CYLINDER HEAD GASKET REPLACEMENT [SKYACTIV-G 2.5T]

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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.

• 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 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. Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2. Remove the front under cover No.1 and No.2. (See FRONT UNDER COVER No.1 REMOVAL/INSTALLATION.) (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

3. Remove the front splash shield. (See FRONT SPLASH SHIELD REMOVAL/INSTALLATION.)

4. Drain the engine oil. (See ENGINE OIL REPLACEMENT [SKYACTIV-G 2.5T].)

5. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-G 2.5T].)

6. Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

7. Remove the air cleaner, air hose and fresh air duct as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

8. Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION.)

9. Remove the air inlet pipe. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

10. Remove the EGR cooler and EGR valve component. (See EGR COOLER REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].) (See EGR VALVE REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

11. Remove the intake manifold. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

12. Remove the WU-TWC. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

13. Remove the dynamic pressure turbo. (See DYNAMIC PRESSURE TURBO REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

14. Remove the exhaust manifold. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

15. Remove the ignition coil/ion sensors. (See IGNITION COIL/ION SENSOR REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

16. Remove the vacuum pump. (See VACUUM PUMP REMOVAL/INSTALLATION.)

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

18. Remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

19. Remove the oil pan. (See OIL PAN REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

20. Remove the timing chain and chain guide. (See TIMING CHAIN REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

21. Remove the OCV. (See OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

22. Disconnect the radiator hoses shown in the figure.

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23. Remove in the order indicated in the table.

24. Install in the reverse order of removal.

25. Refill with the specified type and amount of the engine oil. (See ENGINE OIL REPLACEMENT [SKYACTIV-G 2.5T].)

26. Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-G 2.5T].)

27. 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. (See ENGINE TUNE-UP [SKYACTIV-G 2.5T].)

• Compression pressure (See COMPRESSION INSPECTION [SKYACTIV-G 2.5T].)

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1	Water pipe component (See Water Pipe Component Removal Note.) (See Water Pipe Component Installation Note.)
2	Oil cooler pipe component (See Oil Cooler Pipe Component Removal Note.) (See Oil Cooler Pipe Installation Note.)
3	Flange (See Flange and Water Inlet Pipe Removal Note.) (See Flange and Water Inlet Pipe Installation Note.)
4	Water inlet pipe (See Flange and Water Inlet Pipe Removal Note.) (See Flange and Water Inlet Pipe Installation Note.)
5	Camshaft (See Camshaft Removal Note.) (See Camshaft Installation Note.)
6	OCV oil filter
7	Rocker arm (See HYDRAULIC LASH ADJUSTER (HLA) REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)
8	Cylinder head (See Cylinder Head Removal Note.) (See Cylinder Head Installation Note.)
9	Cylinder head gasket

Water Pipe Component Removal Note

1. Remove the bolts shown in the figure and set the water pipe component aside.

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Oil Cooler Pipe Component Removal Note

1. Remove the bolt shown in the figure and set the oil cooler pipe component aside.

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Flange and Water Inlet Pipe Removal Note

1. Disconnect the hoses shown in the figure.

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2. Disconnect the hose shown in the figure.

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3. Remove the bolts shown in the figure and remove the flange and water inlet pipe.

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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.

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2. Remove the camshaft.

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.

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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.

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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

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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

Caution

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

2. 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 cylinder head on cylinder block within 10 min after silicone sealant is applied

? After setting cylinder head, tighten cylinder head bolts immediately

3. Apply silicone sealant (TB1217D or equivalent) to the areas shown in the figure.

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Silicone sealant application diameter

5—10 mm {0.2—0.3 in}

4. Install a new cylinder head gasket to the cylinder block.

5. Apply silicone sealant (TB1217D or equivalent) to the areas shown in the figure.

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Silicone sealant application diameter

5—10 mm {0.2—0.3 in}

6. Set the cylinder head on the cylinder block.

7. Tighten the cylinder head bolts in the order shown in the following 4 steps.

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Tightening torque

Step 1: 13—17 N·m {133—173 kgf·cm, 116—150 in·lbf}

Step 2: 32—36 N·m {3.3—3.6 kgf·m, 24—26 ft·lbf}

Step 3: 85—95°

Step 4: 85—95°

8. Install the chain for the SST which was set aside and secure the engine.

9. Remove the engine lifter or garage jack.

10. Remove the temporarily assembled oil pan.

Camshaft Installation Note

1. Apply SAE 90 gear oil or equivalent, or engine oil to the positions shown in the figure.

Caution

• Apply 0.05 ml {0.05 cc, 0.003 in³} or less of oil to area A in the figure.

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2. Apply SAE 90 gear oil or equivalent, or engine oil to the following locations of each camshaft.

• Thrust surface of front journal (both surfaces front and back)

Caution

• Be careful not to let oil adheres the engine front cover installation surface. If oil adheres to the engine front cover installation surface, a sealing malfunction may occur when the engine front cover is installed.

• If oil adheres to the engine front cover installation surface, remove any oil completely.

Note

• If oil is applied to the front camshaft cap, oil should not be applied to the thrust surface of the front journal.

3. Install the camshaft with the timing chain alignment marks aligned as shown in the figure.

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Note

• The timing mark of SKYACTIV-G 2.5T is not completely parallel with the upper surface of the cylinder head.

4. Apply SAE 90 gear oil or equivalent, or engine oil to the central area of each journal on the camshaft.

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5. Apply SAE 90 gear oil or equivalent, or engine oil to the thrust surface of the front camshaft cap.

Caution

• If oil adheres to the engine front cover installation surface, remove any oil completely.

Note

• If oil is applied to the front journal thrust surface of each camshaft, oil should not be applied to the front camshaft cap.

6. Apply sealant (LOCTITE 962T, 518, 272 or equivalent) to the rear camshaft cap installation area on the exhaust side or the rear camshaft caps on the exhaust side of the cylinder head.

Note

• To prevent engine oil leakage, apply sealant to the rear camshaft cap installation area on the exhaust side or the rear camshaft caps on the exhaust side of the cylinder head, and seal the journal.

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Caution

• Do not spill sealant on the journal.

Sealant agent bead width

1—3 mm {0.04—0.11 in}

7. Install the camshaft caps in the marked number order, and temporarily tighten the camshaft cap installation bolts in two or three passes evenly.

8. Tighten the camshaft cap installation bolts in two steps in the order shown in the figure.

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Tightening torque

Step 1: 3.0—6.0 N·m {31—61 kgf·cm, 27—53 in·lbf}

Step 2: 8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}

Flange and Water Inlet Pipe Installation Note

Caution

• Do not apply oil (such as engine oil, ATF) to the O-ring of the water inlet pipe. Otherwise, the O-ring could swell causing a seal malfunction.

• Do not apply oil (such as engine oil, ATF) to the gasket of the flange. Otherwise, the gasket could swell causing a seal malfunction.

1. Apply engine coolant to the O-ring.

2. Install the O-ring to the water inlet pipe.

3. Insert the water inlet pipe into the water pump and flange being careful not to damage the O-ring.

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

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5. Connect the hose shown in the figure.

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6. Connect the hoses shown in the figure.

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Oil Cooler Pipe Installation Note

1. Install the the oil cooler pipe component.

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Water Pipe Component Installation Note

Caution

• Do not apply oil (such as engine oil, ATF) to the O-ring of the water pipe component. Otherwise, the O-ring could swell causing a seal malfunction.

1. Apply engine coolant to the O-ring.

2. Install the O-ring to the water pipe component.

3. Insert the water pipe component into the flange being careful not to damage the O-ring.

4. Tighten the bolts shown in the figure.

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