ENGINE DISASSEMBLY/ASSEMBLY [SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5]

id0110h6800500

Caution
•  When the transaxle is installed, do not suspend the engine. Otherwise, the SST installation area of the cylinder head may be damaged due to excess weight. Only suspend the engine after separating the engine and transaxle.
•  Applying excessive force (force of 100 N {10.2 kgf, 22.5 lbf} or more) to the electric variable valve timing motor/driver may cause a malfunction. When servicing, be careful not to apply excessive force to the electric variable valve timing motor/driver using other parts or tools.

1.  To enable to install the SST, disconnect the clip shown in the figure and set the wiring harness aside.

am6zzw00012076

2.  Install the SST and the following bolt to the position shown in the figure.

Engine front side

am6zzw00011712

Engine rear side

am6zzw00011713
Bolt:
part number 99794 1025 or an M10 × 1.25, length 25 mm {0.98 in}
Tightening torque
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

3.  Engage the hooks of the SST (49 L017 5A0) to the SST (49 UN30 3050).

am6zzw00011714

Caution
•  Do not lift up the engine.

4.  To ensure the safety of the work (control engine and transaxle sway), set a hoist as shown in the figure.

am6zzw00011715

5.  Remove the insulator shown in the figure.

am6zzw00011716

6.  Remove the exhaust system. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

7.  Remove the exhaust manifold bracket using the following procedure:

(1)  Loosen the bolt shown in the figure.

MTX

am3zzw00014970

ATX

am3zzw00014971
(2)  Remove the bolts in the order shown in the figure, then remove the exhaust manifold bracket.

MTX

am3zzw00014972

ATX

am3zzw00014973
•  When installing, install the exhaust manifold bracket using the following procedure:
1)  Temporarily tighten the exhaust manifold bracket installation bolts in the order as shown in the figure.

MTX

am3zzw00019157

ATX

ac3wzw00001942
2)  Loosen the bolt shown in the figure until it is no longer seated on the surface.

MTX

am3zzw00019158

ATX

am3zzw00014971
3)  Tighten the bolt in the order shown in the figure.

MTX

am3zzw00014974
Tightening torque
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

ATX

am3zzw00014975
Tightening torque
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

8.  Remove the bracket No.1 (drive shaft bracket). (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)

9.  Remove the starter. (See STARTER REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

10.  Fix the drive plate using the crankshaft pulley lock bolt. (ATX)

11.  Remove the torque converter installation nut from the starter installation hole. (See AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [FW6A-EL].)

12.  Disconnect the engine and transaxle, and lower only the engine from the engine lifter.

•  MTX (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [C66M-R (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].) (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [F66M-R].)
•  ATX (See AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [FW6A-EL].) (See AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [CW6A-EL].)

13.  Remove the generator. (See GENERATOR REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT i-ELOOP)].) (See GENERATOR REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITH i-ELOOP)].)

14.  Remove the intake-air system. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

15.  Remove the oil separator. (See POSITIVE CRANKCASE VENTILATION (PCV) VALVE REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

16.  Remove the KS. (See KNOCK SENSOR (KS) REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

17.  Remove the fuel injectors. (See FUEL INJECTOR REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

18.  Remove the camshaft position (CMP) sensor. (See CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

19.  Remove the vacuum pump. (See VACUUM PUMP REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

20.  Remove the high pressure fuel pump and rear housing. (See HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

21.  Remove the electric variable valve timing motor/driver. (See ELECTRIC VARIABLE VALVE TIMING MOTOR/DRIVER REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

22.  Remove the oil filter. (See OIL FILTER REPLACEMENT [SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

23.  Remove the oil cooler. (if equipped) (See OIL COOLER REMOVAL/INSTALLATION [SKYACTIV-G 2.0].)

24.  Remove the engine oil solenoid valve. (See ENGINE OIL SOLENOID VALVE REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

25.  Remove the crankshaft position (CKP) sensor. (See CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

26.  Remove the dipstick.

27.  Remove the ignition coil/ion sensors. (See IGNITION COIL/ION SENSOR REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

28.  Remove the wiring harness bracket shown in the figure.

SKYACTIV-G 1.5

am3zzw00014684

SKYACTIV-G 2.0, SKYACTIV-G 2.5

am6zzw00011359

29.  Remove the emission harness.

30.  Remove the water pump drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

31.  Remove the water inlet pipe. (See CYLINDER HEAD GASKET REPLACEMENT [SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

32.  Remove the water pump. (See WATER PUMP REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

33.  Remove the clutch cover and clutch disc. (MTX) (See CLUTCH UNIT REMOVAL/INSTALLATION [C66M-R].) (See CLUTCH UNIT REMOVAL/INSTALLATION [F66M-R].)

34.  Remove in the order indicated in the table

35.  Assemble in the reverse order of disassembly.

Exhaust side

am3zzw00016085

1
Oil cooler water pipe component (with oil cooler)
(See Oil Cooler Water Pipe Component Installation Note.)
2
Oil filter body
(See Oil Filter Body Installation Note.)
3
Exhaust manifold bracket
(See Exhaust Manifold Bracket Installation Note.)

Engine rear side

am3zzw00020029

1
Water outlet component
(See Water Outlet Component Installation Note.)


Water Outlet Component Installation Note

1.  Temporarily tighten the water outlet component installation bolts.

2.  Tighten the bolts in the order shown in the figure.

am3zzw00020030

Tightening torque
8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}


Exhaust Manifold Bracket Installation Note


SKYACTIV-G 1.5

1.  Temporarily tighten the exhaust manifold bracket installation bolts.

2.  Tighten the bolts in the order shown in the figure.

am3zzw00014685

Tightening torque
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}


SKYACTIV-G 2.0, SKYACTIV-G 2.5

Type A
1.  Temporarily tighten the bolt (3) shown in the figure, insert the exhaust manifold bracket from the side, and temporarily install the exhaust manifold bracket.
am3uuw00012061
2.  Temporarily tighten the bolt (1) shown in the figure.
3.  Temporarily tighten the bolt (2) shown in the figure.
4.  Tighten the bolt in the order shown in the figure.
Tightening torque
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}
Type B
1.  Temporarily tighten the bolt (1) shown in the figure.
ac5uuw00002986
2.  Temporarily tighten the bolt (2) shown in the figure.
3.  Temporarily tighten the bolt (3) shown in the figure.
4.  Tighten the bolt in the order shown in the figure.
Tightening torque
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}


Oil Filter Body Installation Note

Note
•  The tightening order of the three bolts is optional.

1.  After tightening the three bolts, tighten the first tightened bolt to the specified tightening torque again.

Tightening torque
20—26 N·m {2.1—2.6 kgf·m, 15—19 ft·lbf}


Oil Cooler Water Pipe Component Installation Note

1.  Install the oil cooler water pipe component in the order shown in the figure.

ac5wzw00004654

Tightening torque
8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}