Special Tools

DW110-030 Engine Overhaul Stand

1. Remove the engine assembly. Refer to Engine Replacement.
2. Install the engine assembly to the DW110-030 stand .
3. Remove the ignition coil. Refer to Ignition Coil Replacement.



4. Detach the PCV clips from the PCV hose.
5. Remove the PCV hose from the cylinder head cover.
6. Remove the cylinder head cover bolts.
7. Remove the cylinder head cover (1).
8. Remove the power steering pump and bracket. Refer to Power Steering Pump Replacement.
9. Remove the timing belt. Refer to Timing Belt Replacement.
10. Remove the timing belt tensioner. Refer to Timing Belt Replacement.
11. Remove the camshaft sprocket. Refer to Camshaft Gear Replacement.



12. Remove the camshaft rear cover (1).
13. Remove the exhaust manifold. Refer to Catalytic Converter Replacement.
14. Remove the throttle body. Refer to Throttle Body Assembly Replacement.
15. Remove the intake manifold. Refer to Intake Manifold Replacement.



16. Remove the engine coolant distributor (1).



17. Remove the cylinder head bolts (1).
18. Remove the cylinder head assembly (2) with the cylinder head gasket.
19. Remove the engine oil cooler. Refer to Engine Oil Cooler Replacement.
20. Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement.
21. Remove the alternator. Refer to Generator Replacement.
22. Remove the starter. Refer to Starter Motor Replacement.
23. Remove the oil pan. Refer to Oil Pan Replacement.
24. Remove the oil pump assembly. Refer to Oil Pump Replacement.
25. Remove the flexible plate or flywheel. Refer to Automatic Transmission Flex Plate Replacement and Engine Flywheel Replacement.




Note: Check and confirm the piston assembly sequence and the connecting rod bearing sequence, to not confuse.

26. Remove the connecting rod cap (2) and bolts (3).
27. Remove the piston assembly. (1)



28. Separate the piston pin (5) from the piston (3).
29. Separate the piston ring (1) from the piston using the expansion tool.

Note: Take extreme care to prevent any scratches or damage to the inner side of the cylinder, piston, and connecting rod cap bearings.

1. Install the piston pin (5) to the piston.
2. Install the piston ring from the piston using the expansion tool.

Note: Check and confirm the piston assembly sequence and the connecting rod bearing sequence, to not confuse.

3. Install the piston assembly using the piston installer.

Caution: Refer to Fastener Caution in the Preface section.

4. Install the connecting rod cap and bolts with bearings.

Tighten
Tighten the connecting rod caps bolts to 35+45° +15° N·m (25.8+45° +15° lb ft).

5. Install the flexible plate or flywheel. Refer to Automatic Transmission Flex Plate Replacement and Engine Flywheel Replacement.



6. Install the oil pump assembly. Refer to Oil Pump Replacement.
7. Install the engine oil cooler. Refer to Engine Oil Cooler Replacement.
8. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement.
9. Install the alternator. Refer to Generator Replacement.
10. Install the starter. Refer to Starter Motor Replacement.
11. Install the oil pan. Refer to Oil Pan Replacement.




Note: Do not reuse the cylinder head gasket.

12. Install the cylinder head assembly (2) with the new cylinder head gasket.
13. Install the cylinder head bolts (1).

Tighten
Tighten the cylinder head bolts to 25+90° +90° +90° +45° N·m (18.4+90° +90° +90° +45° lb ft).




14. Install the engine coolant distributor (1).
15. Install the intake manifold. Refer to Intake Manifold Replacement.
16. Install the throttle body. Refer to Throttle Body Assembly Replacement.
17. Install the exhaust manifold. Refer to Catalytic Converter Replacement.



18. Install the camshaft rear cover (1).
19. Install timing belt system and adjust the timing. Refer to Timing Belt Replacement.
20. Install the timing system. Refer to Timing Belt Replacement.
21. Install the power steering pump and bracket. Refer to Power Steering Pump Replacement.



22. Install the cylinder head cover (1).
23. Install the cylinder head cover bolts.
24. Install the PCV hose from the cylinder head cover.
25. Attach the PCV clips from the PCV hose.
26. Install the ignition coil. Refer to Ignition Coil Replacement.
27. Install the engine assembly. Refer to Engine Replacement.