ENGINE DISASSEMBLY/ASSEMBLY [SKYACTIV-D 2.2]

id0110s5800500

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.

1.  Remove the engine cover adapter.

ac5wzw00005213

2.  Remove the insulator shown in the figure.

ac5wzw00005016

•  When installing the insulator, install it using the following procedure:
1.  Align the position so that the front end of the insulator is positioned at the front side of the vehicle from the exhaust insulator.
2.  Insert the insulator until it contacts completely.

3.  Install the SST to the position shown in the figure using the following bolt and washer.

am6zzw00010863

Bolt: part number 99794 1025 or an M10 x 1.25, length 25 mm {0.98 in}
Washer: approx. 3 mm {0.1 in} thickness
Tightening torque
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

4.  Install the SST to the position shown in the figure using the following bolt and washer.

am6zzw00010864

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

5.  Engage the hook for the SST (49 L017 5A0) to the SST (49 UN30 3050).

ac5wzw00005215

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

ac5jjw00005202

Caution
•  Do not lift up the engine.

7.  Remove the exhaust system. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

8.  Remove the turbocharger. (See TURBOCHARGER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

9.  Remove the vacuum chamber. (See VACUUM CHAMBER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

10.  Remove the following emission system related parts:

•  EGR cooler bypass valve (See EGR COOLER BYPASS VALVE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
•  EGR pipe (See EGR PIPE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
•  EGR valve (See EGR VALVE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
•  EGR cooler (See EGR COOLER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

11.  Remove the bracket No.1. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)

12.  Remove the starter. (See STARTER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

13.  Remove the generator. (See GENERATOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2 (WITHOUT i-ELOOP)].) (See GENERATOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2 (WITH i-ELOOP)].)

14.  Remove the drive belt auto tensioner. (See DRIVE BELT AUTO TENSIONER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

15.  Lock the drive plate against rotation using the crankshaft pulley lock bolt. (ATX)

16.  Remove the torque converter installation nut from the starter installation hole. (See AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [GW6A-EL].)

17.  Disconnect the engine and transaxle, and lower only the engine from the engine lifter. (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [D66M-R] (MTX).) (See AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [GW6A-EL] (ATX).)

18.  Remove the clutch cover and clutch disc. (MTX) (See CLUTCH UNIT REMOVAL/INSTALLATION [D66M-R].)

19.  Remove the intake-air system. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

20.  Remove the following fuel system related parts:

•  Injection pipe (See INJECTION PIPE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
•  Fuel injectors (See FUEL INJECTOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
•  Supply pump (See SUPPLY PUMP REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
•  Lower case (See LOWER CASE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
•  Common rail (See COMMON RAIL REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

21.  Remove the glow plugs. (See GLOW PLUG REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

22.  Remove the vacuum pump. (See VACUUM PUMP REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

23.  Remove the oil cooler. (See OIL COOLER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

24.  Remove the oil filter. (See OIL FILTER REPLACEMENT [SKYACTIV-D 2.2].)

25.  Remove the engine oil solenoid valve. (See ENGINE OIL SOLENOID VALVE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

26.  Remove the following control system related parts:

•  CMP sensor (See CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
•  Engine oil temperature sensor/engine oil pressure sensor (See ENGINE OIL TEMPERATURE SENSOR/ENGINE OIL PRESSURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
•  ECT sensor (See ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
•  CKP sensor (See CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

27.  Remove in the order indicated in the table

28.  Assemble in the reverse order of disassembly.

Step 1

am6zzw00018524

1
Exhaust gas pressure sensor No.1
(See Exhaust gas pressure sensor No.1installation note.)
2
Exhaust insulator
3
Exhaust gas pressure sensor No.2
4
Water pipe
5
Seal rubber
6
Noise suppression cover (No.3)

Step 2

am6zzw00010093

7
Water pump component
(See Water pump component installation note.)
8
Water pipe
9
Water hose and pipe (ATX)
10
Noise suppression cover (No.1), noise suppression cover (No.2), seal rubber
(See Noise Suppression Cover (No.1), Noise Suppression Cover (No.2), Seal Rubber Removal Note.)
(See Noise Suppression Cover (No.1), Noise Suppression Cover (No.2), Seal Rubber Installation Note.)


Noise Suppression Cover (No.1), Noise Suppression Cover (No.2), Seal Rubber Removal Note

1.  Remove the noise suppression covers and seal rubbers in the order shown in the figure.

ac5wzw00005218

2.  Remove the wiring harness using the following procedure:.

(1)  Remove the wiring harness bracket installation bolts shown in the figure.
ac5wzw00005219
(2)  Remove all of the related wiring harness clip.

3.  Remove the seal rubber (No.3) shown in the figure.

ac5wzw00005220


Noise Suppression Cover (No.1), Noise Suppression Cover (No.2), Seal Rubber Installation Note

1.  Temporarily put the seal rubber (No.3) on the engine front cover.

ac5wzw00005220

2.  Install the wiring harness and wiring harness bracket.

Note
•  The seal rubber (No.3) can be fixed by installing the wiring harness bracket.

Caution
•  Be careful that the covers and seal rubbers do not get hung up on the noise suppression cover installation bolts.

3.  Install the noise suppression covers and seal rubbers in the order shown in the figure.

ac5wzw00005275


Water pump component installation note

1.  Tighten the water pump component installation bolts in the order shown in the figure.

ac5wzw00004945

Tightening torque
44—54 N·m {4.5—5.5 kgf·m, 33—39 ft·lbf}


Exhaust gas pressure sensor No.1installation note

1.  Temporarily tighten the bolts.

am3zzw00016520

2.  Tighten the bolt A.

Tightening torque
12—17 N·m {123—173 kgf·cm, 107—150 in·lbf}

3.  Tighten the bolt B.

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