GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Holden 🢒 2007 🢒 Epica 🢒 Engine 🢒 Engine Mechanical - 2.0L and 2.5L 🢒 Crankshaft Replacement

Tools Required
    • DW110-170-02 Piston Ring Compressor (2.5L) or equivalent
    • EN-47617 (DW110-190) Crankshaft Adjuster
    • EN-47616 (DW110-180-02) Crankshaft Rear Oil Seal Installer
    • EN-47615 (DW110-180-01) Crankshaft Front Oil Seal Installer

Removal Procedure

    Object Number: 1376075 Size: SH

    Important: The sizes of each upper crankshaft bearing are marked on the bed plate as shown in the illustration.

  1. Remove the lower crankcase. Refer to Lower Crankcase Replacement .

    2. Object Number: 1376076 Size: SH

    Important: 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 bearings, which are green (Size - 0), yellow (Size - 1), and pink (Size - 2).

  2. Remove the lower crankcase bearings.

    3. Object Number: 1376077 Size: SH
  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. Object Number: 1376079 Size: SH
  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.

Installation Procedure

    Object Number: 1376075 Size: SH
  1. Installation should follow the removal procedure in the reverse order.

    2. Important: The sizes of each upper crankshaft bearing are marked on the bed plate as shown in the illustration.

  2. Install the upper crankshaft bearings.

    3. Important: 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).


    Object Number: 1376081 Size: SH
  3. Install the crankshaft.
  4. Install the piston pin.

    5. Object Number: 1376082 Size: SH

    Notice: Use a piston ring expander to install the piston rings. The rings may be damaged if expanded more than necessary.

  5. Install the piston rings.
  6. Stagger the piston oil rings, the upper oil ring rail gap (2), the lower oil ring rail gap (3), the second compression ring (1), and the top compression ring (4) in relation to the front of the engine, as shown.

    7. Object Number: 1376083 Size: SH
  7. Install the piston using the DW110-170-02 . Observe the installation order of the piston as follows: 2 -5-1-3-4, piston number.

    8. Object Number: 1376085 Size: SH

    Important: 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. Seat the connecting rod bearings and temporarily install the connecting rod cap.

    9. Object Number: 1376086 Size: SH

    Important: Make sure the oil groove on the thrust bearing is installed facing outside.

  9. Install the thrust bearing.

    10. Object Number: 1376087 Size: SH
  10. Tighten the connecting rod cap bolts using the EN-47617  (1). Observe the tightening order of the connecting rod cap bolts as follows: 2-5-1-6-3-4, piston number.

    11. Tighten
    Tighten the connecting rod cap bolts to 20 N·m (15 lb ft). After finishing the initial tightening, turn the bolts by 45 degrees, than another 90 degrees.


    Object Number: 1376088 Size: SH

    Important: 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 lower crankshaft bearing.

    12. Object Number: 1376024 Size: SH
  12. Install the lower crankcase. Refer to Lower Crankcase Replacement .

    13. Object Number: 1376089 Size: SH
  13. Seat and install the crankshaft rear oil seal using the EN-47616  (1).

    14. Object Number: 1376090 Size: SH
  14. Install the cylinder head. Refer to Cylinder Head Replacement .
  15. Install the timing chain cover. Refer to Timing Chain and Sprocket Replacement .
  16. Install the crankshaft front oil seal using the EN-47615  (1).

    17. Object Number: 1375772 Size: SH
  17. Install the cylinder head cover. Refer to Cylinder Head Cover Replacement .
  18. Install the intake manifold. Refer to Intake Manifold Replacement .
  19. Install the engine assembly. Refer to Engine Replacement .