Removal and Replacement
CYLINDER HEAD GASKET REPLACEMENT [SKYACTIV-G 2.0]
WARNING:
- A hot engine can cause severe burns. Turn off the engine and wait until it is cool before servicing.
- Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
- Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure". Before Service Precaution
CAUTION:
- If the camshaft is rotated with the timing chain removed and the piston at the top dead center position, the valve may contact the piston and the engine could be damaged. When rotating the camshaft with the timing chain removed, rotate it after lowering the piston from the top dead center position.
1. Remove the battery cover. Removal and Replacement
2. Disconnect the negative battery cable. Removal and Replacement
3. Remove the plug hole plate. Plug Hole Plate Removal/Installation
4. Remove the ignition coil/ion sensors. Ignition Coil/Ion Sensor Removal/Installation
5. Remove the coolant reserve tank with the hose still connected and set it out of the way. Service and Repair
6. Remove the aerodynamic under cover No.2 and splash shield as a single unit. Aerodynamic Under Cover No. 2 Removal/Installation Splash Shield Removal/Installation
7. Remove the drive belt. Service and Repair
8. Drain the engine oil. Service and Repair
9. Drain the engine coolant. Service and Repair
10. Remove the intake manifold. Service and Repair
11. Set aside the exhaust manifold to the vehicle rear. Service and Repair
12. Disconnect the radiator hose (upper, lower).
13. Remove the vacuum pump. Service and Repair
14. Remove the high pressure fuel pump and rear housing. High Pressure Fuel Pump Removal/Installation
15. Disconnect the heater hose.
16. Remove the oil pan. Service and Repair
17. Remove the timing chain and chain guide. Service and Repair
18. Remove the OCV. Service and Repair
19. Remove in the order indicated in the table.
20. Install in the reverse order of removal.
21. Refill with the specified type and amount of the engine oil. Service and Repair
22. Refill the engine coolant. Service and Repair
23. Start the engine, and inspect and adjust the following:
- Leakage of engine oil, engine coolant.
- Runout and contact of pulley and belt.
- Ignition timing, idle speed and idle mixture. Service and Repair
- Compression pressure Testing and Inspection
Camshaft Removal Note
1. Loosen the camshaft cap installation bolts in a few passes in the order shown in the figure and remove the camshaft caps.
2. Remove the camshaft.
Rocker Arm Removal Note
1. Keep the rocker arms in the order of removal to enable reassembly in their original positions.
Cylinder Head Removal Note
1. Temporarily install the oil pan to support the engine from under the vehicle.
CAUTION:
- To prevent deformation of the oil pan, support the engine using the following methods.
- When using an engine lifter, insert rubber of appropriate size (approx. 20 mm {0.79 in} thickness) between the engine lifter and the oil pan to support the oil pan.
- When using a garage jack, place rubber of appropriate size (approx. 20 mm {0.79 in} thickness) on a batten which is large enough to cover the oil pan to support the oil pan.
2. Support the engine (oil pan) using a commercially available engine lifter or garage jack.
3. Remove the chain on the SST that suspended the engine and set it aside.
4. Loosen the cylinder head installation bolts in two or three passes in the order shown in the figure and remove them.
5. Remove the cylinder head.
Cylinder Head Installation Note
CAUTION:
- If the following condition is met, replace the cylinder head bolts.
- Length exceeds maximum specification
Cylinder head bolt length L
- 145.2-145.8 mm {5.717-5.740 in}
Cylinder head bolt length L maximum
- 146.5 mm {5.767 in}
1. When a cylinder head bolt is reused, apply engine oil to any part of the following:
- Bolt seating surface
- Cylinder head seating surface
2. Tighten the cylinder head bolts in the order shown in the following 4 steps.
Tightening torque
- Step 1: 13-17 Nm {133-173 kgf-cm, 116-150 in-lbf}
- Step 2: 43-47 Nm {4.4-4.7 kgf-m, 32-34 ft-lbf}
- Step 3: 85-95°
- Step 4: 85-95°
3. Install the chain for the SST which was set aside and secure the engine.
4. Remove the engine lifter or garage jack.
5. Remove the temporarily assembled oil pan.
Rocker Arm Installation Note
1. Apply engine oil to the HLAs and the end of the valve stems.
2. Install the rocker arms to the same positions as before removal.
Camshaft Installation Note
1. As shown in the figure, apply gear oil (SAE No. 90 or equivalent) or engine oil to the center area of each journal of the cylinder head.
CAUTION:
- Apply 0.05 ml {0.05 cc, 0.003 in3} or less of oil to journal No.6.
2. Install the camshaft with cylinder No.1 cam aligned to the TDC position as shown in the figure.
3. As shown in the figure, apply gear oil (SAE No. 90 or equivalent) or engine oil to the center area of each journal of the camshaft.
4. Apply sealant (Loctite 962T) around journal No.6 of the cylinder head or the exhaust-side rear camshaft cap.
CAUTION:
- Verify that there is no sealant on the journal.
Sealant bead width
- 0.5-1.5 mm {0.02-0.05 in}
5. Install the camshaft caps in the marked number order, and temporarily tighten the camshaft cap installation bolts in two or three passes evenly.
6. Tighten the camshaft cap installation bolts in two steps in the order shown in the figure.
Tightening torque
- First step: 3.0-6.0 Nm {31-61 kgf-cm, 27-53 in-lbf}
- Second step: 8-11 Nm {82-112 kgf-cm, 71-97 in-lbf}
Water Inlet Pipe Installation Note
CAUTION:
- Do not apply oil (engine oil, ATF etc.) to the O-ring of the water inlet pipe. Otherwise, the O-ring could swell causing a seal malfunction.
1. Clean away the sealant adhering to the bolt hole on the cylinder block side of the water inlet pipe stay.
2. Apply engine coolant to the O-ring.
3. Install the O-ring to the water inlet pipe.
4. Insert the water inlet pipe into the water pump being careful not to damage the O-ring.
5. Tighten the bolts in the order shown in the figure.
