296 Label (Operator Restraint) .................................................................................. 1

3 a . . . . . Nameplate Tag ................................................................................................... 1

4 580008064 Nameplate .......................................................................................................... 1

5 505976530 Rivet .................................................................................................................... 4

5 501904907 Rivet (Optional) ................................................................................................... 4

6 524232141 Label (Standard Transmission) ........................................................................... 1

7 524162256 Label (Patents and Trademarks) ........................................................................ 1

8 504231248 Label (No Riders) ................................................................................................ 2

9 524208880 Label (Yale) ........................................................................................................ 1

10 524310789 Label (Yale Logo) ............................................................................................... 1

11 505977565 Label (Flammable LP-Gas) ................................................................................. 1

12 a . . . . . U.L. Plate ............................................................................................................ 1

13 580051779 Lens (Lift) ............................................................................................................ 1

14 580051780 Lens (Tilt) ............................................................................................................ 1

15 580051790 Lens (Side-Shift) ................................................................................................. 1

15 580052203 Lens (Blank) ........................................................................................................ 1

16 505976530 Rivet .................................................................................................................... 4

16 640032905 Rivet (Optional) ................................................................................................... 1

16 505977584 Gripnail (Optional) ............................................................................................... 4

17 580056430 Label (Parking Brake Warning) ........................................................................... 1

18 550016119 Label (Capacity) .................................................................................................. 2

FOOTNOTES:

a Contact your local Yale dealer

A974

1-27

Page 46

P21901 02-10

LABELS (FIGURE 1-13)

SHEET 2 OF 2

1-28

A974

Page 47

02-10 P21901

LABELS

SHEET 2 OF 2

ITEM PART NO. DESCRIPTION QTY

1 580058821 Label (Mast Warning) ......................................................................................... 2

2 504231252 Label (Pinch Point) ............................................................................................. 2

3 582006614 Label ................................................................................................................... 1

4 580026933 Nameplate (LP Tank) .......................................................................................... 1

5 580055312 Label (Operator Warning) ................................................................................... 1

6 a . . . . . Overhead Guard ................................................................................................. 1

7 580058357 Label (Locking Gas Spring) ................................................................................ 1

7 580058356 Label (Locking Gas Spring) ................................................................................ 1

8 505976556 Label (Fan Warning) ........................................................................................... 1

9 505976545 Label (Antifreeze) ............................................................................................... 1

10 518806645 Label (Boron-Free Antifreeze) ............................................................................ 1

FOOTNOTES:

a Contact your local Yale dealer

A974

1-29

Page 48

P21901 02-10

NOTES

1-30

A974

Page 49

SECTION 2

2 ENGINE ASSEMBLY

Page 50

Page 51

CONTENTS

SECTION 2

ENGINE ASSEMBLY

DESCRIPTION PAGE

ASSEMBLED ENGINE

MAZDA 2.0L, LPG - 2010 EMISSION COMPLIANT ENGINES .................................................................. 2-6

CRANKSHAFT AND PISTONS

MAZDA 2.0L, LPG - 2010 EMISSION COMPLIANT ENGINES .................................................................. 2-14

CYLINDER BLOCK

MAZDA 2.0L LPG - 2010 EMISSION COMPLIANT ENGINES ................................................................... 2-10

CYLINDER HEAD AND COVER

MAZDA 2.0L LPG - 2010 EMISSION COMPLIANT ENGINES ................................................................... 2-8

EMISSION CONTROL SYSTEM

MAZDA 2.0L, LPG - 2010 EMISSION COMPLIANT ENGINES .................................................................. 2-22

ENGINE COOLING SYSTEM

MAZDA 2.0L, LPG - 2010 EMISSION COMPLIANT ENGINES .................................................................. 2-20

ENGINE MOUNTING ...................................................................................................................................... 2-4

EXHAUST MANIFOLD

MAZDA 2.0L, LPG - 2010 EMISSION COMPLIANT ENGINES .................................................................. 2-18

FLYWHEEL AND HOUSING ASSEMBLY

MAZDA 2.0L ................................................................................................................................................ 2-2

INTAKE MANIFOLD

MAZDA 2.0L, LPG - 2010 EMISSION COMPLIANT ENGINES .................................................................. 2-16

OIL PUMP AND FILTER

MAZDA 2.0L, LPG - 2010 EMISSION COMPLIANT ENGINES .................................................................. 2-24

TIMING GEAR COVER AND OIL PAN

MAZDA 2.0L, LPG - 2010 EMISSION COMPLIANT ENGINES .................................................................. 2-12

A974

2-1

Page 52

P21906 05-10

FLYWHEEL AND HOUSING ASSEMBLY (FIGURE 2-1)

MAZDA 2.0L

2-2

A974

Page 53

05-10 P21906

FLYWHEEL AND HOUSING ASSEMBLY

MAZDA 2.0L

ITEM PART NO. DESCRIPTION QTY

1 580048123 Flywheel Housing ............................................................................................... 1

2 940102909 Washer ............................................................................................................... 6

3 930903905 Capscrew ............................................................................................................ 6

4 580032011 Capscrew ............................................................................................................ 4

5 449001138 Capscrew ............................................................................................................ 6

6 504057795

449022013 Lockwasher ......................................................................................................... 6

7 580050042 Dowel .................................................................................................................. 2

8 580039900 Capscrew ............................................................................................................ 5

9 580070914 Dust Cover .......................................................................................................... 1

10 580046451 Capscrew ............................................................................................................ 2

11 580056439 Fitting .................................................................................................................. 1

12 580064311 Flywheel (With Ring Gear) .................................................................................. 1

12 580056441 Flywheel (With Ring Gear) .................................................................................. 1

13 502566902 Washer ............................................................................................................... 6

14 580056440 Capscrew ............................................................................................................ 6

15 582005953 Bracket ................................................................................................................ 1

501702901 Loctite ................................................................................................................. AR

A974

2-3

Page 54

P21903 11-09

ENGINE MOUNTING (FIGURE 2-2)

2-4

A974

Page 55

11-09 P21903

ENGINE MOUNTING

ITEM PART NO. DESCRIPTION QTY

1 580060600 Mount (RH) ......................................................................................................... 1

1 580060601 Mount (LH) .......................................................................................................... 1

2 931017918 Capscrew ............................................................................................................ 2

3 580027945 Washer ............................................................................................................... 2

4 580048458 Washer ............................................................................................................... 4

5 580051383 Isolator ................................................................................................................ 4

6 580051384 Nut (Flange) ........................................................................................................ 2

7 580056444 Bolt (Flange) ....................................................................................................... 8

A974

2-5

Page 56

P21917 05-10

ASSEMBLED ENGINE (FIGURE 2-3)

MAZDA 2.0L, LPG — 2010 EMISSION COMPLIANT ENGINES

2-6

A974

Page 57

05-10 P21917

ASSEMBLED ENGINE

MAZDA 2.0L, LPG – 2010 EMISSION COMPLIANT ENGINES

ITEM PART NO. DESCRIPTION QTY

1 580078922 Long Block .......................................................................................................... 1

2 580053154 Short Block ..................................................................................................... 1

3 901290828 Bolt ............................................................................................................. 2

4 910983100 Cover .......................................................................................................... 1

5 901300827 Gasket ........................................................................................................ 1

A974

2-7

Page 58

P21907 05-10

CYLINDER HEAD AND COVER (FIGURE 2-4)

MAZDA 2.0L LPG — 2010 EMISSION COMPLIANT ENGINES

2-8

A974

Page 59

05-10 P21907

CYLINDER HEAD AND COVER

MAZDA 2.0L LPG – 2010 EMISSION COMPLIANT ENGINES

ITEM PART NO. DESCRIPTION QTY

580078922 Long Block .......................................................................................................... 1

1 901290834 Engine Cover .................................................................................................. 1

2 901290808 Plate ........................................................................................................... 1

3 901848826 Screw ......................................................................................................... 10

4 901290811 Gasket ............................................................................................................ 1

5 580046873 PCV Valve ...................................................................................................... 1

6 901290818 Seal ................................................................................................................ 1

7 901270814 Cap ................................................................................................................. 1

8 901270815 Gasket ........................................................................................................ 1

9 . . . . . Label ............................................................................................................... 1

10 901290843 Screw ............................................................................................................. 2

11 505960516 Bracket ........................................................................................................... 2

12 901290825 Bolt ................................................................................................................. 7

13 901290836 Cylinder Head ................................................................................................. 1

14 901290832 Pin .............................................................................................................. 10

15 901290838 Guide .......................................................................................................... 8

16 901270802 Clip ......................................................................................................... 1

17 b 901274801 Seal (Inlet) .................................................................................................. 4

17 a 901290837 Seal (Exhaust) ............................................................................................ 4

18 901290831 Bolt ............................................................................................................. 10

19 901271817 Plug ............................................................................................................ 1

20 901290803 Bolt ................................................................................................................. 10

21 901290804 Washer ........................................................................................................... 10

22 901290806 Cap ................................................................................................................. 8

23 580033512 Bolt ................................................................................................................. 3

24 901085837 Stud ................................................................................................................ 20

25 901290842 Hanger ............................................................................................................ 1

26 504259764 Gasket (Cylinder Head) .................................................................................. 1

27 901290829 Stud ................................................................................................................ 2

28 901290816 Bracket ........................................................................................................... 1

FOOTNOTES:

a Black b Red/Brown

A974

2-9

Page 60

P21908 05-10

CYLINDER BLOCK (FIGURE 2-5)

MAZDA 2.0L LPG — 2010 EMISSION COMPLIANT ENGINES

2-10

A974

Page 61

05-10 P21908

CYLINDER BLOCK

MAZDA 2.0L LPG – 2010 EMISSION COMPLIANT ENGINES

ITEM PART NO. DESCRIPTION QTY

580078922 Long Block .......................................................................................................... 1

580053154 Short Block ..................................................................................................... 1

1 580046879 Cylinder Block ............................................................................................ 1

2 900542813 Plug ........................................................................................................ 2

3 900281820 Plug ........................................................................................................ 2

4 901015826 Plug ........................................................................................................ 2

5 901291803 Joint Fitting ............................................................................................ 1

6 901271817 Plug ........................................................................................................ 4

7 901291801 Pin .......................................................................................................... 2

8 901291804 Tube Assy .............................................................................................. 1

9 901291813 Pin .......................................................................................................... 2

10 901271816 Plug ........................................................................................................ 2

11 901291814 Bolt ......................................................................................................... 10

12 901291807 Dipstick ....................................................................................................... 1

13 900281819 Plug ............................................................................................................ 1

14 901574814 Plug ............................................................................................................ 2

15 580046878 Plug ............................................................................................................ 2

A974

2-11

Page 62

P21909 05-10

TIMING GEAR COVER AND OIL PAN (FIGURE 2-6)

MAZDA 2.0L, LPG — 2010 EMISSION COMPLIANT ENGINES

2-12

A974

Page 63

05-10 P21909

TIMING GEAR COVER AND OIL PAN

MAZDA 2.0L, LPG – 2010 EMISSION COMPLIANT ENGINES

ITEM PART NO. DESCRIPTION QTY

580078922 Long Block (2.0L LPG) ....................................................................................... 1

1 901290825 Bolt ................................................................................................................. 5

2 580046886 Cover (Upper Timing Belt) (2.0L) ................................................................... 1

3 580046887 Gasket (2.0L) ............................................................................................. 1

4 580046885 Housing (2.0L) ................................................................................................ 1

4 901292811 Oil Seal ....................................................................................................... 1

5 901292816 Stud ............................................................................................................ 2

6 505960594 Connector ................................................................................................... 1

7 901292819 Screw ............................................................................................................. 2

8 900559852 Nut .................................................................................................................. 2

9 901292831 Gasket ............................................................................................................ 1

10 901292812 Cover .............................................................................................................. 1

11 901292814 Oil Seal (Rear) ........................................................................................... 1

12 505960538 Pin .............................................................................................................. 2

13 901575820 Bolt ................................................................................................................. 6

14 911378400 Cover (Lower) ................................................................................................. 1

15 901292832 Gasket ............................................................................................................ 1

16 901292803 Oil Pan (2.0L) ................................................................................................. 1

17 900543845 Gasket ........................................................................................................ 1

18 901272802 Drain Plug .................................................................................................. 1

19 901272820 Capscrew ....................................................................................................... 19

20 901575826 Cover .............................................................................................................. 1

21 901575808 Gasket ........................................................................................................ 1

22 901575824 Bolt ................................................................................................................. 1

504259763 Kit-Gasket ....................................................................................................... 1

A974

2-13

Page 64

P21910 05-10

CRANKSHAFT AND PISTONS (FIGURE 2-7)

MAZDA 2.0L, LPG — 2010 EMISSION COMPLIANT ENGINES

2-14

A974

Page 65

05-10 P21910

CRANKSHAFT AND PISTONS

MAZDA 2.0L, LPG – 2010 EMISSION COMPLIANT ENGINES

ITEM PART NO. DESCRIPTION QTY

580078922 Long Block (2.0L, LPG) ...................................................................................... 1

1 524319552 Piston Rod ...................................................................................................... 4

2 901293825 Nut .............................................................................................................. 2

3 901293811 Piston Rod Bearing (Standard) ...................................................................... 1

3 901293812 Piston Rod Bearing (0.25 mm) ....................................................................... 1

3 901293813 Piston Rod Bearing (0.50 mm) ....................................................................... 1

3 901293814 Piston Rod Bearing (0.75 mm) ....................................................................... 1

4 580053173 Piston and Rod (Standard) ............................................................................. 4

4 580053177 Piston (0.25 mm) ............................................................................................ 4

4 580053175 Piston (0.50 mm) ............................................................................................ 4

5 580024213 Kit-Piston Ring (Standard) .............................................................................. 1

5 580024215 Kit-Piston Ring (0.25 mm) .............................................................................. 1

5 580024214 Kit-Piston Ring (0.50 mm) .............................................................................. 1

6 505960536 Bolt ................................................................................................................. 6

7 580046889 Crankshaft Pulley ........................................................................................... 1

8 504259749 Bolt ................................................................................................................. 1

9 504259748 Plate ............................................................................................................... 1

10 504259745 Pulley .............................................................................................................. 1

11 505960548 Key ................................................................................................................. 1

12 505960503 Crankshaft (2.0L) ............................................................................................ 1

13 901293861 Kit-Crankshaft Bearing (Standard) ................................................................. 1

13 901293862 Crankshaft Bearing (0.25 mm) ....................................................................... 1

13 901293863 Crankshaft Bearing (0.50 mm) ....................................................................... 1

13 901293864 Crankshaft Bearing (0.75 mm) ....................................................................... 1

A974

2-15

Page 66

P21911 05-10

INTAKE MANIFOLD (FIGURE 2-8)

MAZDA 2.0L, LPG — 2010 EMISSION COMPLIANT ENGINES

2-16

A974

Page 67

05-10 P21911

INTAKE MANIFOLD

MAZDA 2.0L, LPG – 2010 EMISSION COMPLIANT ENGINES

ITEM PART NO. DESCRIPTION QTY

1 900559852 Nut ...................................................................................................................... 4

2 580046909 Gasket ................................................................................................................ 1

3 901295811 Bolt ...................................................................................................................... 2

4 580089541 Intake Manifold ................................................................................................... 1

5 580053508 Clamp ............................................................................................................. 1

6 580053803 Cap ................................................................................................................. 1

7 580041817 Sensor (Air Temperature) ............................................................................... 1

7 901084817 Plug ................................................................................................................ 1

8 900542824 Washer ........................................................................................................... 1

9 580078951 Connector ....................................................................................................... 1

10 900529808 Seal ................................................................................................................ 1

11 901085825 Bolt ...................................................................................................................... 1

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Page 68

P21912 05-10

EXHAUST MANIFOLD (FIGURE 2-9)

MAZDA 2.0L, LPG — 2010 EMISSION COMPLIANT ENGINES

ITEM PART NO. DESCRIPTION QTY

1 901290828 Bolt ...................................................................................................................... 3

2 901296807 Cover .................................................................................................................. 1

3 901296805 Washer ............................................................................................................... 6

4 901276803 Nut ...................................................................................................................... 6

5 901296806 Exhaust Manifold ................................................................................................ 1

6 901276809 Stud ................................................................................................................ 4

7 912189300 Gasket ................................................................................................................ 2

8 901296804 Gasket ................................................................................................................ 1

9 504256775 Gasket ............................................................................................................ 2

2-18

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NOTES

05-10 P21912

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2-19

Page 70

P21913 05-10

ENGINE COOLING SYSTEM (FIGURE 2-10)

MAZDA 2.0L, LPG — 2010 EMISSION COMPLIANT ENGINES

2-20

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Page 71

05-10 P21913

ENGINE COOLING SYSTEM

MAZDA 2.0L, LPG – 2010 EMISSION COMPLIANT ENGINES

ITEM PART NO. DESCRIPTION QTY

580078922 Long Block .......................................................................................................... 1

1 900559852 Nut .................................................................................................................. 2

2 901302814 Cover .............................................................................................................. 1

3 580024168 Thermostat ..................................................................................................... 1

4 524253576 Thermostat ................................................................................................. 1

5 901282846 Gasket ........................................................................................................ 1

6 580046981 Pipe (Water) ................................................................................................... 1

7 505960545 Cap ............................................................................................................. 1

8 580053508 Clamp ......................................................................................................... 1

9 901579818 Clip ............................................................................................................. 1

10 505959558 Clamp ......................................................................................................... 4

11 901579806 Radiator Hose (Water) ............................................................................... 1

12 901290828 Bolt ................................................................................................................. 1

13 901302834 Bolt ................................................................................................................. 1

14 901292819 Screw ............................................................................................................. 2

15 901302821 O-Ring ............................................................................................................ 1

16 901579833 Gasket (Inlet) .................................................................................................. 1

17 901579811 Adapter (Inlet) ................................................................................................. 1

18 580053400 Bracket (Fan) .................................................................................................. 1

19 504258737 Screw ......................................................................................................... 3

20 901579827 Shaft ........................................................................................................... 1

21 504258725 Clip ............................................................................................................. 1

22 900526819 Bolt ................................................................................................................. 4

23 524264688 Bolt ................................................................................................................. 5

24 901579805 Gasket ............................................................................................................ 1

25 524242078 Water Pump ................................................................................................... 1

26 901579804 Seal ................................................................................................................ 1

27 901579802 Seal ................................................................................................................ 1

28 901579803 Seal ................................................................................................................ 1

29 901302840 Stud ................................................................................................................ 1

30 901096876 Seal ................................................................................................................ 1

31 504258732 Baffle .............................................................................................................. 1

32 524264690 Bolt ................................................................................................................. 1

33 505960550 Radiator Hose ................................................................................................ 1

34 505960521 Pipe (Water Bypass) ...................................................................................... 1

35 580024169 Hose Clamp .................................................................................................... 1

36 505960531 Cap ................................................................................................................. 1

37 901302839 Bolt ................................................................................................................. 1

38 582005785 Fan Pulley ...................................................................................................... 1

a 580000727 Fan ...................................................................................................................... 1

FOOTNOTES:

a Not Illustrated

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Page 72

P21914 05-10

EMISSION CONTROL SYSTEM (FIGURE 2-11)

MAZDA 2.0L, LPG — 2010 EMISSION COMPLIANT ENGINES

ITEM PART NO. DESCRIPTION QTY

1 580045523 Sensor (Boost, M.A.P.) (Boost) .......................................................................... 1

2 580078965 Hose (PCV) ......................................................................................................... 1

3 505960520 Clamp ................................................................................................................. 1

4 580078950 Intake Manifold ................................................................................................... 1

4 580089541 Intake Manifold ................................................................................................... 1

2-22

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NOTES

05-10 P21914

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2-23

Page 74

P21916 05-10

OIL PUMP AND FILTER (FIGURE 2-12)

MAZDA 2.0L, LPG — 2010 EMISSION COMPLIANT ENGINES

2-24

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Page 75

05-10 P21916

OIL PUMP AND FILTER

MAZDA 2.0L, LPG – 2010 EMISSION COMPLIANT ENGINES

ITEM PART NO. DESCRIPTION QTY

580078922 Long Block .......................................................................................................... 1

1 580001828 Engine Oil Pump ............................................................................................ 1

2 901271803 Pin (Timing Indicator) ................................................................................. 2

3 901292811 Oil Seal ....................................................................................................... 1

4 580001826 Plunger ....................................................................................................... 1

5 900291803 Spring ......................................................................................................... 1

6 900291804 Spring Seat ................................................................................................ 1

7 901301821 Snap Ring .................................................................................................. 1

8 580024166 Plug ............................................................................................................ 1

9 901578809 Cover .......................................................................................................... 1

10 580001829 Screw ......................................................................................................... 7

11 901578811 Gear (Inner) ................................................................................................ 1

12 901578812 Gear (Outer) ............................................................................................... 1

13 901301823 Strainer ........................................................................................................... 1

14 901301822 Gasket ............................................................................................................ 1

15 901301815 Oil Filter .......................................................................................................... 1

16 901578816 Bolt ................................................................................................................. 2

17 901301802 O-Ring ............................................................................................................ 1

18 901301818 Screw ............................................................................................................. 2

19 901282833 Screw ............................................................................................................. 1

20 580024167 Pin (Top Indicator) .......................................................................................... 1

21 901292819 Screw ............................................................................................................. 4

524264678 Gasket (Liquid) ............................................................................................... AR

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P21916 05-10

NOTES

2-26

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Page 77

SECTION 3

3 EXHAUST SYSTEM

Page 78

Page 79

CONTENTS

SECTION 3

EXHAUST SYSTEM

DESCRIPTION PAGE

EXHAUST SYSTEM WITH CATALYTIC CONVERTER

MAZDA 2.0L, LPG ....................................................................................................................................... 3-2

MAZDA 2.0L, LPG - LATIN AMERICAN SERIES ....................................................................................... 3-4

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3-1

Page 80

P21904 11-09

EXHAUST SYSTEM WITH CATALYTIC CONVERTER (FIGURE 3-1)

MAZDA 2.0L, LPG

3-2

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Page 81

11-09 P21904

EXHAUST SYSTEM WITH CATALYTIC CONVERTER

MAZDA 2.0L, LPG

ITEM PART NO. DESCRIPTION QTY

1 580056381 Locknut ............................................................................................................... 6

2 912189300 Gasket ................................................................................................................ 1

3 580093953 Exhaust Pipe ....................................................................................................... 1

4 580057842 Exhaust Shield .................................................................................................... 1

5 580097537 Isolator ................................................................................................................ 4

6 580027572 Nut ...................................................................................................................... 4

7 580039142 Bracket ................................................................................................................ 1

8 582000157 Spacer ................................................................................................................ 2

9 580030968 Capscrew ............................................................................................................ 2

10 580058890 Exhaust Pipe ....................................................................................................... 1

11 057092500 Clamp ................................................................................................................. 1

12 580073415 Muffler (Welded) (Optional) ................................................................................ 1

12 580073416 Muffler (Crimped) ................................................................................................ 1

13 580087650 Gasket ................................................................................................................ 2

14 580073413 Exhaust Pipe ....................................................................................................... 1

15 580020060 Nut ...................................................................................................................... 2

16 449022017 Lockwasher ......................................................................................................... 2

17 580087651 Gasket ................................................................................................................ 1

18 582001684 Catalytic Converter ............................................................................................. 1

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Page 82

P21905 02-10

EXHAUST SYSTEM WITH CATALYTIC CONVERTER (FIGURE 3-2)

MAZDA 2.0L, LPG — LATIN AMERICAN SERIES

3-4

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02-10 P21905

EXHAUST SYSTEM WITH CATALYTIC CONVERTER

MAZDA 2.0L, LPG – LATIN AMERICAN SERIES

ITEM PART NO. DESCRIPTION QTY

1 580056381 Locknut ............................................................................................................... 6

2 912189300 Gasket ................................................................................................................ 1

3 580093953 Exhaust Pipe ....................................................................................................... 1

4 580057842 Exhaust Shield .................................................................................................... 1

5 580097537 Isolator ................................................................................................................ 4

6 580027572 Nut ...................................................................................................................... 4

7 582006504 Bracket ................................................................................................................ 1