Engine Mechanical: Removal & Installation Suzuki Verona I

Engine Mount (LH) Installation

1. Installation should follow the removal procedure in the reverse order.
2. Install the engine mount (LH). Tighten: Tighten the 4 transaxle mount cage-to-longitudinal member bolts to 55 - 75 N.m (41 - 55 lb-ft). Tighten the transaxle mount cage-to-transaxle mount bracket bolt to 55 - 75 N.m (41 - 55 lb-ft). Tighten the transaxle mount cage-to-transaxle mount bracket nut to 55 - 75 N.m (41 - 55 lb-ft). Tighten the transaxle mount cage through bolt to 100 - 120 N.m (74 - 89 lb-ft).

Engine Assembly Removal

Tools Required

DW110-060 Engine Assembly Lift Support

DW010-010 Power Pack Stand

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1. Remove the fuel pump fuse.
2. Start the engine and repeat cranking until the remaining fuel in the fuel line is all consumed.
3. Disconnect the negative battery cable.
4. Drain the engine coolant. Refer to «DRAINING AND REFILLING THE COOLING SYSTEM»(ref-257290-S30388178292007070900000) .
5. Drain the engine oil.
6. Drain the transaxle oil.
7. Drain the power steering oil.
8. Recover the refrigerant. Refer to «DISCHARGING, ADDING OIL, EVACUATING AND CHARGING PROCEDURES FOR A/C SYSTEM»(ref-257313-S22811448672007070900000) .
9. Remove the engine beautification cover.
10. Remove the air filter snorkel.
11. Remove the air filter housing assembly.
12. Remove the breather hose.
13. Disconnect the coolant reservoir hoses.
14. Remove the coolant reservoir. Refer to «SURGE TANK REMOVAL»(ref-257290-S14034785052007070900000) .
15. Disconnect the power steering pump outlet pipe.
16. Disconnect the fuel rail hose and fuel feeding/return pipe.
17. Disconnect the connectors on the O2S, EGR, charcoal canister purge solenoid valve, MAP sensor, Throttle body, engine oil pressure sensor, CMP sensor, knock sensor, VIS and the engine coolant temperature sensor.
18. Detach wiring harness from the wiring harness bracket on the cylinder block.
19. Disconnect the engine block ground by removing the engine block ground bolts.
20. Remove the battery.
21. Disconnect the automatic transaxle cable.
22. Disconnect the inhibit switch connector.
23. Disconnect the connectors on the transaxle. Refer to «TRANSAXLE ASSEMBLY REMOVAL»(ref-257306-S19054211392007070900000) .
24. Disconnect the generator connector and wiring harness. Refer to «GENERATOR REMOVAL»(ref-257294-S05060234262007070900000) .
25. Remove the upper and lower radiator hoses. Refer to «RADIATOR REMOVAL»(ref-257290-S25696121392007070900000) .
26. Remove the front wheels.
27. Remove the engine under covers.
28. Remove the front axle shaft. Refer to «DRIVE AXLE ASSEMBLY REMOVAL»(ref-257299-S10203536352007070900000) .
29. Remove the front muffler. Refer to «MUFFLER - FRONT REMOVAL»(ref-257291-S17143744012007070900000) .
30. Support the engine assembly using the engine assembly lift support DW110-060.
31. Remove the impact beam. Refer to «IMPACT BEAM REMOVAL»(ref-257288-S41785055042007070900000) .
32. Remove the front engine mount bracket-to-damper bush bolt/nut and the rear transaxle mount bracket-to-damper bush bolt/nut.
33. Remove the center front suspension member bolts and the center front suspension member.
34. Disconnect the connector on the compressor.
35. Disconnect the refrigerant suction and discharge pipe block from the compressor.
36. Remove the oil filter.
37. Support the engine and transaxle with the power pack stand DW010-010.
38. Remove the engine mount bracket (RH). Refer to «Engine Mount (RH) Removal»(ref-257287-S12259165242007070900000) .
39. Remove the engine mount bracket (LH). Refer to «Engine Mount (LH) Removal»(ref-257287-S06917748712007070900000) .
40. Separate the engine and transaxle assembly from the engine compartment.
41. Remove the starter. Refer to «STARTER REMOVAL»(ref-257293-S24857688332007070900000) .
42. Remove three (3) transaxle torque converter bolts.
43. Remove the transaxle-to-engine block bolts.
44. Remove the rear transaxle mount bracket.
45. Remove the front damper bush bracket.
46. Remove the engine block-to-transaxle bolts.
47. Remove the engine block-to-transaxle bolts.
48. Remove the engine assembly from the transaxle. CAUTION: Be careful not to damage the torque converter when removing the transaxle.

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1. Installation should follow the removal procedure in the reverse order.
2. Tighten the engine block-to-transaxle bolts near the rear transaxle bracket. Tighten: Tighten the engine block-to-transaxle bolts to 60 - 85 N.m (44 - 63 lb-ft).
3. Tighten the engine block-to-transaxle bolts near the front engine mount bracket. Tighten: Tighten the engine block-to-transaxle bolts to 60 - 85 N.m (44 - 63 lb-ft).
4. Tighten the transaxle-to-engine block bolts near the rear support bracket. Tighten: Tighten the transaxle-to-engine block bolts to 60 - 85 N.m (44 - 63 lb-ft).
5. Tighten the 3 flexible plate-to-torque converter retaining bolts. Tighten: Tighten the transaxle torque converter bolts to 40 - 50 N.m (30 - 37 lb-ft).
6. Install the rear transaxle mount bracket. Tighten: Tighten the rear transaxle mount bracket bolts to 55 - 75 N.m (26 - 55 lb-ft).
7. Install the front damper bush bracket. Tighten: Tighten the front damper bush bracket bolts to 55 - 75 N.m (26 - 55 lb-ft).
8. Install the starter. Refer to «STARTER INSTALLATION»(ref-257293-S16114737922007070900000) .
9. Install the engine and transaxle assembly using the power pack stand DW010-010.
10. Install the engine mount bracket (LH). Refer to «Engine Mount (LH) Installation»(ref-257287-S07425906512007070900000) .
11. Install the engine mount bracket (RH). Refer to «Engine Mount (RH) Installation»(ref-257287-S33241070542007070900000) .
12. Support the engine and transaxle assembly using the engine assembly lift support DW110-060.
13. Remove the power pack stand DW010-010.
14. Install the oil filter. Tighten: Tighten the oil filter to 12 - 16 N.m (106 - 142 lb-in.).
15. Install the center front suspension member. Tighten: Tighten the center front suspension member bolts to 80 - 100 N.m (59 - 74 lb-ft).
16. Tighten the front engine mount bracket-to-damper bush bolt/nut and the rear transaxle mount bracket-to-damper bush bolt/nut. Tighten: Tighten the front engine mount bracket-to-damper bush bolt/nut to 70 - 90 N.m (52 - 66 lb-ft). Tighten the rear transaxle mount bracket-to-damper bush bolt/nut to 70 - 90 N.m (52 - 66 lb-ft).
17. Install the front muffler. Refer to «MUFFLER - FRONT INSTALLATION»(ref-257291-S20805229172007070900000) .
18. Install the impact beam. Refer to " «IMPACT BEAM INSTALLATION»(ref-257288-S35833697012007070900000) ".
19. Install the axle shaft. Refer to «DRIVE AXLE ASSEMBLY INSTALLATION»(ref-257299-S20501949482007070900000) .
20. Install the engine under cover. Tighten: Tighten the engine under cover bolts to 17 - 27 N.m (13 - 20 lb-ft).
21. Install the battery. Tighten: Tighten the battery retaining nuts to 4 N.m (35 lb-in.).
22. Connect the connectors and cables on the transaxle. Refer to «TRANSAXLE ASSEMBLY INSTALLATION»(ref-257306-S04299207632007070900000) .
23. Connect the wiring harness, hoses, pipes, and connectors to the engine assembly.
24. Install the coolant reservoir. Refer to «SURGE TANK INSTALLATION»(ref-257290-S37072799822007070900000) . Tighten: Tighten the coolant reservoir bolts to 3.5 - 4.5 N.m (31 - 40 lb-in.).
25. Install the air filter housing. Tighten: Tighten the air filter housing bolt to 8 - 12 N.m (71 - 106 lb-in.).
26. Install the air filter snorkel. Tighten: Tighten the air filter snorkel retaining bolt to 5 - 7 N.m (44 - 62 lb-in.).
27. Install the engine beautification cover. Tighten: Tighten the engine beautification cover bolts to 8 - 12 N.m (71 - 106 lb-in.).
28. Connect the connectors and hoses.
29. Recharge the refrigerant. Refer to «DISCHARGING, ADDING OIL, EVACUATING AND CHARGING PROCEDURES FOR A/C SYSTEM»(ref-257313-S22811448672007070900000) .
30. Fill the power steering oil.
31. Fill the transaxle oil.
32. Fill the engine oil.

Timing Chain Removal

Tools Required

DW110-060 Engine Assembly Lift Support

DW010-010 Power Pack Stand

DW110-030 Engine Overhaul Stand

DW110-130-01 Crankshaft Pulley Holder

DW110-130-02 Crankshaft Pulley Installer/Remover

DW110-150 Camshaft Sprocket Holder

DW110-190 Crankshaft Adjuster

DW110-140 Timing Chain Cover Install Guide Pin

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1. Remove the fuel pump fuse.
2. Start the engine and repeat cranking until the remaining fuel in the fuel line is all consumed.
3. Disconnect the negative battery cable.
4. Drain the engine coolant. Refer to «DRAINING AND REFILLING THE COOLING SYSTEM»(ref-257290-S30388178292007070900000) .
5. Drain the engine oil.
6. Drain the transaxle oil.
7. Drain the power steering oil.
8. Recover the refrigerant.
9. Remove the engine assembly. Refer to «Engine Assembly Removal»(ref-257287-S03362334742007070900000) .
10. Remove the flexible plate bolts and the flexible plate.
11. Support the engine assembly with the engine overhaul stand DW110-030.
12. Remove the intake manifold. Refer to «Intake Manifold Removal»(ref-257287-S00484189752007070900000) .
13. Remove the cylinder head cover. Refer to «Cylinder Head Cover Removal»(ref-257287-S18058593362007070900000) .
14. Remove the drive belt.
15. Remove the oil pan. Refer to «OIL PAN / OIL PUMP REMOVAL»(ref-257289-S42367583452007070900000) .
16. Install the crankshaft pulley holder DW110-130-01 to the crankshaft pulley bolt. CAUTION: Very high torque is required to remove or to install the crankshaft pulley. Never remove the crankshaft pulley when the vehicle is hung on the lift.
17. Remove the crankshaft pulley bolt using the crankshaft pulley installer/remover DW110-130-02.
18. Remove the engine mount bracket support.
19. Remove the water pump pulley.
20. Remove the drive belt automatic tensioner retaining bolts and the tensioner.
21. Remove the timing chain cover.
22. Remove 2 dowel rings for timing cover.
23. Remove the timing chain tensioner.
24. Remove the fixed timing chain guide.
25. Remove the timing chain lever.
26. Remove the top chain guide.
27. Remove the timing chain.
28. Remove the crankshaft sprocket and the woodruff key.

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1. Installation should follow the removal procedure in the reverse order.
2. Install the timing chain after aligning both the mark on the camshaft sprocket and on the timing chain using camshaft sprocket holder DW110-150.
3. Align both the timing mark on the crankshaft sprocket and on the timing chain.
4. Adjust the crankshaft using the crankshaft adjuster DW110-190.
5. Make sure the 3 timing marks on the timing chain are exactly aligned with the marks on the exhaust camshaft sprocket, intake camshaft sprocket, and crankshaft sprocket respectively.
6. Install the fixed timing chain guide. Tighten: Tighten the fixed timing chain guide bolts to 18 - 22 N.m (13 - 16 lb-ft).
7. Install the timing chain lever. Tighten: Tighten the timing chain lever bolt to 18 - 22 N.m (13 - 16 lb-ft).
8. Install the timing chain tensioner. Tighten: Tighten the timing chain tensioner bolt to 18 - 22 N.m (13 - 16 lb-ft).
9. Install the top chain guide. Tighten: Tighten the top chain guide bolt to 9 - 11 N.m (80 - 97 lb-in.).
10. Install 2 dowel rings.
11. Apply the liquid gasket (Loctite® 5900-M8585) on the timing chain cover.
12. Install the timing chain cover install guide pin DW110-140 and position the timing chain cover. CAUTION: Be sure the applied liquid gasket is not damaged when installing the timing chain cover.
13. Install the timing chain cover. Tighten: Tighten the timing chain cover bolt (Center) to 18 - 22 N.m (13 - 16 lb-ft). Tighten the timing chain cover bolts to 6 - 10 N.m (53 - 89 lb-in.).
14. Install the drive belt automatic tensioner. Tighten: Tighten the drive belt automatic tensioner retaining bolt to 20 - 30 N.m (15 - 22 lb-ft).
15. Install the water pump pulley. Tighten: Tighten the water pump pulley bolts to 8 - 12 N.m (71 - 106 lb-in.).
16. Install the engine mount bracket support. Tighten: Tighten the engine mount bracket support bolts to 25 - 31 N.m (18 - 23 lb-ft).
17. Install the crankshaft pulley. Tighten the crankshaft pulley bolt using the crankshaft pulley holder DW110-130-01 and the crankshaft pulley installer/remover DW110-130-02. CAUTION: Very high torque is required to remove or to install the crankshaft pulley. Never remove the crankshaft pulley when the vehicle is hung on the lift. Tighten: Tighten the crankshaft pulley bolt to 500 - 600 N.m (369 - 443 lb-ft).
18. Install the oil pan. Refer to «OIL PAN / OIL PUMP INSTALLATION»(ref-257289-S34870784172007070900000) .
19. Install the cylinder head cover. Refer to «Cylinder Head Cover Installation»(ref-257287-S07218163042007070900000) .
20. Install the intake manifold. Refer to «Intake Manifold Installation»(ref-257287-S15190862132007070900000) .
21. Install the flexible plate. Tighten: Tighten the flexible plate bolts to 70 - 80 N.m (52 - 59 lb-ft).
22. Install the transaxle to the engine assembly.
23. Install the engine and transaxle assembly. Refer to «Engine Assembly Installation»(ref-257287-S39846853922007070900000) .

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1. Remove the fuel pump fuse.
2. Start the engine and repeat cranking until the remaining fuel in the fuel line is all consumed.
3. Disconnect the negative battery cable.
4. Drain the engine coolant. Refer to «DRAINING AND REFILLING THE COOLING SYSTEM»(ref-257290-S30388178292007070900000) .
5. Drain the engine oil.
6. Drain the transaxle oil.
7. Drain the power steering oil.
8. Recover the refrigerant.
9. Remove the engine assembly. Refer to «Engine Assembly Removal»(ref-257287-S03362334742007070900000) .
10. Remove the timing chain. Refer to «Timing Chain Removal»(ref-257287-S26667711312007070900000) .
11. Remove the intake manifold support bracket.
12. Remove the power steering pump.
13. Remove the EGR valve. Refer to «EXHAUST GAS RECIRCULATION (EGR) VALVE REMOVAL»(ref-257285-S29709039492007070900000) .
14. Remove the EGR pipes. Refer to «INTAKE EGR PIPE REMOVAL»(ref-257285-S34572751202007070900000) and «EXHAUST EGR PIPE REMOVAL»(ref-257285-S24442589812007070900000) .
15. Remove the EGR adapter.
16. Remove the heater pipe.
17. Remove the exhaust manifold. Refer to «EXHAUST MANIFOLD REMOVAL»(ref-257291-S29730723242007070900000) .
18. Remove the exhaust manifold gasket.
19. Remove the CMP (Camshaft Position) sensor. Refer to «CAMSHAFT POSITION (CMP) SENSOR REMOVAL»(ref-257286-S29998511292007070900000) .
20. Remove the ECTS (Engine Coolant Temperature Sensor). Refer to «ENGINE COOLANT TEMPERATURE SENSOR REMOVAL»(ref-257286-S31652180072007070900000) .
21. Remove the coolant outlet port.
22. Remove the cylinder head bolts in the sequence shown and the cylinder head.
23. Remove the cylinder head gasket.
24. Remove the liquid gasket.

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1. Installation should follow the removal procedure in the reverse order.
2. Clean the contact surfaces between the cylinder head and the cylinder block.
3. Install the dowel pin.
4. Apply the liquid gasket (Loctite® 5900-M8585) on the surface of the cylinder block as described in the illustration.
5. Install the cylinder head gasket.
6. Apply the liquid gasket (Loctite® 5900-M8585) on the upper surface of the cylinder head gasket as described in the illustration
7. Install the cylinder head. Tighten the cylinder head bolts from center to outer as is described in the illustration. Tighten: Tighten the cylinder head bolts to 20 N.m (15 lb-ft). After finishing the initial tightening, tighten all the cylinder head bolts to 25 N.m (18 lb-ft) and turn the bolts another 2 turns of 70°.
8. Install the coolant outlet port. Tighten: Tighten the coolant outlet port retaining bolts to 8 - 12 N.m (71 - 106 lb-in.).
9. Install the ECTS (Engine Coolant Temperature Sensor). Refer to «ENGINE COOLANT TEMPERATURE SENSOR INSTALLATION»(ref-257286-S31566140852007070900000) .
10. Install the CMP (Camshaft Position) sensor. Refer to «CAMSHAFT POSITION (CMP) SENSOR INSTALLATION»(ref-257286-S34978207342007070900000) .
11. Discard used exhaust manifold gasket and replace with a new one.
12. Install the exhaust manifold. Refer to «EXHAUST MANIFOLD INSTALLATION»(ref-257291-S09498448242007070900000) .
13. Install the heater pipe.
14. Install the EGR adapter. Tighten: Tighten the EGR adapter retaining bolts to 18 - 22 N.m (13 - 16 lb-ft).
15. Install the EGR pipes. Refer to «INTAKE EGR PIPE INSTALLATION»(ref-257285-S12383789252007070900000) and «EXHAUST EGR PIPE INSTALLATION»(ref-257285-S40878852272007070900000) .
16. Install the EGR valve. Refer to «EXHAUST GAS RECIRCULATION (EGR) VALVE INSTALLATION»(ref-257285-S28679765542007070900000) .
17. Install the power steering pump. Tighten: Tighten the power steering pump retaining bolts to 20 - 30 N.m (15 - 22 lb-ft).
18. Install the intake manifold support bracket. Tighten: Tighten the intake manifold support bracket bolt to 20 - 30 N.m (15 - 22 lb-ft).
19. Install the timing chain and the timing chain cover. Refer to «Timing Chain Installation»(ref-257287-S42181717312007070900000) .
20. Install the cylinder head cover. Refer to «Cylinder Head Cover Installation»(ref-257287-S07218163042007070900000) .
21. Install the oil pan. Refer to «OIL PAN / OIL PUMP INSTALLATION»(ref-257289-S34870784172007070900000) .
22. Install the engine assembly. Refer to «Engine Assembly Installation»(ref-257287-S39846853922007070900000) .

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1. Remove the fuel pump fuse.
2. Start the engine and repeat cranking until the remaining fuel in the fuel line is all consumed.
3. Disconnect the negative battery cable.
4. Drain the engine coolant. Refer to «DRAINING AND REFILLING THE COOLING SYSTEM»(ref-257290-S30388178292007070900000) .
5. Drain the engine oil.
6. Drain the transaxle oil.
7. Drain the power steering oil.
8. Recover the refrigerant.
9. Remove the engine assembly. Refer to «Engine Assembly Removal»(ref-257287-S03362334742007070900000) .
10. Remove the timing chain cover. Refer to «Timing Chain Removal»(ref-257287-S26667711312007070900000) .
11. Remove the compressor.
12. Remove the power steering pump.
13. Remove the generator. Refer to «GENERATOR REMOVAL»(ref-257294-S05060234262007070900000) .
14. Remove the idler retaining bolt, upper pad-to-lower pad bracket bolt, and the idler. Refer to «Timing Chain Removal»(ref-257287-S26667711312007070900000) .
15. Remove the bracket.
16. Remove the engine oil dipstick tube.
17. Remove the CKP (Crankshaft Position) sensor. Refer to «CRANKSHAFT POSITION (CKP) SENSOR REMOVAL»(ref-257286-S08539437692007070900000) .
18. Remove the bed plate baffle.
19. Remove the oil pump chain lever.
20. Remove the bed plate outer bolts in the sequence shown.
21. Remove the bed plate inner bolts in the sequence shown.

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1. Installation should follow the removal procedure in the reverse order.
2. Clean the contact surfaces between the bed plate and the cylinder block.
3. Apply the liquid gasket (Loctite® 5900-M8585) on the bed plate.
4. Install the bed plate. Tighten: Tighten the bed plate inner bolts to 33 N.m (24 lb-ft). After tightening all the inner bolts, turn the bolts by 135° each.
5. Tighten the bed plate outer bolts. Tighten: Tighten the bed plate outer bolts to 20 - 26 N.m (15 - 19 lb-ft).
6. Install the oil pump. Refer to «OIL PAN / OIL PUMP INSTALLATION»(ref-257289-S34870784172007070900000) .
7. Install the oil pump chain lever. Tighten: Tighten the oil pump chain lever bolt to 6 - 10 N.m (53 - 89 lb-in.).
8. Install the bed plate baffle. Tighten: Tighten the bed plate baffle bolts to 7 - 9 N.m (62 - 80 lb-in.).
9. Install the oil pan. Refer to «OIL PAN / OIL PUMP INSTALLATION»(ref-257289-S34870784172007070900000) .
10. Install the engine oil dipstick tube. Tighten: Tighten the engine oil dipstick tube bracket bolt to 18 - 22 N.m (13 - 16 lb-ft). Tighten the engine oil dipstick tube bolt to 8 - 10 N.m (71 - 89 lb-in.).
11. Install the CKP (Crankshaft Position) sensor. Refer to «CRANKSHAFT POSITION (CKP) SENSOR INSTALLATION»(ref-257286-S17166514102007070900000) .
12. Install the bracket. Tighten: Tighten the bracket bolts to 35 - 55 N.m (26 - 33 lb-ft).
13. Install the idler. Tighten: Tighten the idler retaining bolt to 35 - 55 N.m (26 - 33 lb-ft). Tighten the upper pad-to-lower pad bracket bolt to 30 - 40 N.m (22 - 30 lb-ft).
14. Install the compressor. Tighten: Tighten the compressor retaining bolts and nuts to 20 - 30 N.m (15 - 22 lb-ft).
15. Install the generator.
16. Install the power steering pump.
17. Install the timing chain and timing chain cover. Refer to «Timing Chain Installation»(ref-257287-S42181717312007070900000) .
18. Install the cylinder head cover. Refer to «Cylinder Head Cover Installation»(ref-257287-S07218163042007070900000) .
19. Install the engine assembly. Refer to «Engine Assembly Installation»(ref-257287-S39846853922007070900000) .

Cylinder Head and Valve Train Components Removal

Tools Required

DW110-150 Camshaft Sprocket Holder

DW110-160 Rocker Arm Shaft Installer/Remover

09916-14510 Valve Spring Compressor

09916-48210 Valve Spring Compressor Attachment

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1. Remove the cylinder head. Refer to «Cylinder Head Removal»(ref-257287-S41192311672007070900000) .
2. Remove the intake cam sprocket and the exhaust cam sprocket.
3. Remove the camshaft cap bolts gradually and in the sequence shown for each camshaft cap. NOTE: Make sure the engraved position numbers on the camshaft caps are not mixed up. Camshaft caps should follow the numeric order when installing, intake camshaft caps 1-3-5-7-9-11-13 and exhaust camshaft caps 2-4-6-8-10-12-14.
4. Remove the intake camshaft and the exhaust camshaft.
5. Remove the rocker arm shaft plugs at both ends of the cylinder block.
6. Remove the front and rear rocker arm shafts using rocker arm shaft installer/remover DW110-160. CAUTION: To prevent the oil from leaking through the pressure chamber, do not flip the cylinder head over when removing or installing the rocker arm.
7. Remove the rocker arms.
8. Remove the valve spring retainer, valve spring, valve key, and valve stem using the valve spring compressor 09916-14510/valve spring compressor attachment 09916-48210.
9. Remove the intake and exhaust valves.

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1. Installation should follow the removal procedure in the reverse order.
2. Install the intake and exhaust valves, valve spring retainer, valve spring, valve key, and valve stem using the valve spring compressor 09916-14510/valve spring compressor attachment 09916-48210.
3. Make sure the correct positions for the intake and exhaust valves. The diameter of the intake valves is larger than the diameter of the exhaust valves.
4. Install the rocker arms.
5. Install the rocker arm shafts using the rocker arm shaft installer/remover DW110-160. NOTE: Front rocker arm shaft which will be installed to the timing chain side can be identified by the hole for the rocker arm spring.
6. Apply the sealant to the rocker arm shaft plugs.
7. Install the rocker arm shaft plugs. Tighten: Tighten the rocker arm shaft plug to 35 - 45 N.m (26 - 33 lb-ft).
8. Position the intake and exhaust camshafts. NOTE: The intake camshaft can be identified by the groove near the cam sprocket flange. The exhaust camshaft has no groove.
9. Install the camshaft caps in the sequence shown. NOTE: Make sure the engraved position numbers on the camshaft caps are not mixed up. Camshaft caps should follow the numeric order when installing, intake camshaft caps 1-3-5-7-9-11-13 and exhaust camshaft caps 2-4-6-8-10-12-14.
10. Tighten the camshaft cap bolts in the sequence shown. Tighten: Tighten the camshaft cap bolts to 10 - 14 N.m (89 - 124 lb-in.).
11. Install the cam sprockets. NOTE: Intake and exhaust cam sprockets are identified by the engraved marks, "IN" for intake and "EX" for exhaust respectively. Tighten: Tighten the cam sprocket bolts to 18 - 22 N.m (13 - 16 lb-ft).

Crankshaft Bearings and Connecting Rod Bearings Removal

Tools Required

DW110-170-02 Piston Ring Compressor

DW110-190 Crankshaft Adjuster

DW110-180-02 Crankshaft Rear Oil Seal Installer

DW110-180-01 Crankshaft Front Oil Seal Installer

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1. Remove the bed plate. Refer to «Bed Plate Removal»(ref-257287-S24106329252007070900000) . NOTE: The sizes of each upper crankshaft bearing are marked on the bed plate as shown in the illustration.
2. Remove the lower crankshaft bearings. NOTE: The lower crankshaft bearings have different groove shape and the sizes of the crankshaft bearings are identified by the color marks on the side of the bearing, which are green (Size-0), yellow (Size-1), and pink (Size-2).
3. Move the piston to the bottom of the piston stroke.
4. Mark the connecting rod cap for position.
5. Remove the connecting rod caps and bearings.
6. Remove the piston.
7. Remove the piston rings.
8. Remove the crankshaft.
9. Remove the upper connecting rod bearing.
10. Remove the rear crankshaft seal.

Scheme 115

Scheme 116

Scheme 117

Scheme 118

Scheme 119

Scheme 120

Scheme 121

Scheme 122

1. Installation should follow the removal procedure in the reverse order.
2. Install the upper crankshaft bearings. NOTE: The sizes of each upper crankshaft bearing are marked on the bed plate as shown in the illustration. NOTE: The lower crankshaft bearings have different groove shape and the sizes of the crankshaft bearings are identified by the color marks on the side of the bearing, which are green (Size-0), yellow (Size-1), and pink (Size-2).
3. Install the crankshaft.
4. Install the piston pin.
5. Install the piston rings.
6. Install the piston using the piston ring compressor DW110-170-02. Observe the installation order of the piston as follows: 2 -> 5 -> 1 -> 6 -> 3 -> 4 (piston number).
7. Seat the connecting rod bearings and temporarily install the connecting rod cap. NOTE: The sizes of the connecting rod bearings are identified by the color marks on the side of the bearing, which are green (Size-0) and yellow (Size-1).
8. Install the thrust bearing. NOTE: Make sure the oil groove on the thrust bearing is installed facing outside.
9. Tighten the connecting rod cap bolts using crankshaft adjuster DW110-190. Observe the tightening order of the connecting rod cap bolts as follows: 2 -> 5 -> 1 -> 6 -> 3 -> 4 (piston number). Tighten: Tighten the connecting rod cap bolts to 20 N.m (15 lb-ft). After finishing the initial tightening, turn the bolts by 45° then another 90°.
10. Install the lower crankshaft bearing. NOTE: The lower crankshaft bearings have different groove shape and the sizes of the crankshaft bearings are identified by the color marks on the side of the bearing, which are green (Size-0), yellow (Size-1), and pink (Size-2).
11. Install the bed plate. Refer to «Bed Plate Installation»(ref-257287-S04875719282007070900000) .
12. Seat and install the crankshaft rear oil seal using the crankshaft rear oil seal installer DW110-180-02.
13. Install the cylinder head. Refer to «Cylinder Head Installation»(ref-257287-S06564391272007070900000) .
14. Install the timing chain cover. Refer to «Timing Chain Installation»(ref-257287-S42181717312007070900000) .
15. Install the crankshaft front oil seal using the crankshaft front oil seal installer DW110-180-01.
16. Install the cylinder head cover. Refer to «Cylinder Head Cover Installation»(ref-257287-S07218163042007070900000) .
17. Install the intake manifold. Refer to «Intake Manifold Installation»(ref-257287-S15190862132007070900000) .
18. Install the engine assembly. Refer to «Engine Assembly Installation»(ref-257287-S39846853922007070900000) .