2.5L Non-Turbo Engine Complete Assembly for 2021-2024 Hyundai & Kia

A quick look at your own vehicle makes sure the right engine shows up:

• Check your VIN's 8th digit: Look at the 17-digit VIN plate on your dashboard or on the driver's side door jamb sticker. Confirm that the 8th digit matches the required code for your specific model: 8 for Kia K5, F for Kia Sorento or Hyundai Santa Cruz, L for Hyundai Santa Fe, C for Hyundai Sonata.
• Verify your Engine Code: Locate the engine code stamping on the front of your engine block. It must read G4KP to confirm you have the transverse 2.5L Smartstream T-GDI engine.
• Confirm your Transmission: Ensure your vehicle is equipped with the 8-speed wet Dual-Clutch Transmission (DCT). This engine will not mate to the standard 8-speed torque-converter automatic used on naturally aspirated models.
• Confirm your Drivetrain: Check if your vehicle is FWD or AWD. If crossing drivetrains, you must swap your original oil pan and accessory brackets.
• Check Your Turbo Status: Confirm whether your vehicle is turbocharged. This unit does not include a turbocharger; you must retain and transfer your original turbo, exhaust manifold, and plumbing.

What the install really takes — plan and budget with confidence:

Special tools this job needs:

• GDI Fuel Injector Puller/Installer Tool
• High-Pressure Fuel Line Disconnect Tool
• Engine Hoist/Crane with Load Leveler
• Factory-level bi-directional scan tool

Budget for these consumables at install:

• Intake manifold gasket
• Exhaust manifold gasket
• Valve cover gasket
• High-pressure fuel pump O-ring
• GDI Teflon injector seals
• Turbocharger mounting gaskets
• 0W-30 or 0W-20 Full Synthetic Oil (SP/GF-6A certified)
• OEM cartridge or spin-on oil filter
• OE-spec phosphate-organic acid technology (P-OAT) green or blue coolant
• OEM-spec Iridium spark plugs
• New OEM high-pressure fuel pipe (one-time-use)

What your vehicle’s computers will need after the swap:

What’s involved: Crankshaft Position (CKP) Sensor Relearn, Camshaft Position Sensor Relearn, CVVD (Continuously Variable Valve Duration) Actuators Relearn, Electronic Throttle Body Relearn, ITM Module Relearn, and Transmission (TCU) Adaptive Values Reset

While the ECU itself does not need to be replaced or re-married if you are using your original computer, you must use a bi-directional scan tool to perform mandatory sensor and actuator relearns. Failing to clear the adaptive values for the CVVD system will result in limp mode, poor idle, and check engine lights.

Pro tips for a smooth first start-up — hand them to whoever does the install:

• GDI Teflon Injector Seals: If you transfer your original fuel injectors to this replacement engine, you must replace the Teflon seals and use a special resizing tool to prevent immediate high-pressure fuel leaks.
• High-Pressure Fuel Pipe Torque: The high-pressure fuel pipe is a one-time-use component. Reusing the old pipe or failing to torque the new pipe to exact factory specifications will result in a severe fuel leak and engine fire hazard.
• Stretch Belt Installation: The water pump on this engine is driven by a stretch belt. You must use a dedicated stretch belt installation tool to prevent tearing the belt or damaging the pulleys.
• 8-Speed DCT Alignment: When mating the engine to the 8-speed wet DCT, ensure the dual-clutch assembly is perfectly aligned to avoid bending the input shaft or damaging the clutch pack.
• AWD vs. FWD Oil Pan: If you are installing this engine into an AWD vehicle and the donor was a FWD vehicle, you must swap your original oil pan and the passenger-side axle/PTU mounting brackets before dropping the engine in.
• CVVD Actuators: The Continuously Variable Valve Duration system on the valve cover is highly sensitive. Handle the engine carefully during transport and installation to avoid cracking the actuator housings.

Easy to get right once you know them:

• Reusing the High-Pressure Fuel Line: This is the #1 cause of post-install engine fires and fuel leaks on this engine family. Always replace it with a new OEM line.
• Using the Wrong Oil Viscosity: The 2.5T Smartstream requires specific SP / GF-6 certified synthetic oil. Using incorrect oil grades leads to Low-Speed Pre-Ignition (LSPI), which can crack pistons and destroy the engine.
• Attempting a Non-Turbo to Turbo Swap: Buyers often purchase this engine hoping to swap it into a vehicle that originally had the naturally aspirated 2.5L engine. The wiring harnesses, ECU, cooling systems, and transmissions are completely incompatible.
• Neglecting the CKP and CVVD Relearns: Skipping the sensor and actuator relearns after installation often results in a 'crank, no-start' condition, limp mode, poor idle, or persistent random misfire codes.
• Not Swapping the Oil Pan for AWD: Dropping the engine into an AWD chassis only to realize the FWD oil pan lacks the necessary clearance or bolt holes for the transfer case/PTU.
• Ignoring the ITM Module: Leaving a high-mileage or unknown-condition ITM (electronic thermostat) on the replacement engine is a massive risk. It is highly recommended to swap in a brand-new OEM ITM module while the engine is on the stand.

Not issues with the units on this page — the manufacturer documented these for every engine of this family, wherever you buy one. Handy for your installer: