Engine Mechanical [SKYACTIVE-G2.0L]: Removal & Installation Mazda CX-5 I

PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.0]

Caution For Removing Plug Hole Plate. Scheme 12

Scheme 13

Scheme 14

1. Pull up the front part of the plug hole plate at the same time and remove the rubber from the adapter on the engine side. (Scheme 13): Removing Rubber From Engine Side Adapter
2. Pull up the plug hole plate in the order shown in the figure and remove the adapter from the rubber on the engine side. (Scheme 14): Pulling Up Plug Hole Plate

Scheme 15

Scheme 16

1. Press the plug hole plate in the order shown in the figure to insert the adapter to the rubber on the engine side. (Scheme 15): Pressing Plug Hole Plate
2. Press the front part of the plug hole plate at the same time to insert the rubber to the adapter on the engine side. (Scheme 16): Inserting Rubber Onto Engine Side Adapter

DRIVE BELT REMOVAL/INSTALLATION [SKYACTIV-G 2.0]

Note. Remove/install the drive belt from the underside of the vehicle.

Generator Drive Belt Removal/Installation

Scheme 17

1. Remove the splash shield. (See «SPLASH SHIELD REMOVAL/INSTALLATION»(ref-615433-S30142483462014051000000) ).
2. Insert a wrench onto the cast hexagon on the drive belt auto tensioner and release the tension by slowly turning in the direction shown in the figure.
3. Remove the generator drive belt.
4. Install the generator drive belt.
5. Rotate the crankshaft pulley clockwise approx. halfway and verify that the generator drive belt is installed correctly. If the rib of the drive belt and the groove of each pulley are not aligned, remove the drive belt and re-install it.
6. Verify that the indicator part of the cast hexagon on the drive belt auto tensioner is within the normal range. (See «DRIVE BELT INSPECTION [SKYACTIV-G 2.0]»(ref-615399-S31918412762014051000000) ).
7. Install the splash shield. (See «SPLASH SHIELD REMOVAL/INSTALLATION»(ref-615433-S30142483462014051000000) ). (Scheme 17): Releasing Tension From Cast Hexagon On Drive Belt Auto Tensioner Using Wrench

Scheme 18

Scheme 19

1. Remove the generator drive belt. (See «GENERATOR DRIVE BELT REMOVAL/INSTALLATION»(ref-615399-S10334484472014051000000) ).
2. Apply a clean cloth to the water pump drive belt as shown in the figure. (Scheme 18): Applying Cloth To Water Pump Drive Belt
3. Pull the cloth in the direction of the arrow and rotate the crankshaft pulley clockwise. CAUTION: To prevent damaging the drive belt, do not stop rotating the crankshaft pulley while performing the removal procedure (with inserted cloth between drive belt and water pump pulley). NOTE: The rib of the drive belt can be slid from the groove of the water pump pulley by rotating the crankshaft pulley while pulling the cloth in the direction of the arrow. (Scheme 19): Rotating Crankshaft Pulley
4. Remove the water pump drive belt.

Scheme 20

Scheme 21

1. Set one side of the water pump drive belt into the groove of the crankshaft pulley.
2. Set the other side of the water pump drive belt into the groove of the water pump pulley with the smaller circumference. CAUTION: Be careful not to get a finger caught in between the drive belt and pulley when performing the following procedure. Wearing gloves could result in fingers getting caught between the drive belt and pulley. Do not wear cotton gloves when performing the procedure. (Scheme 20): Locating Water Pump Pulley
3. Press the drive belt up from the smaller circumference pulley into the groove of the larger circumference pulley, and rotate the crankshaft pulley clockwise. CAUTION: To prevent damaging the drive belt, do not stop rotation of the crankshaft pulley while pressing the drive belt up from the height difference of the water pump pulley to the groove of the pulley. (Scheme 21): Pressing Drive Belt
4. After drive belt installation, rotate the crankshaft pulley clockwise approx. halfway and verify that the water pump drive belt is installed correctly. If the rib of the drive belt and the groove of the pulley are not aligned, remove the drive belt and re-install it.
5. Install the generator drive belt. (See «GENERATOR DRIVE BELT REMOVAL/INSTALLATION»(ref-615399-S10334484472014051000000) ).

ELECTRIC VARIABLE VALVE TIMING MOTOR/DRIVER REMOVAL/INSTALLATION [SKYACTIV-G 2.0]

Scheme 22

1. Disconnect the negative battery cable. (See «NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 2.0]»(ref-615412-S04991947062014051000000) ).
2. Remove the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615399-S02010689542014051000000) ).
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal. (Scheme 22): Identifying Electric Variable Valve Timing Motor/Driver, Connector, No. 3 Engine Mount And O-Ring With Torque Specifications

Scheme 23

Scheme 24

Scheme 25

1. Remove the clips shown in the figure and set the ground cable aside.
2. Remove the front under cover No.2. (See «FRONT UNDER COVER NO.2 REMOVAL/INSTALLATION»(ref-615433-S21444705852014051000000) ). 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. (Scheme 23): Identifying No. 3 Engine Mount, Ground Cable And Clip
3. Before removing the No.3 engine mount, support the engine (oil pan) using a commercially available engine lifter or garage jack. CAUTION: Slots have been adopted for the No.3 engine mount installation holes. If the No.3 engine mount is deviated from the original position when installing the No.3 engine mount, engine noise or vibration could increase. Before removing the No.3 engine mount, place alignment marks on the No.3 engine mount and body so that they can be assembled to the same positions as before removal. (Scheme 24): Supporting Engine Oil Pan Using Engine Lifter
4. Place alignment marks on the locations shown in the figure so that they can be assembled to the same positions as before removal. NOTE: Paint so that the No.3 engine mount is framed on the body side and the outline of the nut is framed on the No.3 engine mount side.
5. Remove the No. 3 engine mount. (Scheme 25): Identifying Aligning Marks On No. 3 Engine Mount And Nut

Scheme 26

Scheme 27

Scheme 28

1. Install a new O-ring to the O-ring installation groove of the engine front cover. CAUTION: To prevent damage to the electric variable valve timing motor/driver, do not apply excessive force (force of 100 N {10.2 kgf, 22.5 lbf} or more) to the shaded areas shown in the figure.
2. Install the electric variable valve timing motor/driver using the following procedures. (Scheme 26): Identifying Electric Variable Valve Timing Motor/Driver NOTE: The eccentric shaft on the electric variable valve timing actuator side can be rotated to the left and right. The electric variable valve timing motor/driver can be assembled with the joint groove of the eccentric shaft in any position, and it will not lead to vehicle damage or performance reduction. (Scheme 27): Rotating Electric Variable Valve Timing Actuator Before installation, rotate the joint of the end of the electric variable valve timing motor so that it is aligned to the joint groove on the electric variable valve timing actuator side. Engage the joint on the end of the electric variable valve timing motor with the joint groove on the electric variable valve timing actuator side. Attach the seal surface. Tighten the electric variable valve timing motor/driver installation bolts. Tightening torque 20-26 N.m {2.1-2.6 kgf.m, 15-19 ft.lbf} (Scheme 28): Identifying Joint And Joint Groove

No.3 Engine Mount Installation Note

Note. When replacing the No.3 engine mount, place a mark at the same position as the one placed before removal. If the No.3 engine mount nut is loosened, tighten the stud bolts of the engine front cover because they may be loosened.

Scheme 29

Scheme 30

Scheme 31

Scheme 32

1. Tighten the stud bolts of the engine front cover. Tightening torque 7-13 N.m {72-132 kgf.cm, 62-115 in.lbf}
2. Temporarily tighten the No.3 engine mount installation bolts and nuts using the following procedure: Align the alignment marks on the body side and No.3 engine mount, and temporarily tighten the bolts shown in the figure. (Scheme 29): Identifying Engine Front Cover Stud Bolts (Scheme 30): Identifying Alignment Marks On Body Side And No.3 Engine Mount Temporarily tighten the nuts shown in the figure while aligning the alignment marks of the No.3 engine mount and nuts. (Scheme 31): Identifying Alignment Marks On No. 3 Engine Mount And Nuts NOTE: If the alignment marks are not aligned, align the alignment marks while slightly moving the engine and temporarily tighten the nuts.
3. Tighten the No.3 engine mount installation bolts and nuts in the order shown in the figure. No. Tightening torque 1 76-95 N.m {7.8-9.6 kgf.m, 57-70 ft.lbf} 2 82-95 N.m {8.4-9.6 kgf.m, 61-70 ft.lbf} 3 49-65 N.m {5.0-6.6 kgf.m, 37-47 ft.lbf}
4. Remove the engine lifter or garage jack.
5. Install in the reverse order of removal. (Scheme 32): Identifying No.3 Engine Mount Installation Bolts And Nuts Tightening Sequence

ELECTRIC VARIABLE VALVE TIMING ACTUATOR, HYDRAULIC VARIABLE VALVE TIMING ACTUATOR REMOVAL/INSTALLATION [SKYACTIV-G 2.0]

Securing Clearance Between Cam Using Wrench. Scheme 33

Note. Width at the cast hexagon of the camshaft is 22-24 mm {0.87-0.94 in}.

Scheme 34

Scheme 35

1. Disconnect the negative battery cable. (See «NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 2.0]»(ref-615412-S04991947062014051000000) ).
2. Remove the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615399-S02010689542014051000000) ).
3. Remove the ignition coil/ion sensors. (See «IGNITION COIL/ION SENSOR REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615408-S22625302992014051000000) ). (Scheme 34): Identifying Camshaft Cast Hexagon Dimension
4. Remove the cylinder head cover. (See «TIMING CHAIN REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615399-S31439702542014051000000) ).
5. Remove the front under cover No.2. (See «FRONT UNDER COVER NO.2 REMOVAL/INSTALLATION»(ref-615433-S21444705852014051000000) ).
6. Remove the electric variable valve timing motor/driver. (See «ELECTRIC VARIABLE VALVE TIMING MOTOR/DRIVER REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615399-S26956923822014051000000) ).
7. Remove the vacuum pump. (Only when hydraulic variable valve timing actuator is removed). (See «VACUUM PUMP REMOVAL/INSTALLATION»(ref-615413-S40147185192014051000000) ).
8. Remove the high pressure fuel pump and rear housing. (Only when hydraulic variable valve timing actuator is removed). (See «HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615403-S21413673672014051000000) ).
9. Remove in the order indicated in the table.
10. Install in the reverse order of removal.
11. Start the engine and inspect the following: Ignition timing, idle speed and idle mixture. (See «ENGINE TUNE-UP [SKYACTIV-G 2.0]»(ref-615399-S37949971622014051000000) ). (Scheme 35): Identifying Timing Chain, OCV Related Components With Torque Specifications

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Scheme 40

Scheme 41

1. Release the tension on the timing chain using the following procedure: NOTE: Release the tension on the timing chain by securing the timing chain tensioner arm through the service 1 hole on the engine front cover. Remove the blind plugs (upper and lower) on the engine front cover service holes. (Scheme 36): Identifying Upper And Lower Blind Plugs Insert an M6 bolt (35-60 mm {1.4-2.3 in} length with thread to the end) to the upper service hole and tighten it until it contacts the tensioner arm, then loosen it approx. 180 degrees. (Set the bolt so that it sits slightly in front of the tensioner arm). NOTE: The bolt contacts the tensioner arm when it is inserted approx. 20 mm {0.79 in}. (Scheme 37): Identifying M6 Bolt Insertion Position Into Tensioner Arm Hold the exhaust camshaft using a wrench on the cast hexagon and move it back and forth a few times as shown in the figure. This will drain the oil from the chain tensioner and make the following servicing easier. Insert a precision screwdriver into the lower service hole. (Scheme 38): Moving Exhaust Camshaft Using Wrench While moving the exhaust camshaft back and forth in the direction of the arrow using a wrench on the cast hexagon, press down the link plate of the timing chain tensioner using a precision screwdriver and release the plunger lock. see scheme 39: Moving Exhaust Camshaft Using Wrench NOTE: When moving the exhaust camshaft back and forth, the timing chain pushes the plunger in the chain tensioner making it easier to operate the link plate. With the plunger lock released, rotate the exhaust camshaft clockwise until the timing chain loosens. (Scheme 39): Loosening Timing Chain (Scheme 40): Rotating Exhaust Camshaft Clockwise With the chain loosened, tighten the M6 bolt in the upper service hole so that the bolt is inserted approx. 5 mm {0.2 in} additionally to secure the tensioner arm. (Scheme 41): Locating M6 Bolt Insertion Position If the bolt cannot be inserted approx. 5 mm {0.2 in}, the plunger lock of the chain tensioner may not release, or the chain may not loosen enough. Return the bolt to the original position and restart the procedure from step ( 3 ). NOTE: By rotating the exhaust camshaft clockwise, the timing chain pushes the tensioner arm and the rib position deviates. The entire tensioner arm can be secured by hooking the bolt onto the deviated rib. After securing the tensioner arm, remove the chain guide (No.1).

Electric Variable Valve Timing Actuator Removal Note

Scheme 42

Scheme 43

Scheme 44

Scheme 45

Scheme 46

Scheme 47

1. Rotate the crankshaft clockwise so that cylinder No.1 is positioned around before top dead center (TDC) as shown in the figure. (Scheme 42): Identifying Timing Chain Alignment Mark NOTE: With cylinder No.1 positioned around before top dead center (TDC), there is no large movement (rotation) of the exhaust camshaft when the timing chain is removed. Therefore, installation of the electric variable valve timing actuator to the camshaft will be easier. (If there is a large movement of the exhaust camshaft, installation of the electric variable valve timing actuator to the camshaft must be performed while loosening the chain by rotating the exhaust camshaft).
2. Mark the timing chain and each actuator so that they can be reassembled in the same condition as before removal. (Scheme 43): Identifying Timing Chain And Actuator Alignment Mark
3. Hold the intake camshaft using a wrench on the cast hexagon and remove the electric variable valve timing actuator installation bolt. (Scheme 44): Removing Electric Variable Valve Timing Actuator Installation Bolt
4. Using a screwdriver wrapped in a clean cloth, lightly press the electric variable valve timing actuator to the front and separate the intake camshaft and the actuator. (Scheme 45): Pressing Electric Variable Valve Timing Actuator Using Screwdriver Wrapped In Cloth
5. Remove the timing chain from the exhaust and intake camshaft sprockets and set is aside, and remove the electric variable valve timing actuator. (Scheme 46): Removing Timing Chain From Exhaust And Intake Camshaft Sprockets
6. Return the timing chain to the exhaust camshaft sprocket, and pull the timing chain up and suspend it using a rope as shown in the figure. (Scheme 47): Suspending Timing Chain Using Rope

Hydraulic Variable Valve Timing Actuator and Exhaust Camshaft Component Removal Note

Scheme 48

Scheme 49

Scheme 50

Scheme 51

1. Leave the timing chain as it is, which was suspended after electric variable valve timing actuator removal.
2. Temporarily install the cylinder head cover bolt to the position shown in the figure to use it for suspending the timing chain. (Scheme 48): Identifying Cylinder Head Cover Bolt
3. Loosen the exhaust-side camshaft cap bolts in two or three passes in the order shown in the figure, and remove the camshaft cap. (Scheme 49): Identifying Exhaust-Side Camshaft Cap Bolts Loosening Sequence
4. While setting the timing chain aside, remove the hydraulic variable valve timing actuator and the exhaust camshaft as a single unit. (Scheme 50): Installing Timing Chain
5. Pull up the timing chain and suspend it using a rope as shown in the figure. (Scheme 51): Suspending Timing Chain Using Rope

Scheme 52

1. Lock the exhaust camshaft against rotation by holding the exhaust camshaft with a vise and securing the cast hexagon with a wrench.
2. Loosen the hydraulic variable valve timing actuator installation bolt and remove the actuator. (Scheme 52): Loosening Hydraulic Variable Valve Timing Actuator Installation Bolt Using Tools

Scheme 53

Scheme 54

1. When replacing the hydraulic variable valve timing actuator, place a mark at the same position as the one placed before removal.
2. Align the knock pin on the end of the exhaust camshaft with the knock pin installation hole on the actuator side, and temporarily assemble the bolt. (Scheme 53): Identifying Hydraulic Variable Valve Timing Actuator, Exhaust Camshaft, Knock Pin And Installation Hole
3. Lock the exhaust camshaft against rotation by holding the exhaust camshaft with a vise and securing the cast hexagon with a wrench.
4. Tighten the hydraulic variable valve timing actuator installation bolt. Tightening torque 75-85 N.m {7.7-8.6 kgf.m, 56-62 ft.lbf} (Scheme 54): Tightening Hydraulic Variable Valve Timing Actuator Installation Bolt Using Tools

Scheme 55

Scheme 56

Scheme 57

Scheme 58

Scheme 59

1. As shown in the figure, apply gear oil (SAE No. 90 or equivalent) or engine oil to the center area (exhaust side) of each journal of the cylinder head. (Scheme 55): Identifying Engine Oil Applying Areas On Center Area (Exhaust Side) Of Cylinder Head Journal CAUTION: Apply 0.05 ml {0.05 cc, 0.003 in 3 } or less of oil to journal No.6.
2. Remove the rope suspending the timing chain on the exhaust side.
3. While aligning the mark on the timing chain placed during removal with the one on the hydraulic variable valve timing actuator, place the exhaust camshaft component on the cylinder head.
4. 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 exhaust camshaft. (Scheme 56): Placing Exhaust Camshaft Component On Cylinder Head (Scheme 57): Identifying Gear Oil Applying Areas On Center Of Exhaust Camshaft Journal
5. Apply adhesive agent (Loctite 962T) around journal No.6 of the cylinder head or the exhaust-side rear camshaft cap. CAUTION: Verify that there is no adhesive agent on the journal. Adhesive agent bead width 0.5-1.5 mm {0.02-0.05 in}
6. Install the camshaft caps in the marked number order, and temporarily tighten the camshaft cap installation bolts in two or three passes evenly.
7. Tighten the camshaft cap installation bolts in two steps in the order shown in the figure. (Scheme 58): Identifying Adhesive Applying Area Around Journal No.6 Of Cylinder Head Or Exhaust-Side Rear Camshaft Cap (Scheme 59): Identifying Camshaft Cap Installation Bolts Tightening Sequence Tightening torque First step: 3.0-6.0 N.m {31-61 kgf.cm, 27-53 in.lbf} Second step: 8-11 N.m {82-112 kgf.cm, 71-97 in.lbf}

Scheme 60

Scheme 61

Scheme 62

1. When replacing the electric variable valve timing actuator with a new one, place a mark at the same position as the one placed before removal.
2. Remove the rope suspending the timing chain on the intake side.
3. Remove the timing chain from the exhaust and intake camshaft sprockets and set it aside to the rear, then insert the electric variable valve timing actuator between the engine front cover and the cylinder head.
4. Return the timing chain to the exhaust camshaft sprocket. see scheme 61: Removing Timing Chain From Exhaust And Intake Camshaft Sprockets
5. While aligning the mark on the timing chain placed during removal with the one on the electric variable valve timing actuator, engage the chain with the sprocket. (Scheme 60): Engaging Timing Chain With Sprocket
6. Align the knock pin on the end of the intake camshaft with the notch on the actuator side, then assemble the actuator. NOTE: Adjust the knock pin with the notch while adjusting the knock pin position by rotating the camshaft. (Scheme 61): Identifying Intake Camshaft, Knock Pin, Electric Variable Valve Timing Actuator And Notch
7. Hold the intake camshaft using a wrench on the cast hexagon, and tighten the electric variable valve timing actuator installation bolt. Tightening torque 102-114 N.m {10.5-11.6 kgf.m, 76-84 ft.lbf} (Scheme 62): Tightening Electric Variable Valve Timing Actuator Installation Bolt Using Tools

Scheme 63

1. Install the chain guide (No.1).
2. Remove the bolt securing the tensioner arm and apply tension to the timing chain.
3. Rotate the crankshaft clockwise two turns and verify that the valve timing is correct. (Scheme 63): Identifying Timing Chain Alignment Mark If the valve timing is not correct, remove the engine front cover and reassemble the timing chain to each sprocket. (See «TIMING CHAIN REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615399-S31439702542014051000000) ).
4. Install the blind plugs (upper and lower) for the engine front cover service holes. Tightening torque Upper: 8-11 N.m {82-112 kgf.cm, 71-97 in.lbf} Lower: 17-23 N.m {1.8-2.3 kgf.m, 13-16 ft.lbf} see scheme 66: Identifying Upper And Lower Blind Plugs

Scheme 64

1. Install the oil shower pipe in the order shown in the figure. TIGHTENING TORQUE SPECIFICATION Installation position Tightening torque 1 9-12 N.m {92-122 kgf.cm, 80-106 in.lbf} 2,3 8.0-9.0 N.m {82-91 kgf.cm, 71-79 in.lbf} (Scheme 64): Identifying Oil Shower Pipes Installation Sequence

Scheme 65

1. Disconnect the negative battery cable. (See «NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 2.0]»(ref-615412-S04991947062014051000000) ).
2. Remove the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615399-S02010689542014051000000) ).
3. Disconnect the OCV connector.
4. Measure the resistance between terminals A and B using an ohmmeter. OCV coil resistance 6.9-7.5 ohms [20°C {68°F}] If not as specified, replace the OCV. (See «OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615399-S17688077422014051000000) ).
5. Install in the reverse order of removal. (Scheme 65): Identifying Oil Control Valve Connector

Scheme 66

Scheme 67

1. Disconnect the negative battery cable. (See «NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 2.0]»(ref-615412-S04991947062014051000000) ).
2. Remove the OCV. (See «OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615399-S17688077422014051000000) ).
3. Verify that the spool valve in the OCV is in the maximum valve timing advance position as indicated in the figure. If not as specified, replace the OCV. (See «OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615399-S17688077422014051000000) ).
4. Verify that the battery is fully charged. (See «BATTERY INSPECTION [SKYACTIV-G 2.0]»(ref-615412-S10301123762014051000000) ). If not as specified, recharge the battery. (See «BATTERY RECHARGING [SKYACTIV-G 2.0]»(ref-615412-S16236247302014051000000) ). (Scheme 66): Identifying Spool Valve NOTE: When applying battery positive voltage between the OCV terminals, the connection can be either of the following: Positive battery cable to terminal A, negative battery cable to terminal B Positive battery cable to terminal B, negative battery cable to terminal A see scheme 70: Identifying Oil Control Valve Connector
5. Apply battery positive voltage between the OCV terminals and verify that the spool valve operates and moves to the maximum valve timing retard position. If not as specified, replace the OCV. (See «OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615399-S17688077422014051000000) ).
6. Stop applying battery positive voltage and verify that the spool valve returns to the maximum valve timing advance position. If not as specified, replace the OCV. (See «OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615399-S17688077422014051000000) ). (Scheme 67): Identifying Spool Valve
7. Install the OCV. (See «OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615399-S17688077422014051000000) ).

OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION [SKYACTIV-G 2.0]

Scheme 68

1. Disconnect the negative battery cable. (See «NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 2.0]»(ref-615412-S04991947062014051000000) ).
2. Remove the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615399-S02010689542014051000000) ).
3. Remove the ignition coil/ion sensors. (See «IGNITION COIL/ION SENSOR REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615408-S22625302992014051000000) ).
4. Remove the cylinder head cover. (See «TIMING CHAIN REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615399-S31439702542014051000000) ).
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal. (Scheme 68): Identifying Oil Control Valve Bolts With Torque Specification

TIMING CHAIN REMOVAL/INSTALLATION [SKYACTIV-G 2.0]

Securing Clearance Between Cam Using Wrench. Scheme 69

Note. Width at the cast hexagon of the camshaft is 22-24 mm {0.87-0.94 in}.

Scheme 70

1. Disconnect the negative battery cable. (See «NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 2.0]»(ref-615412-S04991947062014051000000) ).
2. Remove the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615399-S02010689542014051000000) ). see scheme 74: Identifying Camshaft Cast Hexagon Dimension
3. Remove the ignition coil/ion sensors. (See «IGNITION COIL/ION SENSOR REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615408-S22625302992014051000000) ).
4. Remove the front under cover No.2. (See «FRONT UNDER COVER NO.2 REMOVAL/INSTALLATION»(ref-615433-S21444705852014051000000) ).
5. Remove the splash shield. (See «SPLASH SHIELD REMOVAL/INSTALLATION»(ref-615433-S30142483462014051000000) ).
6. Remove the drive belt. (See «DRIVE BELT REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615399-S40242248072014051000000) ).
7. Drain the engine oil. (See «ENGINE OIL REPLACEMENT [SKYACTIV-G 2.0]»(ref-615400-S30421887502014051000000) ).
8. Remove the oil pan. (See «OIL PAN REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615400-S09243944792014051000000) ).
9. Remove in the order indicated in the table.
10. Install in the reverse order of removal.
11. Refill with the specified type and amount of the engine oil. (See «ENGINE OIL REPLACEMENT [SKYACTIV-G 2.0]»(ref-615400-S30421887502014051000000) ).
12. Start the engine and inspect the following: Leakage of engine oil. Runout and contact of pulley and belt. Ignition timing, idle speed and idle mixture. (See «ENGINE TUNE-UP [SKYACTIV-G 2.0]»(ref-615399-S37949971622014051000000) ). (Scheme 70): Identifying Cylinder Head Cover, Crankshaft Pulley Related Components With Torque Specifications

Scheme 71

1. Disconnect the OCV connector.
2. Remove the wiring harness clips secured to the cylinder head cover.
3. Remove the wiring harness clip secured to the intake manifold as shown in the figure, and set the wiring harness aside.
4. Disconnect the ventilation hose.
5. Disconnect the brake vacuum hose from the intake manifold and set it aside.
6. Remove the cylinder head cover. (Scheme 71): Identifying Intake Manifold Wiring Harness Clip

Water Pump Pulley Removal Note

Scheme 72

Scheme 73

1. Align the water pump pulley hole with the water pump hole as shown in the figure. (Scheme 72): Identifying Water Pump, Pulley And Holes
2. Insert an appropriate bolt (length approx. 70 mm {2.8 in} ) into the water pump hole as shown in the figure, and lock the water pump pulley against rotation.
3. Remove the water pump pulley.
4. Remove the bolt used for locking the water pump pulley against rotation. (Scheme 73): Inserting Bolt Into Water Pump Hole Using Tool

Crankshaft Pulley Lock Bolt Removal Note

Scheme 74

1. Install the SST to the crankshaft pulley, and lock the crankshaft against rotation.
2. Remove the crankshaft pulley lock bolt. (Scheme 74): Removing Crankshaft Pulley Lock Bolt Using Tools

Scheme 75

Scheme 76

Scheme 77

Scheme 78

Scheme 79

Scheme 80

Scheme 81

Scheme 82

1. Remove the clips shown in the figure and set the ground cable aside. (Scheme 75): Identifying No.3 Engine Mount, Ground Cable And Clips
2. 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. CAUTION: Slots have been adopted for the No.3 engine mount installation holes. If the No.3 engine mount is deviated from the original position when installing the No.3 engine mount, engine noise or vibration could increase. Before removing the No.3 engine mount, place alignment marks on the No.3 engine mount and body so that they can be assembled to the same positions as before removal. (Scheme 76): Installing SST Into Intake Manifold Installation Hole
3. Place alignment marks on the locations shown in the figure so that they can be assembled to the same positions as before removal. NOTE: Paint so that the No.3 engine mount is framed on the body side and the outline of the nut is framed on the No.3 engine mount side.
4. Install the SST using the following procedures. CAUTION: Refer to the SST instruction manual for the basic handing procedure. NOTE: Install front feet No. 2 to the left and right front shafts of the SST. (Scheme 77): Identifying Alignment Marks On No.3 Engine Mount And Nuts Protect the positions shown in the figure using tape. (Scheme 78): Securing Front Foot No. 2, Side Bar, Front And Rear Shaft Using Tool (Scheme 79): Securing Bolt Using Tape As shown in the figure, set the rear shafts of the SST to the left and right shock absorber nuts. (Scheme 80): Setting Rear Shafts Of SST To Left And Right Shock Absorber Nuts As shown in the figure, set the front shafts of the SST to the left and right bolts. (Scheme 81): Setting Front Shafts Of SST To Left And Right Bolts Adjust the height of the left and right side bars of the SST so that they are leveled, then tighten each part. Apply tension to the chain to hold the engine.
5. Remove the No.3 engine mount. (Scheme 82): Adjusting Height Of Left And Right Side Bars Of SST

Scheme 83

Scheme 84

Scheme 85

Scheme 86

1. Remove the insulator shown in the figure. (Scheme 83): Identifying Engine Front Cover Insulator And Mounting Nut With Torque Specification
2. Set the ground cable and wiring harness bracket shown in the figure aside.
3. Remove the engine front cover installation bolts.
4. Using a screwdriver wrapped in a cloth, peel the sealant away a little at a time, and remove the engine front cover. CAUTION: Do not apply excessive force to the screwdriver. Otherwise, the engine front cover could be damaged. Be careful not to scratch or damage the seal surface. Otherwise, it could cause oil leakage. (Scheme 84): Identifying Ground Cable, Wiring Harness Bracket And Mounting Bolts With Torque Specification (Scheme 85): Removing Sealant From Engine Front Cover Using Screwdriver Wrapped In Cloth (Scheme 86): Identifying Engine Oil Applying Areas

Scheme 87

Scheme 88

Scheme 89

Scheme 90

1. Rotate the crankshaft clockwise to align the timing marks and the key position as shown in the figure, and set cylinder No.1 at top dead center (TDC). (Scheme 87): Identifying Timing Chain Alignment Mark, Pin And Key
2. While moving the exhaust camshaft back and forth in the direction of the arrow using a wrench on the cast hexagon, press down the link plate of the timing chain tensioner using a precision screwdriver and release the plunger lock. see scheme 93: Moving Exhaust Camshaft Using Wrench NOTE: When moving the exhaust camshaft back and forth, the timing chain pushes the plunger in the chain tensioner making it easier to operate the link plate. (Scheme 88): Pressing Down Link Plate Of Timing Chain Tensioner Using Screwdriver
3. Push back the plunger slowly in the direction shown in the figure with the link plate still pushed down.
4. Remove the screwdriver from the link plate with the plunger still pushed down.
5. Release the force slightly from the plunger, and move it back and forth 2-3 mm {0.08-0.11 in}. (Scheme 89): Pushing Back Plunger
6. Insert a wire with an approx. diameter of 1.5 mm {0.059 in} or a paper clip where the link plate hole and the tensioner body hole overlap to secure the link plate and lock the plunger.
7. Remove the chain tensioner, tensioner arm, and the chain guide (No.1).
8. Remove the timing chain. (Scheme 90): Inserting Wire Or Paper Clip Into Link Plate Hole And Tensioner Body Hole

Scheme 91

1. Temporarily assemble the crankshaft pulley lock bolt, and lock the oil pump against rotation as shown in the figure.
2. Remove the oil pump driven sprocket.
3. Remove the temporarily assembled crankshaft pulley lock bolt. (Scheme 91): Removing Oil Pump Driven Sprocket

Scheme 92

1. Temporarily assemble the crankshaft pulley lock bolt, and lock the oil pump against rotation as shown in the figure.
2. Install the oil pump driven sprocket. Tightening torque 20-30 N.m {2.1-3.0 kgf.m, 15-22 ft.lbf}
3. Remove the temporarily assembled crankshaft pulley lock bolt. (Scheme 92): Installing Oil Pump Driven Sprocket

Scheme 93

Scheme 94

Scheme 95

1. Verify that the timing marks and the key are aligned to the position shown in the figure. (Scheme 93): Identifying Timing Chain Alignment Mark, Timing Mark, Key And Pin If they are not in the position shown in the figure, rotate the camshaft and crankshaft to set the cylinder No.1 top dead center (TDC).
2. Install the timing chain while aligning the marks on each sprocket and the timing chain as shown in the figure. (Scheme 94): Identifying Hydraulic Variable Valve Timing Actuator And Crankshaft Sprocket Timing Chain Alignment Marks
3. Install the chain guide (No.1).
4. Install the tensioner arm.
5. Install the chain tensioner.
6. After installing the chain tensioner, remove the installed wire or paper clip, and then apply tension to the timing chain. If a new chain tensioner is used, remove the installed stopper.
7. Verify that there is no looseness in the timing chain, and re-verify that each sprocket is in the specified location. (Scheme 95): Identifying Link Plate And Stopper
8. Rotate the crankshaft clockwise two turns and inspect the valve timing. see scheme 102: Identifying Timing Chain Alignment Mark, Pin And Key

Engine Front Cover Installation Note

Note. For a new engine front cover, the positioning pins in the two locations shown in the figure project to the outside of the engine.

Locating Positioning Pins In Engine Front Cover. Scheme 96

Scheme 97

Scheme 98

Scheme 99

Scheme 100

Scheme 101

Scheme 102

1. If the engine front cover is newly replaced, tap the positioning pins in the two locations to the seal surface side.
2. Remove oil, dirt, and sealant adhering to the engine front cover, cylinder head, and cylinder block.
3. When reusing an engine front cover installation bolts, remove sealant adhering to the bolts. CAUTION: Apply the silicon sealant in a single, unbroken line. To prevent silicone sealant from hardening, adhere the engine front cover and the cylinder block firmly within 10 min. after applying silicone sealant. After adhering them, tighten the installation bolts immediately. (Scheme 97): Tapping Positioning Pins If a bolt with sealant adhering to it is used, it could result in cracks in the cylinder head and cylinder block. (Scheme 98): Caution For Using Bolt With Sealant Adhering
4. Apply silicone sealant to the engine front cover as shown in the figure. (Scheme 99): Identifying Silicone Sealant Application Areas On Engine Front Cover Bead thickness 2-6 mm {0.1-0.2 in} 4-6 mm {0.16-0.23 in} 4-8 mm {0.2-0.3 in}
5. Apply silicone sealant to the areas shown in the figure. CAUTION: Apply the silicone sealant so that it goes into the cylinder head gasket.
6. Install the engine front cover to the engine. NOTE: Temporarily install an appropriate bolt to the drive belt auto tensioner installation bolt hole to prevent: A silicone sealant adhesion malfunction in the drive belt auto tensioner installation bolt hole. A bolt mis-installation due to silicone sealant hardening. (Scheme 100): Locating Silicone Sealant Application Areas On Cylinder Head Gasket
7. Prepare an appropriate M8 X 1.25 bolt (length 40 mm {1.6 in} ). (Scheme 101): Identifying Drive Belt Auto Tensioner Installation Bolt Hole
8. Tighten the engine front cover installation bolts in the order shown in the figure. Tightening torque 20-26 N.m {2.1-2.6 kgf.cm, 15-19 in.lbf}
9. Remove the bolt installed to the drive belt auto tensioner installation bolt hole when installing the drive belt auto tensioner. (Scheme 102): Identifying Engine Front Cover Installation Bolts Tightening Sequence
10. Install the ground cable and wiring harness bracket shown in the figure. see scheme 110: Identifying Ground Cable, Wiring Harness Bracket And Mounting Bolts With Torque Specification

Scheme 103

Scheme 104

Scheme 105

1. Install a new O-ring to the O-ring installation groove of the engine front cover. CAUTION: To prevent damage to the electric variable valve timing motor/driver, do not apply excessive force (force of 100 N {10.2 kgf, 22.5 lbf} or more) to the shaded areas shown in the figure.
2. Install the electric variable valve timing motor/driver using the following procedures. (Scheme 103): Identifying Electric Variable Valve Timing Motor/Driver NOTE: The eccentric shaft on the electric variable valve timing actuator side can be rotated to the left and right. The electric variable valve timing motor/driver can be assembled with the joint groove of the eccentric shaft in any position, and it will not lead to vehicle damage or performance reduction. (Scheme 104): Checking Rotation Of Eccentric Shaft On Electric Variable Valve Timing Actuator Before installation, rotate the joint of the end of the electric variable valve timing motor so that it is aligned to the joint groove on the electric variable valve timing actuator side. Engage the joint on the end of the electric variable valve timing motor with the joint groove on the electric variable valve timing actuator side. Attach the seal surface. Tighten the electric variable valve timing motor/driver installation bolts. Tightening torque 20-26 N.m {2.1-2.6 kgf.m, 15-19 ft.lbf} (Scheme 105): Identifying Joint And Joint Groove

Note. When replacing the No.3 engine mount, place a mark at the same position as the one placed before removal. If the No.3 engine mount nut is loosened, tighten the stud bolts for the No.3 engine mount bracket because they may be loosened.

Scheme 106

Scheme 107

Scheme 108

Scheme 109

1. Tighten the No.3 engine mount stud bolts. Tightening torque 7-13 N.m {72-132 kgf.cm, 62-115 in.lbf}
2. Temporarily tighten the No.3 engine mount installation bolts and nuts using the following procedure: (Scheme 106): Identifying No.3 Engine Mount Stud Bolts Align the alignment marks on the body side and No.3 engine mount, and temporarily tighten the bolts shown in the figure. (Scheme 107): Identifying Proper And Improper Alignment Marks On Body Side And No.3 Engine Mount Temporarily tighten the nuts shown in the figure while aligning the alignment marks of the No.3 engine mount and nuts. (Scheme 108): Identifying Proper And Improper Alignment Marks On No. 3 Engine Mount And Nuts NOTE: If the alignment marks are not aligned, align the alignment marks while slightly moving the engine and temporarily tighten the nuts.
3. Tighten the No.3 engine mount installation bolts and nuts in the order as shown in the figure. No. Tightening torque 1 76-95 N.m {7.8-9.6 kgf.m, 57-70 ft.lbf} 2 82-95 N.m {8.4-9.6 kgf.m, 61-70 ft.lbf} 3 49-65 N.m {5.0-6.6 kgf.m, 37-47 ft.lbf}
4. Remove the SST.
5. Install the clip of ground cable to the No.3 engine mount. (Scheme 109): Identifying No.3 Engine Mount Installation Bolts And Nuts Tightening Sequence

Crankshaft Pulley Lock Bolt Installation Note

Scheme 110

1. Install the SST on the crankshaft pulley to lock the crankshaft against rotation.
2. Tighten the crankshaft pulley lock bolt in the order shown in the following two steps. Tightening procedure Step 1: 90-110 N.m {9.2-11 kgf.m, 67-81 ft.lbf} Step 2: 55-65° (Scheme 110): Tightening Crankshaft Pulley Lock Bolt Using Tools (49 B011 105 And 49 UN20 5072)

Water Pump Pulley Installation Note

Scheme 111

1. Install the water pump pulley to the water pump and temporarily tighten the bolt.
2. Align the water pump pulley hole with the water pump hole as shown in the figure. see scheme 119: Identifying Water Pump, Pulley And Holes
3. Insert an appropriate bolt (length 70 mm {2.8 in} ) into the water pump hole shown in the figure and lock the water pump pulley against rotation.
4. Completely tighten the water pump pulley bolt to the specified torque. Tightening torque 8-11 N.m {82-112 kgf.cm, 71-97 in.lbf}
5. Remove the bolt used for locking the water pump pulley against rotation. (Scheme 111): Tightening Water Pump Pulley Bolt Using Tool

Drive Belt Auto Tensioner Installation Note

Scheme 112

1. Install the drive belt auto tensioner to the engine. CAUTION: To prevent damage to the drive belt auto tensioner, do not apply excessive torque after the tensioner moves full-stroke.
2. Insert the wrench into the cast hexagon on the drive belt auto tensioner, move the drive belt auto tensioner up and down at full-stroke three times to bleed the air. NOTE: By moving the drive belt auto tensioner up and down full-stroke three times, the piston inside the tensioner moves to bleed the air. (Scheme 112): Moving Drive Belt Auto Tensioner Using Wrench

Scheme 113

1. Install the oil shower pipe in the order shown in the figure. TIGHTENING TORQUE SPECIFICATION Installation position Tightening torque 1 9-12 N.m {92-122 kgf.cm, 80-106 in.lbf} 2,3 8.0-9.0 N.m {82-91 kgf.cm, 71-79 in.lbf} (Scheme 113): Identifying Oil Shower Pipes Installation Sequence

Cylinder Head Cover Installation Note

Scheme 114

Scheme 115

1. Insert a new cylinder head cover gasket into the cylinder head cover groove.
2. Apply silicone sealant to the areas shown in the figure. (Scheme 114): Identifying Silicone Sealant Application Areas On Cylinder Head Cover
3. Tighten the cylinder cover bolts in the order shown in the figure. Tightening torque 4.5-7.0 N.m {46-71 kgf.cm, 40-61 in.lbf} (Scheme 115): Identifying Cylinder Cover Bolts Tightening Sequence

HYDRAULIC LASH ADJUSTER (HLA) REMOVAL/INSTALLATION [SKYACTIV-G 2.0]

Securing Clearance Between Cam Using Wrench. Scheme 116

Note. Width at the cast hexagon of the camshaft is 22-24 mm {0.87-0.94 in}.

Scheme 117

1. Disconnect the negative battery cable. (See «NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 2.0]»(ref-615412-S04991947062014051000000) ).
2. Remove the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615399-S02010689542014051000000) ).
3. Remove the ignition coil/ion sensors. (See «IGNITION COIL/ION SENSOR REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615408-S22625302992014051000000) ).
4. Remove the cylinder head cover. (See «TIMING CHAIN REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615399-S31439702542014051000000) ).
5. Remove the front undercover No.2. (See «FRONT UNDER COVER NO.2 REMOVAL/INSTALLATION»(ref-615433-S21444705852014051000000) ). see scheme 127: Identifying Camshaft Cast Hexagon Dimension
6. Remove the electric variable valve timing motor/driver. (See «ELECTRIC VARIABLE VALVE TIMING MOTOR/DRIVER REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615399-S26956923822014051000000) ).
7. Remove the vacuum pump. (See «VACUUM PUMP REMOVAL/INSTALLATION»(ref-615413-S40147185192014051000000) ).
8. Remove the high pressure fuel pump and rear housing. (See «HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615403-S21413673672014051000000) ).
9. Remove in the order indicated in the table.
10. Install in the reverse order of removal. Ignition timing, idle speed and idle mixture. (See «ENGINE TUNE-UP [SKYACTIV-G 2.0]»(ref-615399-S37949971622014051000000) ). (Scheme 117): Identifying Cylinder Cover Components With Torque Specifications

Scheme 118

Scheme 119

Scheme 120

Scheme 121

Scheme 122

Scheme 123

1. Release the tension on the timing chain using the following procedure: NOTE: Release the tension on the timing chain by securing the timing chain tensioner arm through the service hole on the engine front cover. Remove the blind plugs (upper and lower) on the engine front cover service holes. (Scheme 118): Identifying Upper And Lower Blind Plugs Insert an M6 bolt ( 35-60 mm {1.4-2.3 in} length with thread to the end) to the upper service hole and tighten it until it contacts the tensioner arm, then loosen it approx. 180 degrees. (Set the bolt so that it sits slightly in front of the tensioner arm). NOTE: The bolt contacts the tensioner arm when it is inserted approx. 20 mm {0.79 in}. (Scheme 119): Identifying M6 Bolt Insertion Position Into Tensioner Arm Hold the exhaust camshaft using a wrench on the cast hexagon and move it back and forth a few times as shown in the figure. This will drain the oil from the chain tensioner and make the following servicing easier. Insert a precision screwdriver into the lower service hole. (Scheme 120): Moving Exhaust Camshaft Using Wrench While moving the exhaust camshaft back and forth in the direction of the arrow using a wrench on the cast hexagon, press down the link plate of the timing chain tensioner using a precision screwdriver and release the plunger lock. see scheme 132: Moving Exhaust Camshaft Using Wrench NOTE: When moving the exhaust camshaft back and forth, the timing chain pushes the plunger in the chain tensioner making it easier to operate the link plate. (Scheme 121): Pressing Down Link Plate Of Timing Chain Tensioner Using Screwdriver With the plunger lock released, rotate the exhaust camshaft clockwise until the timing chain loosens. (Scheme 122): Loosening Timing Chain With the chain loosened, tighten the M6 bolt in the upper service hole so that the bolt is inserted approx. 5 mm {0.2 in} additionally to secure the tensioner arm. (Scheme 123): Locating M6 Bolt Insertion Position If the bolt cannot be inserted approx. 5 mm {0.2 in}, the plunger lock of the chain tensioner may not release, or the chain may not loosen enough. Return the bolt to the original position and restart the procedure from step ( 3 ). NOTE: By rotating the exhaust camshaft clockwise, the timing chain pushes the tensioner arm and the rib position deviates. The entire tensioner arm can be secured by hooking the bolt onto the deviated rib. After securing the tensioner arm, remove the chain guide (No.1).

Scheme 124

Scheme 125

Scheme 126

Scheme 127

Scheme 128

Scheme 129

1. Rotate the crankshaft clockwise so that cylinder No.1 is positioned around before top dead center (TDC) as shown in the figure. (Scheme 124): Identifying Timing Chain Alignment Mark NOTE: With cylinder No.1 positioned around before top dead center (TDC), there is no large movement (rotation) of the exhaust camshaft when the timing chain is removed. Therefore, installation of the electric variable valve timing actuator to the camshaft will be easier. (If there is a large movement of the exhaust camshaft, installation of the electric variable valve timing actuator to the camshaft must be performed while loosening the chain by rotating the exhaust camshaft).
2. Mark the timing chain and each actuator so that they can be reassembled in the same condition as before removal. (Scheme 125): Identifying Timing Chain And Actuator Alignment Mark
3. Hold the intake camshaft using a wrench on the cast hexagon and remove the electric variable valve timing actuator installation bolt. (Scheme 126): Removing Electric Variable Valve Timing Actuator Installation Bolt
4. Using a screwdriver wrapped in a clean cloth, lightly press the electric variable valve timing actuator to the front and separate the intake camshaft and the actuator. (Scheme 127): Pressing Electric Variable Valve Timing Actuator Using Screwdriver Wrapped In Cloth
5. Remove the timing chain from the exhaust and intake camshaft sprockets and set is aside, and remove the electric variable valve timing actuator. (Scheme 128): Removing Timing Chain From Exhaust And Intake Camshaft Sprockets
6. Return the timing chain to the exhaust camshaft sprocket, and pull the timing chain up and suspend it using a rope as shown in the figure. (Scheme 129): Suspending Timing Chain Using Rope

Camshaft Removal Note

Note. Remove the exhaust camshaft and the hydraulic variable valve timing actuator as a single unit.

Scheme 130

Scheme 131

Scheme 132

Scheme 133

1. Leave the timing chain as it is, which was suspended after electric variable valve timing actuator removal.
2. Temporarily install the cylinder head cover bolt to the position shown in the figure to use it for suspending the timing chain. (Scheme 130): Identifying Cylinder Head Cover Bolt
3. Loosen the camshaft cap bolts in two or three passes in the order shown in the figure, and remove the camshaft cap.
4. Remove the intake camshaft. (Scheme 131): Identifying Camshaft Cap Bolts Loosening Sequence
5. While setting the timing chain aside, remove the hydraulic variable valve timing actuator and the exhaust camshaft as a single unit. (Scheme 132): Removing Hydraulic Variable Valve Timing Actuator And Exhaust Camshaft
6. Pull up the timing chain and suspend it using a rope as shown in the figure. (Scheme 133): Suspending Timing Chain Using Rope

Rocker Arm Removal Note

1. Keep the rocker arms in the order of removal to enable reassembly in their original positions.

HLA Removal Note

1. Keep the HLAs in the order of removal to enable reassembly in their original positions.

Scheme 134

Scheme 135

1. Perform HLA air bleeding using the following procedure. Put the HLA in a container filled with engine oil. CAUTION: Do not insert the round bar firmly because the check ball spring force is extremely weak. While lightly pressing the check ball using a round bar ( approx. 1.0 mm {0.039 in} diameter), bleed air by moving the plunger up and down. Press the end of the plunger in the oil and verify that there is no rebounding feel. If rebounding feel cannot be eliminated, replace the HLA. (Scheme 134): Pressing Check Ball Using Round Bar
2. Visually inspect the HLA surface where it contacts the rocker arm for wear or damage. If there is any malfunction, replace the HLA.
3. Assemble the HLAs to their original positions. (Scheme 135): Identifying Rocker Arm Contact Surface

Scheme 136

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. (Scheme 136): Identifying Engine Oil Application Areas On HLA And Valve Stems

Scheme 137

Scheme 138

Scheme 139

Scheme 140

Scheme 141

Scheme 142

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. (Scheme 137): Identifying Gear Oil Application Areas On Center Of Cylinder Head Journal CAUTION: Apply 0.05 ml {0.05 cc, 0.003 in 3 } or less of oil to journal No.6.
2. As shown in the figure, align the cam position of cylinder No.1 around top dead center (TDC) and place the intake camshaft on the cylinder head.
3. Remove the rope suspending the timing chain on the exhaust side. (Scheme 138): Identifying Intake Camshaft And Cylinder Head
4. While aligning the mark on the timing chain placed during removal with the one on the hydraulic variable valve timing actuator, place the exhaust camshaft component on the cylinder head.
5. 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. (Scheme 139): Engaging Timing Chain With Sprocket (Scheme 140): Identifying Gear Oil Applying Areas On Center Of Cylinder Head Journal
6. Apply adhesive agent (Loctite 962T) around journal No.6 of the cylinder head or the exhaust-side rear camshaft cap. CAUTION: Verify that there is no adhesive agent on the journal. Adhesive agent bead width 0.5-1.5 mm {0.02-0.05 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. (Scheme 141): Identifying Adhesive Application Area Around Journal No.6 Of Cylinder Head Or Exhaust-Side Rear Camshaft Cap (Scheme 142): Identifying Camshaft Cap Installation Bolts Tightening Sequence Tightening torque First step: 3.0-6.0 N.m {31-61 kgf.cm, 27-53 in.lbf} Second step: 8-11 N.m {82-112 kgf.cm, 71-97 in.lbf}

Scheme 143

Scheme 144

Scheme 145

1. Remove the rope suspending the timing chain on the intake side.
2. Remove the timing chain from the exhaust and intake camshaft sprockets and set it aside to the rear, then insert the electric variable valve timing actuator between the engine front cover and the cylinder head.
3. Return the timing chain to the exhaust camshaft sprocket. see scheme 155: Removing Timing Chain From Exhaust And Intake Camshaft Sprockets
4. While aligning the mark on the timing chain placed during removal with the one on the electric variable valve timing actuator, engage the chain with the sprocket. (Scheme 143): Engaging Timing Chain With Sprocket
5. Align the knock pin on the end of the intake camshaft with the notch on the actuator side, then assemble the actuator. NOTE: Adjust the knock pin with the notch while adjusting the knock pin position by rotating the camshaft. (Scheme 144): Identifying Intake Camshaft, Knock Pin, Electric Variable Valve Timing Actuator And Notch
6. Hold the intake camshaft using a wrench on the cast hexagon, and tighten the electric variable valve timing actuator installation bolt. Tightening torque 102-114 N.m {10.5-11.6 kgf.m, 76-84 ft.lbf} (Scheme 145): Tightening Electric Variable Valve Timing Actuator Installation Bolt Using Tool

Scheme 146

1. Install the chain guide (No.1).
2. Remove the bolt securing the tensioner arm and apply tension to the timing chain.
3. Rotate the crankshaft clockwise two turns and verify that the valve timing is correct. (Scheme 146): Identifying Timing Chain Alignment Mark If the valve timing is not correct, remove the engine front cover and reassemble the timing chain to each sprocket. (See «TIMING CHAIN REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615399-S31439702542014051000000) ).
4. Install the blind plugs (upper and lower) for the engine front cover service holes. Tightening torque Upper: 8-11 N.m {82-112 kgf.cm, 71-97 in.lbf} Lower: 17-23 N.m {1.8-2.3 kgf.m, 13-16 ft.lbf} see scheme 160: Identifying Upper And Lower Blind Plugs

Oil Shower Pipe Installation Note

1. Install the oil shower pipe in the order shown in the figure. TIGHTENING TORQUE SPECIFICATION Installation position Tightening torque 1 9-12 N.m {92-122 kgf.cm, 80-106 in.lbf} 2,3 8.0-9.0 N.m {82-91 kgf.cm, 71-79 in.lbf} see scheme 161: Identifying Oil Shower Pipes Installation Sequence

CYLINDER HEAD GASKET REPLACEMENT [SKYACTIV-G 2.0]

Scheme 147

1. Disconnect the negative battery cable. (See «NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 2.0]»(ref-615412-S04991947062014051000000) ).
2. Remove the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615399-S02010689542014051000000) ).
3. Remove the ignition coil/ion sensors. (See «IGNITION COIL/ION SENSOR REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615408-S22625302992014051000000) ).
4. Remove the front under cover No.2. (See «FRONT UNDER COVER NO.2 REMOVAL/INSTALLATION»(ref-615433-S21444705852014051000000) ).
5. Remove the splash shield. (See «SPLASH SHIELD REMOVAL/INSTALLATION»(ref-615433-S30142483462014051000000) ).
6. Remove the drive belt. (See «DRIVE BELT REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615399-S40242248072014051000000) ).
7. Drain the engine oil. (See «ENGINE OIL REPLACEMENT [SKYACTIV-G 2.0]»(ref-615400-S30421887502014051000000) ).
8. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [SKYACTIV-G 2.0]»(ref-615406-S03293741932014051000000) ).
9. Remove the intake manifold. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615404-S24638618012014051000000) ).
10. Set aside the exhaust manifold to the vehicle rear. (See «EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615409-S05941657582014051000000) ).
11. Disconnect the radiator hose (upper, lower).
12. Remove the vacuum pump. (See «VACUUM PUMP REMOVAL/INSTALLATION»(ref-615413-S40147185192014051000000) ).
13. Remove the high pressure fuel pump and rear housing. (See «HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615403-S21413673672014051000000) ).
14. Disconnect the heater hose from the water outlet and water inlet pipe.
15. Remove the oil pan. (See «OIL PAN REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615400-S09243944792014051000000) ).
16. Remove the timing chain and chain guide. (See «TIMING CHAIN REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615399-S31439702542014051000000) ).
17. Remove the OCV. (See «OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615399-S17688077422014051000000) ).
18. Remove in the order indicated in the table.
19. Install in the reverse order of removal.
20. Refill with the specified type and amount of the engine oil. (See «ENGINE OIL REPLACEMENT [SKYACTIV-G 2.0]»(ref-615400-S30421887502014051000000) ).
21. Refill the engine coolant. (See «ENGINE COOLANT REPLACEMENT [SKYACTIV-G 2.0]»(ref-615406-S03293741932014051000000) ).
22. 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 2.0]»(ref-615399-S37949971622014051000000) ). Compression pressure (See «COMPRESSION INSPECTION [SKYACTIV-G 2.0]»(ref-615399-S31950252172014051000000) ). (Scheme 147): Identifying Water Hose, Water Inlet Pipe, Camshaft, Rocker Arm, Cylinder Head And Gasket With Torque Specifications

Scheme 148

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. (Scheme 148): Identifying Camshaft Cap Installation Bolts Loosening Sequence

1. Keep the rocker arms in the order of removal to enable reassembly in their original positions.

Scheme 149

Scheme 150

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. (Scheme 149): Supporting Engine Oil Pan Using Engine Lifter
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. (Scheme 150): Identifying Cylinder Head Installation Bolts Loosening Sequence

Cylinder Head Installation Note

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}

Scheme 151

Scheme 152

1. When a cylinder head bolt is reused, apply engine oil to any part of the following: Bolt surface Cylinder head seating surface (Scheme 151): Identifying Cylinder Head Bolt Length
2. Tighten the cylinder head bolts in the order shown in the following 4 steps. Tightening torque Step 1: 13-17 N.m {133-173 kgf.cm, 116-150 in.lbf} Step 2: 43-47 N.m {4.4-4.7 kgf.m, 32-34 ft.lbf} Step 3: 85-95° Step 4: 85-95° (Scheme 152): Identifying Cylinder Head Bolt Tightening Sequence
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.

Scheme 153

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. (Scheme 153): Identifying Engine Oil Application Areas On HLA And Valve Stems

Scheme 154

Scheme 155

Scheme 156

Scheme 157

Scheme 158

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 in 3 } or less of oil to journal No.6. (Scheme 154): Identifying Gear Oil Application Areas On Center Of Cylinder Head Journal
2. Install the camshaft with cylinder No.1 cam aligned to the TDC position as shown in the figure. (Scheme 155): Identifying Timing Mark And Pin On Cylinder No. 1 Cam
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. (Scheme 156): Identifying Gear Oil Application Areas On Center Of Cylinder Head Journal
4. Apply adhesive agent (Loctite 962T) around journal No.6 of the cylinder head or the exhaust-side rear camshaft cap. CAUTION: Verify that there is no adhesive agent on the journal. Adhesive agent 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. (Scheme 157): Identifying Adhesive Application Area Around Journal No.6 Of Cylinder Head Or Exhaust-Side Rear Camshaft Cap
6. Tighten the camshaft cap installation bolts in two steps in the order shown in the figure. (Scheme 158): Identifying Camshaft Cap Installation Bolts Tightening Sequence Tightening torque First step: 3.0-6.0 N.m {31-61 kgf.cm, 27-53 in.lbf} Second step: 8-11 N.m {82-112 kgf.cm, 71-97 in.lbf}

Water Inlet Pipe Installation Note

Scheme 159

Scheme 160

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. Install the water inlet pipe gasket with the gasket projection facing the direction shown in the figure. (Scheme 159): Identifying Water Inlet Pipe Gasket Projection Area
6. Tighten the bolts in the order shown in the figure. (Scheme 160): Identifying Water Inlet And Outlet Pipe Mounting Bolts Tightening Sequence

FRONT OIL SEAL REPLACEMENT [SKYACTIV-G 2.0]

Scheme 161

1. Remove the front under cover No.2. (See «FRONT UNDER COVER NO.2 REMOVAL/INSTALLATION»(ref-615433-S21444705852014051000000) ).
2. Remove the splash shield. (See «SPLASH SHIELD REMOVAL/INSTALLATION»(ref-615433-S30142483462014051000000) ).
3. Remove the drive belt. (See «DRIVE BELT REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615399-S40242248072014051000000) ). E
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal. (Scheme 161): Identifying Crankshaft Pulley, Lock Bolt And Front Oil Seal With Torque Specifications

Scheme 162

1. Hold the crankshaft pulley using the SSTs.
2. Remove the crankshaft pulley lock bolt. (Scheme 162): Removing Crankshaft Pulley Lock Bolt Using Tools (49 B011 105 And 49 UN20 5072)

Scheme 163

1. Cut the oil seal lip using a utility knife.
2. Remove the oil seal using a flathead screwdriver with the tip protected by a clean cloth to prevent damage to the oil seal sliding part of the crankshaft. (Scheme 163): Removing Front Oil Seal Using Screwdriver Wrapped With Cloth

Scheme 164

Scheme 165

1. Apply clean engine oil to the inner surface of a new front oil seal.
2. Insert the front oil seal into the engine front cover by hand.
3. Tap the oil seal in evenly using the SST and a hammer. (Scheme 164): Tapping Front Oil Seal Using SST And Hammer Front oil seal press-in amount 0-0.5 mm {0-0.019 in} (Scheme 165): Identifying Front Oil Seal Installation Position

Scheme 166

1. Hold the crankshaft pulley using the SSTs.
2. Tighten the crankshaft pulley lock bolt in the order shown in the following two steps. Tightening torque Step 1: 90-110 N.m {9.2-11 kgf.m, 67-81 ft.lbf} Step 2: 55-65° (Scheme 166): Tightening Crankshaft Pulley Lock Bolt Using Tools (49 B011 105 And 49 UN20 5072)

Scheme 167

1. Remove the transaxle. (See «MANUAL TRANSAXLE REMOVAL/INSTALLATION [C66M-R]»(ref-615415-S08227211042014051000000) ). (See «AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [FW6A-EL] (ATX, 2WD)»(ref-615418-S02210776302014051000000) ). (See «AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [FW6AX-EL] (ATX, AWD)»(ref-615418-S14215775662014051000000) ).
2. Remove the flywheel (MTX) or the drive plate (ATX). (See «CLUTCH UNIT REMOVAL/INSTALLATION [C66M-R] (MTX)»(ref-615414-S41576897522014051000000) ). (See «DRIVE PLATE REMOVAL/INSTALLATION [FW6A-EL, FW6AX-EL] (ATX)»(ref-615418-S32390553572014051000000) ).
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal. (Scheme 167): Identifying Rear Oil Seal

Scheme 168

1. Cut the oil seal lip using a utility knife.
2. Remove the oil seal using a flathead screwdriver with the tip protected by a clean cloth to prevent damage to the oil seal sliding part of the crankshaft. (Scheme 168): Removing Rear Oil Seal Using Screwdriver Wrapped With Cloth

Scheme 169

Scheme 170

1. Apply clean engine oil to the inner surface of a new rear oil seal.
2. Insert the rear oil seal into the cylinder block by hand.
3. Tap the oil seal in evenly using the SST and a hammer. (Scheme 169): Tapping Rear Oil Seal Using SST And Hammer Rear oil seal press-in amount 0-0.5 mm {0-0.019 in} (Scheme 170): Identifying Rear Oil Seal Installation Position

Scheme 171

1. Remove the front under cover No.2. (See «FRONT UNDER COVER NO.2 REMOVAL/INSTALLATION»(ref-615433-S21444705852014051000000) ).
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal. (Scheme 171): Identifying No.1 Engine Mount Rubber, Bracket, Bracket Plates And Mounting Bolts With Torque Specifications

Scheme 172

1. Loosen the bolts shown in the figure. NOTE: The bracket plate (No.1) can move slightly by loosening the bolts shown in the figure and the No.1 engine mount rubber can be easily removed.
2. Remove the No.1 engine mount rubber. (Scheme 172): Identifying Bracket Plate (No.1) And Mounting Bolts

Scheme 173

Scheme 174

Scheme 175

1. Install the No.1 engine mount bracket, plate (No.1), and plate (No.2) and temporarily tighten the installation bolts.
2. Tighten the bolt shown in the figure. Tightening torque 8-10 N.m {82-101 kgf.cm, 71-88 in.lbf}
3. Install the No.1 engine mount rubber and temporarily tighten the installation bolts. (Scheme 173): Identifying Bracket Plate (No.1) And Mounting Bolts
4. Tighten the No.1 engine mount bracket, plate (No.1) and plate (No.2) installation bolts in the order shown in the figure. Tightening torque 84-98 N.m {8.6-9.9 kgf.m, 62-72 ft.lbf} (Scheme 174): Identifying No.1 Engine Mount Bracket, Plate (No.1) And Plate (No.2) Installation Bolts Tightening Sequence
5. Tighten the No.1 engine mount rubber installation bolts. (Scheme 175): Identifying No.1 Engine Mount Rubber Installation Bolts With Torque Specifications

No.1 engine mount bracket removal note (AWD)

1. Remove the front crossmember component and No.1 engine mount rubber as a single unit. (See «FRONT CROSSMEMBER REMOVAL/INSTALLATION»(ref-615436-S20840311802014051000000) ).
2. Remove the exhaust manifold. (See «EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615409-S05941657582014051000000) ).
3. Remove the transfer. (See «TRANSFER REMOVAL/INSTALLATION [FW6AX-EL]»(ref-615437-S21739154882014051000000) ).
4. Remove the No.1 engine mount bracket.

Scheme 176

1. Install the No.1 engine mount bracket and tighten the bolts in the order shown in the figure. Tightening torque 131-153 N.m {14-15 kgf.m, 97-112 ft.lbf}
2. Install in the reverse order of removal. (Scheme 176): Identifying No.1 Engine Mount Bracket Mounting Bolts Tightening Sequence

Scheme 177

1. Install the No.1 engine mount rubber to the front crossmember.
2. Tighten the front crossmember installation bolts. (See «FRONT CROSSMEMBER REMOVAL/INSTALLATION»(ref-615436-S20840311802014051000000) ).
3. Remove the jack.
4. Tighten the No.1 engine mount rubber installation bolts.
5. Install in the reverse order of removal. (Scheme 177): Identifying No.1 Engine Mount Rubber And Bracket Plate Bolts Tightening Sequence With Torque Specifications

Note. When replacing the No.3 engine mount, place a mark at the same position as the one placed before removal. If the No.3 engine mount nut is loosened, tighten the stud bolts for the No.3 engine mount bracket because they may be loosened.

Scheme 178

Scheme 179

Scheme 180

Scheme 181

1. Tighten the No.3 engine mount stud bolts. Tightening torque 7-13 N.m {72-132 kgf.cm, 62-115 in.lbf}
2. Temporarily tighten the No.3 engine mount installation bolts and nuts using the following procedure: Align the alignment marks on the body side and No.3 engine mount, and temporarily tighten the bolts shown in the figure. (Scheme 178): Identifying No.3 Engine Mount Stud Bolts (Scheme 179): Identifying Proper And Improper Alignment Marks On No.3 Engine Mount And Bolts Temporarily tighten the nuts shown in the figure while aligning the alignment marks of the No.3 engine mount and nuts. (Scheme 180): Identifying Proper And Improper Alignment Marks On No.3 Engine Mount And Nuts NOTE: If the alignment marks are not aligned, align the alignment marks while slightly moving the engine and temporarily tighten the nuts.
3. Tighten the No.3 engine mount installation bolts and nuts in the order shown in the figure. No. Tightening torque 1 76-95 N.m {7.8-9.6 kgf.m, 57-70 ft.lbf} 2 82-95 N.m {8.4-9.6 kgf.m, 61-70 ft.lbf} 3 49-65 N.m {5.0-6.6 kgf.m, 37-47 ft.lbf}
4. Remove the engine lifter or garage jack.
5. Install in the reverse order of removal. (Scheme 181): Identifying No.3 Engine Mount Installation Bolts And Nuts Tightening Sequence

No.4 engine mount bracket installation note

Note. When replacing the No.4 engine mount bracket, place a mark at the same position as the one placed before removal. If the No.4 engine mount bracket nut is loosened, tighten the stud bolts for the transaxle because they may be loosened.

Scheme 182

Scheme 183

Scheme 184

Scheme 185

1. Tighten the stud bolts for the transaxle. Tightening torque 15-25 N.m {1.6-2.5 kgf.m, 12-18 ft.lbf} (Scheme 182): Identifying Transaxle And Stud Bolts
2. Align the alignment marks on the No.4 engine mount bracket and nuts, and temporarily tighten the nuts shown in the figure. (Scheme 183): Identifying Proper And Improper Alignment Marks On No.4 Engine Mount Bracket And Nuts
3. Tighten the No.4 engine mount bracket installation nuts in the order shown in the figure. Tightening torque 92-116 N.m {9.4-11 kgf.m, 68-85 ft.lbf} (Scheme 184): Identifying No.4 Engine Mount Bracket Installation Nuts Tightening Sequence
4. Install the ground cable to the No.4 engine mount bracket. Tightening torque 8-11 N.m {82-112 kgf.cm, 71-97 in.lbf} (Scheme 185): Identifying Ground Cable And Mounting Bolt With Torque Specification

Scheme 186

Scheme 187

1. Install the No.4 engine mount rubber and temporarily tighten the bolts and nut shown in the figure. (Scheme 186): Identifying No.4 Engine Mount Rubber
2. Tighten the No.4 engine mount rubber installation bolts and nut in the order shown in the figure. No. Tightening torque 1,2 131-153 N.m {14-15 kgf.m, 97-112 ft.lbf} 3 54-62 N.m {5.6-6.3 kgf.m, 40-45 ft.lbf} 4 81-99 N.m {8.3-10 kgf.m, 60-73 ft.lbf}
3. Remove the engine lifter or garage jack.
4. Install in the reverse order of removal. (Scheme 187): Identifying No.4 Engine Mount Rubber Installation Bolts And Nut Tightening Sequence

ENGINE REMOVAL/INSTALLATION [SKYACTIV-G 2.0]

Note. Perform the engine and transaxle component removal/installation from below the vehicle.

Scheme 188

Scheme 189

Scheme 190

1. Disconnect the negative battery cable. (See «NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 2.0]»(ref-615412-S04991947062014051000000) ).
2. Remove the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615399-S02010689542014051000000) ).
3. Remove the air cleaner, air hose and fresh air duct as a single unit. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615404-S24638618012014051000000) ).
4. Remove the bolts, nut and connector shown in the figure, and set the wiring harness aside.
5. Remove the battery tray and PCM component. (See «BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615412-S41218039042014051000000) ).
6. Remove the front under cover No.1 and No.2. (See «FRONT UNDER COVER NO.1 REMOVAL/INSTALLATION»(ref-615433-S34343193522014051000000) ). (See «FRONT UNDER COVER NO.2 REMOVAL/INSTALLATION»(ref-615433-S21444705852014051000000) ).
7. Remove the splash shield. (See «SPLASH SHIELD REMOVAL/INSTALLATION»(ref-615433-S30142483462014051000000) ).
8. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [SKYACTIV-G 2.0]»(ref-615406-S03293741932014051000000) ).
9. Drain the transaxle oil (MTX) or ATF (ATX). (See «MANUAL TRANSAXLE OIL REPLACEMENT [C66M-R]»(ref-615415-S42228409712014051000000) ). (See «AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [FW6A-EL, FW6AX-EL]»(ref-615418-S19503034452014051000000) ). (Scheme 188): Identifying Bolts, Nut, Connector And Wiring Harness With Torque Specifications
10. Remove the front wheels and tires. (See «GENERAL PROCEDURES (SUSPENSION)»(ref-615438-S05391525002014051000000) ).
11. Disconnect the selector cable. (ATX) (See «AUTOMATIC TRANSAXLE SHIFT MECHANISM REMOVAL/INSTALLATION»(ref-615439-S02571559392014051000000) ).
12. Disconnect the control cable. (MTX) (See «MANUAL TRANSAXLE SHIFT MECHANISM REMOVAL/INSTALLATION [C66M-R]»(ref-615440-S42122392892014051000000) ).
13. Remove the clutch release cylinder with the pipe still connected. (MTX) (See «CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION [C66M-R]»(ref-615414-S11678563242014051000000) ).
14. Disconnect the brake vacuum hose. (See «VACUUM HOSE REMOVAL/INSTALLATION»(ref-615413-S37199264122014051000000) ).
15. Disconnect the evaporative hose. (See «PURGE SOLENOID VALVE REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615405-S01787745672014051000000) ).
16. Disconnect the fuel hose. (See «QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615403-S41684314122014051000000) ).
17. Disconnect the lower radiator hose. (See «RADIATOR REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615406-S23709300162014051000000) ).
18. Disconnect the upper radiator hose. (See «RADIATOR REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615406-S23709300162014051000000) ).
19. Disconnect the heater hose. (See «A/C UNIT REMOVAL/INSTALLATION»(ref-615407-S33029614062014051000000) ).
20. Remove the generator drive belt. (See «DRIVE BELT REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615399-S40242248072014051000000) ).
21. Remove the A/C compressor with the cooler hose still connected and secure it using wire or rope so that it is out of the way. (See «A/C COMPRESSOR REMOVAL/INSTALLATION»(ref-615407-S32851211722014051000000) ).
22. Remove the propeller shaft. (AWD) (See «PROPELLER SHAFT REMOVAL/INSTALLATION»(ref-615441-S14515617552014051000000) ).
23. Remove the TWC installation nuts (exhaust manifold side) and secure the TWC using wire or rope so that it is out of the way. (See «EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-615409-S05941657582014051000000) ).
24. Disconnect the drive shaft (LH) from the transaxle side, set the drive shaft (LH) out of the way. (See «FRONT DRIVE SHAFT REMOVAL/INSTALLATION»(ref-615442-S19145957892014051000000) ).
25. Disconnect the drive shaft (RH) from the transaxle side, set the drive shaft (RH) out of the way. (2WD) (See «FRONT DRIVE SHAFT REMOVAL/INSTALLATION»(ref-615442-S19145957892014051000000) ).
26. Remove the drive shaft (RH). (AWD) (See «FRONT DRIVE SHAFT REMOVAL/INSTALLATION»(ref-615442-S19145957892014051000000) ).
27. Remove the bolt and clips, and set the ground cable aside. (Scheme 189): Identifying No. 3 Engine Mount, Ground Cable, Bolt And Clips With Torque Specification
28. Remove in the order indicated in the table.
29. Install in the reverse order of removal.
30. Refill the transaxle oil (MTX) or ATF (ATX). (See «MANUAL TRANSAXLE OIL REPLACEMENT [C66M-R]»(ref-615415-S42228409712014051000000) ). (See «AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [FW6A-EL, FW6AX-EL]»(ref-615418-S19503034452014051000000) ).
31. Refill the engine coolant. (See «ENGINE COOLANT REPLACEMENT [SKYACTIV-G 2.0]»(ref-615406-S03293741932014051000000) ).
32. Start the engine, and inspect and adjust the following: (Scheme 190): Identifying No. 4 Engine Mount Bracket, Ground Cable And Bolts With Torque Specification Front wheel alignment (See «FRONT WHEEL ALIGNMENT»(ref-615434-S26623192832014051000000) ). Leakage of engine oil, engine coolant, ATF (ATX), transaxle oil (MTX), and fuel. Runout and contact of pulley and belt. Ignition timing, idle speed and idle mixture. (See «ENGINE TUNE-UP [SKYACTIV-G 2.0]»(ref-615399-S37949971622014051000000) ). Engine-driven accessories operation. NOTE: If the engine is overhauled and assembled to the vehicle, perform a road test to verify that there is no abnormal vibration and noise.

Identifying Bracket Plate, Engine Mount Rubbers, Brackets, Nuts And Bolt With Torque Specifications (2WD). Scheme 191

Identifying Bracket Plate, Engine Mount Rubbers, Brackets, Nuts And Bolt With Torque Specifications (AWD). Scheme 192

Scheme 193

Scheme 194

1. Loosen the No.1 engine mount rubber installation bolt (front crossmember side) shown in the figure. 2WD (Scheme 193): Identifying No.1 Engine Mount Rubber Installation Bolt AWD
2. Remove the No.1 engine mount rubber and the front crossmember component as a single unit. (See «FRONT CROSSMEMBER REMOVAL/INSTALLATION»(ref-615436-S20840311802014051000000) ). (Scheme 194): Identifying No.1 Engine Mount Rubber Installation Bolt

No.3 Engine Mount, No.4 Engine Mount Bracket Removal Note

Scheme 195

1. Secure the engine and transaxle using a commercially available engine lifter.
2. Remove the No.4 engine mount bracket.
3. Remove the No.3 engine mount. (Scheme 195): Securing Engine And Transaxle Using Engine Lifter

Engine Mount installation Note

Note. Retighten the stud bolts of the No.3 engine mount bracket and transaxle when the nuts of No.3 engine mount and No.4 engine mount bracket are loosened.

Scheme 196

Scheme 197

Scheme 198

Scheme 199

Scheme 200

Scheme 201

Scheme 202

Scheme 203

Scheme 204

Scheme 205

Scheme 206

Scheme 207

1. Tighten the No.3 engine mount stud bolts. Tightening torque 7-13 N.m {72-132 kgf.cm, 62-115 in.lbf} see scheme 230: Identifying No.3 Engine Mount Stud Bolts
2. Tighten the stud bolts for the transaxle. Tightening torque 15-25 N.m {1.6-2.5 kgf.m, 12-18 ft.lbf} CAUTION: When supporting the engine and transaxle, insert rubber of appropriate size (approx. 20 mm {0.79 in} thickness) between the engine lifter and the oil pan, transaxle to prevent the deformation of the oil pan and damage of the transaxle. (Scheme 196): Identifying Transaxle And Stud Bolts
3. Secure the engine and transaxle using a commercially available engine lifter.
4. Temporarily tighten the No.3 engine mount installation bolts and nuts using the following procedure: see scheme 232: Securing Engine And Transaxle Using Engine Lifter Temporarily tighten the bolts shown in the figure so that they are centered on the No.3 engine mount slots. (Scheme 197): Identifying Proper And Improper Bolt Holes Position On No.3 Engine Mount Slots Temporarily tighten the nuts shown in the figure so that they are centered on the No.3 engine mount slots. (Scheme 198): Identifying Proper And Improper Stud Bolts Position On No.3 Engine Mount Slots NOTE: If the stud bolts are deviated from the center of the slot, align the stud bolts with the center of the slot while slightly moving the engine, and temporarily tighten the installation nuts.
5. Temporarily tighten the No.4 engine mount bracket installation bolt and nuts using the following procedure: Temporarily tighten the bolt shown in the figure. Temporarily tighten the nuts shown in the figure so that they are centered on the No.4 engine mount bracket slots. (Scheme 199): Identifying No.4 Engine Mount Bracket And Bolt (Scheme 200): Identifying Proper And Improper Stud Bolts Position On Centered On No.4 Engine Mount Bracket Slots NOTE: If the stud bolts are deviated from the center of the slot, align the stud bolts with the center of the slot while slightly moving the transaxle, and temporarily tighten the installation nuts.
6. Install the No.1 engine mount rubber and the front crossmember component as a single unit. (See «FRONT CROSSMEMBER REMOVAL/INSTALLATION»(ref-615436-S20840311802014051000000) ).
7. Temporarily tighten the following parts: 2WD No.1 engine mount bracket, No.1 engine mount rubber and bracket plate (Scheme 201): Identifying No.1 Engine Mount Rubber, Bracket And Bracket Plate AWD No.1 engine mount rubber and bracket plate (Scheme 202): Identifying No.1 Engine Mount Rubber And Bracket Plate
8. Tighten the No.1 engine mount bracket and bracket plate installation bolts in the order shown in the figure. (2WD) Tightening torque 84-98 N.m {8.6-9.9 kgf.m, 62-72 ft.lbf} (Scheme 203): Identifying No.1 Engine Mount Bracket And Bracket Plate Installation Bolts Tightening Sequence
9. Tighten the No.3 engine mount installation bolts and nuts in the order shown in the figure. No. Tightening torque 1 76-95 N.m {7.8-9.6 kgf.m, 57-70 ft.lbf} 2 82-95 N.m {8.4-9.6 kgf.m, 61-70 ft.lbf} 3 49-65 N.m {5.0-6.6 kgf.m, 37-47 ft.lbf} (Scheme 204): Identifying No.3 Engine Mount Installation Bolts And Nuts Tightening Sequence
10. Tighten the No.4 engine mount bracket installation bolt and nuts in the order shown in the figure. No. Tightening torque 1,2,3 92-116 N.m {9.4-11 kgf.m, 68-85 ft.lbf} 4 81-99 N.m {8.3-10 kgf.m, 60-73 ft.lbf} (Scheme 205): Identifying No.4 Engine Mount Bracket Installation Bolts And Nuts Tightening Sequence
11. Tighten the No.1 engine mount rubber installation bolts. 2WD (Scheme 206): Identifying No.1 Engine Mount Rubber And Installation Bolts With Torque Specifications (2WD) AWD (Scheme 207): Identifying No.1 Engine Mount Rubber And Installation Bolts With Torque Specifications (AWD)

Oil Filter Body Installation Note

Note. The tightening order for 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}

Scheme 208

1. Install the oil cooler water pipe component in the order shown in the figure. Tightening torque 8-11 N.m {82-112 kgf.cm, 71-97 in.lbf} (Scheme 208): Identifying Oil Cooler Water Pipe And Mounting Bolts Tightening Sequence