ENGINE DISASSEMBLY/ASSEMBLY [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)]

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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.  Install the SST using part number 99794 1025 or an M10 x 1.25, length 25 mm {0.98 in} bolt as shown in the figure.

Engine front side

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Engine rear side

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

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

Caution

•  Do not lift up the engine.

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4.  Remove the insulators using the following procedure:

(1)  Disconnect the A/F sensor connector and clip shown in the figure.

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(2)  Remove the insulator shown in the figure.

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(3)  Remove the insulator shown in the figure.

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5.  Remove the exhaust system. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)].)

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

(1)  Loosen the bolt shown in the figure.

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

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•  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.

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

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

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Tightening torque

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

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

8.  Remove the starter. (See STARTER REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)].)

9.  Remove the coolant control valve. (See COOLANT CONTROL VALVE REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)].)

10.  Fix the drive plate using the crankshaft pulley lock bolt.

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. (See AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [FW6A-EL].)

13.  Remove the generator. (See GENERATOR REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)].)

14.  Remove the intake-air system. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)].)

15.  Remove the oil separator. (See POSITIVE CRANKCASE VENTILATION (PCV) VALVE REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)].)

16.  Remove the knock sensor (KS). (See KNOCK SENSOR (KS) REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)].)

17.  Remove the fuel injectors. (See FUEL INJECTOR REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)].)

18.  Remove the camshaft position (CMP) sensor. (See CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)].)

19.  Remove the vacuum pump. (See VACUUM PUMP REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)].)

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

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

22.  Remove the OCV for No.1 cylinder deactivation. (See OIL CONTROL VALVE (OCV) FOR CYLINDER DEACTIVATION REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)].)

23.  Remove the OCV for No.4 cylinder deactivation. (See OIL CONTROL VALVE (OCV) FOR CYLINDER DEACTIVATION REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)].)

24.  Remove the oil filter. (See OIL FILTER REPLACEMENT [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)].)

25.  Remove the engine oil solenoid valve. (See ENGINE OIL SOLENOID VALVE REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)].)

26.  Remove the engine oil temperature sensor/engine oil pressure sensor. (See ENGINE OIL TEMPERATURE SENSOR/ENGINE OIL PRESSURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)].)

27.  Remove the crankshaft position (CKP) sensor. (See CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)].)

28.  Remove the dipstick.

29.  Remove the purge solenoid valve, catch tank and bracket as a single unit. (See PURGE SOLENOID VALVE REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)].)

30.  Remove the ignition coil/ion sensors. (See IGNITION COIL/ION SENSOR REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)].)

31.  Remove the wiring harness bracket using the following procedure:

(1)  Remove the clip shown in the figure.

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(2)  Remove the bolts shown in the figure.

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32.  Remove the wiring harness bracket and wiring harness protector shown in the figure.

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33.  Remove the emission harness.

34.  Remove the water pump drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)].)

35.  Remove the water inlet pipe and flange component. (See CYLINDER HEAD GASKET REPLACEMENT [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)].)

36.  Remove the water pump. (See WATER PUMP REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)].)

37.  Remove the short cord of the engine oil level sensor. (See ENGINE OIL LEVEL SENSOR REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)].)

38.  Remove in the order indicated in the table.

39.  Assemble in the reverse order of disassembly.

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1	Oil filter body (See Oil Filter Body Installation Note.)
2	Exhaust manifold bracket (See Exhaust Manifold Bracket Installation Note.)

Exhaust Manifold Bracket Installation Note

1.  Temporarily tighten the exhaust manifold bracket installation bolts.

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

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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.