CYLINDER HEAD GASKET REPLACEMENT [SKYACTIV-X 2.0]

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Replacement part

Oil and chemical type

Warning

•  A hot engine can cause severe burns. Turn off the engine and wait until it is cool before performing the servicing.

•  Fuel vapor is hazardous. It can very easily ignite and cause serious injury or death, and damage to equipment. Always keep sparks and flames away from fuel.

•  Highly pressurized fuel may spray out if the fuel line is cut. Due to the following dangers occurring with a fuel spray, always complete the [Fuel Line Safety Procedure] to prevent the fuel from spraying.

―  Fuel may cause irritation if it comes in contact with skin and eyes.

―  If fuel ignites and causes a fire, it may lead to serious injury or death, and damage to property and facilities.

Caution

•  If the camshaft is turned with the piston position at the top dead center while the timing chain is removed, the valve and piston will contact each other and it could cause engine damage. When turning the camshaft while the timing chain is removed, rotate the piston downward from the top dead center position.

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION [(E)].)

2.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)

3.  Remove the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)

4.  Remove front under cover No.2. (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

5.  Remove the front splash shield (RH). (See SPLASH SHIELD REMOVAL/INSTALLATION.)

6.  Remove the water pump drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)

7.  Remove the drive belt auto tensioner. (See DRIVE BELT AUTO TENSIONER REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)

8.  Drain the engine oil. (See ENGINE OIL REPLACEMENT [SKYACTIV-X 2.0].)

9.  Drain the engine coolant and water-cooled charge air cooler coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-X 2.0].)(See WATER-COOLED CHARGE AIR COOLER COOLANT REPLACEMENT [SKYACTIV-X 2.0].)

10.  Remove the intake manifold. (See INTAKE MANIFOLD REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)

11.  Remove the exhaust manifold. (See EXHAUST MANIFOLD REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)

12.  Remove the injection pipe. (See INJECTION PIPE REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)

13.  Remove the coolant switching valve. (See COOLANT SWITCHING VALVE (CSV) REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)

14.  Remove the cylinder head cover. (See CYLINDER HEAD COVER REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)

15.  Remove the engine rear cover (upper). (See ENGINE REAR COVER REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)

16.  Remove the timing chain No.1.(See TIMING CHAIN REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)

17.  Remove using the procedure shown in the figure.

18.  Install in the reverse order of removal.

19.  Add engine oil to the specified level. (See ENGINE OIL REPLACEMENT [SKYACTIV-X 2.0].)

20.  Add engine coolant and water-cooled charge air cooler coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-X 2.0].)(See WATER-COOLED CHARGE AIR COOLER COOLANT REPLACEMENT [SKYACTIV-X 2.0].)

21.  Start the engine and inspect and adjust the following:

•  Engine oil, engine coolant leakage

•  Pulley, belt runout, contact

•  Ignition timing, idle speed, idle CO, and HC concentration verification (See ENGINE TUNE-UP [SKYACTIV-X 2.0].)

•  Compression pressure (See COMPRESSION INSPECTION [SKYACTIV-X 2.0].)

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1	Cylinder head (See Cylinder Head Installation Note.)
2	Cylinder head gasket (See Cylinder Head Gasket Installation Note.)

Cylinder Head Gasket Installation Note

Caution

•  Completely remove oil, dirt, and sealant adhering to the cylinder head gasket contacting surfaces. Otherwise, a sealing malfunction may occur.

1.  Completely remove any oil, dirt, and sealant adhering to the cylinder block.

Caution

•  Be aware of the following points, otherwise a sealing malfunction may occur due to hardening of the sealant.

―  Set the cylinder head gasket on the cylinder block within 10 min after the silicone sealant is applied.

2.  Apply silicone sealant (TB1217D) to the areas shown in the figure.

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3.  Install the cylinder head gasket.

Cylinder Head Installation Note

1.  Measure the length of the cylinder head bolt.

•  If it exceeds the maximum specification, replace the cylinder head bolt.

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2.  When a cylinder head bolt is reused, apply engine oil to any part of the following:

•  Bolt seating surface

•  Cylinder head seating surface

Caution

•  Completely remove oil, dirt, and silicone sealant adhering to the cylinder head gasket contacting surfaces. Otherwise, a sealing malfunction may occur.

3.  Completely remove any oil, dirt, and silicone sealant adhering to the cylinder block.

Caution

•  Be aware of the following points, otherwise a sealing malfunction may occur due to hardening of the sealant.

―  Set the cylinder head on the cylinder block within 10 min after the silicone sealant is applied.

―  After setting the cylinder head, complete the cylinder head bolt tightening immediately.

4.  Apply silicone sealant (TB1217D) to the areas shown in the figure.

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5.  Set the cylinder head on the cylinder block.

6.  Tighten the cylinder head bolts in 5 steps in the order shown in the figure.

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