Honda S2000 F20C Cam Chain Removal and Installation
06-22-2009, 02:54 PM
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Honda S2000 F20C Cam Chain Removal and Installation
To see the original article with images check it out here: Honda S2000 F20C Cam Chain Removal and Installation. Garage411.com
REMOVAL
TOOLS NEEDED
* Holder handle 07JAB-001020B
* Holder attachment, 50 mm 07JAB-001040A
* Socket, 19 mm 07JAA-001020A or a commercially available 19 mm socket
TIP
* Use fender covers to avoid damaging painted surfaces.
* To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
* To avoid damaging the cylinder head, wait until the engine coolant temperature drops below 100°F (38°C) before loosening the cylinder head bolts.
* Mark all wiring and hoses to avoid misconnection. Also, be sure that they do not contact other wiring or hoses, or interfere with other parts.
* Keep the cam chain away from magnets. A magnetized cam chain may misfire or cause false DTCs.
1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons.
2. Disconnect the negative cable from the battery, then disconnect the positive cable.
3. Drain the engine coolant.
4. Drain the engine oil.
5. Disconnect the air control solenoid valve connector, then remove the vacuum hoses and the air cleaner housing/intake air duct assembly.
6. Remove the vacuum tank.
7. Loosen the water pump pulley bolts.
8. Move the auto-tensioner to remove tension from the alternator-compressor belt, then remove the alternator-compressor belt.
9. Remove the water bypass hose, then remove the three bolts securing the water bypass tube.
10. Remove the water pump pulley.
11. Remove the auto-tensioner.
12. Remove the alternator.
13. Remove the idler pulley, then remove the idler pulley base.
14. Remove the throttle cable.
15. Relieve fuel pressure.
16. Remove the fuel feed hose, fuel return hose, and brake booster vacuum hose
17. Remove the evaporative emission (EVAP) canister hose
18. Remove the bolt securing the intake manifold bracket, and remove the air hose
19. Remove the water outlet cover
20. Remove the two bolts securing the intake manifold bracket, and remove the water bypass hose
21. Remove the engine wire harness connectors and wire harness clamps from the cylinder head and intake manifold.
* Four fuel injector connectors
* Intake air temperature (IAT) sensor connector
* Idle air control (IAC) valve connector
* Throttle position (TP) sensor connector
* Manifold absolute pressure (MAP) sensor connector
* Engine coolant temperature (ECT) sensor connector
* Primary heated oxygen sensor (primary HO2S) connector
* VTEC solenoid valve connector
* VTEC pressure switch connector
* Crankshaft position (CKP) sensor connector
22. Remove the four bolts securing the exhaust manifold cover
23. Remove the heat shield
24. Remove the exhaust manifold cover, then remove the exhaust manifold bracket and exhaust manifold
25. Remove the dipstick, Positive Crankcase Ventilation (PCV) hose and breather hose
26. Remove the ignition coil cover, then remove the ignition coils
27. Remove the cylinder head cover
28. Set the No. 1 piston at top dead center (TDC)
29. Remove the end cover and nozzle from the cam chain auto-tensioner
30. Thread a nut onto the 5 x 0.8 mm bolt, then thread the bolt into the maintenance hole in the cam chain auto-tensioner (see step 25 on Cylinder Head Removal ).
31. Turn the bolt clockwise to compress the cam chain auto-tensioner, and lock the bolt with the nut (see step
26 on Cylinder Head Removal ).
32. Remove the cam chain auto-tensioner
33. Loosen the rocker arm adjusting screws
34. Remove the camshaft holders and camshafts.
35. Remove the rocker arm assembly
36. Remove the idler gear/idler gear collar/washer assembly. Do not drop the washer into the chain case (see step 31 on Cylinder Head Removal ).
37. Remove the cylinder head bolts (see step 32 on Cylinder Head Removal ). To prevent warpage, unscrew the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened.
38. Remove the cylinder head.
39. Remove the oil pan.
40. Hold the pulley with holder handle and holder attachment.
41. Remove the bolt with a heavy duty 19 mm socket and breaker bar.
42. Remove the chain case.
43. Remove the oil pump chain guide.
44. Remove the cam chain.
INSTALLATION
TOOLS NEEDED
* Holder handle 07JAB-001020B
* Holder attachment, 50 mm 07JAB-001040A
* Socket, 19 mm 07JAA-001020A or a commercially available 19 mm socket
1. Set the crankshaft sprocket so that the No. 1 piston is at top dead center (TDC). Align the key on the sprocket and crankshaft with the pointer on the cylinder block.
2. Install the cam chain with the colored piece aligned with the punch mark on the crankshaft sprocket.
3. Install the oil pump chain guide.
4. Remove any old liquid gasket from the chain case mating surfaces, bolts, and bolt holes.
5. Clean and dry the chain case mating surfaces.
6. Apply liquid gasket, PN 08718-0009, evenly to the cylinder block mating surface of the chain case and to the inner threads of the bolt holes.
TIP: Do not install the parts if 4 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing the old residue.
7. Install the dowel pins and chain case using a new O-ring.
8. Remove any old liquid gasket from the oil pan mating surfaces, bolts, and bolt holes.
9. Clean and dry the oil pan mating surfaces.
10. Apply liquid gasket, PN 08718-0009, evenly to the cylinder block mating surface of the oil pan and to the inner threads of the bolt holes. Install the oil pan. Do not install the parts if 4 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing the old residue.
11. Tighten the bolts in two or three steps. In the final step, tighten all bolts, in sequence, to 12 N.m (1.2 kgf.m, 8.7 lbf.ft).
12. Clean the bolt, washer, pulley and crankshaft. Lubricate with new engine oil as shown.
13. Install the crankshaft pulley, and tighten the bolt to 245 N.m (25.0 kgf.m, 181 lbf.ft). Do not use an impact wrench.
14. Measure the diameter of each cylinder head bolt at point A and point B (see step 1 on Camshaft Gear Installation). If either diameter is less than 11.5 mm (0.45 in.), replace the cylinder head bolt.
15. Clean the cylinder head and engine block surfaces.
16. Apply liquid gasket, PN 08718-0009, to the shaded areas of the cylinder head gasket mating surface of the block and chain case.
17. Install the dowel pins and new cylinder head gasket.
18. Apply liquid gasket, PN 08718-0009, to the cylinder head mating surface of the engine block and chain case within 5 mm from the edge of the cylinder head gasket.
19. Install the cylinder head on the block.
20. Apply engine oil to the threads and under the heads of all the cylinder head bolts.
21. Tighten the cylinder head bolts in sequence to 29 N.m (3.0 kgf.m, 22 lbf.ft). Use a beam-type torque wrench. When using a preset-type torque wrench, be sure to tighten slowly and do not overtighten. If a bolt makes any noise while you are torquing it, loosen the bolt and retighten it
22. Tighten all cylinder head bolts in two steps (90° per step). If you are using a new cylinder head bolt, tighten the bolt an extra 90°
23. Tighten the 8 mm bolts to 22 N.m (2.2 kgf.m, 16 lbf.ft).
24. Make sure the crankshaft pulley is at TDC.
25. Place the idler gear/cam chain sprocket assembly into the cylinder head.
26. Install the cam chain on the sprocket with the punch mark aligned with the center of the two colored pieces.
27. Fit the cam chain sprocket assembly into the cylinder head.
28. Turn the assembly counterclockwise to relieve cam chain free play, and check alignment of the TDC marks on the cam chain sprocket with the cylinder head surface. If the cam chain sprocket is not positioned at TDC, remove the assembly from the cylinder head and reposition the cam chain to bring the cam chain sprocket to TDC.
29. Apply engine oil to the idler gear center bolt threads. Install a new O-ring on the bolt.
30. Install the washer on the idler gear, and tighten the idler gear center bolt
31. Clamp the cam chain auto-tensioner in a soft-jawed vise.
32. Turn the 5 x 0.8 mm bolt clockwise to compress the bottom of the auto-tensioner, then insert the set pin
33. Remove the 5 x 0.8 mm bolt from the maintenance hole. Install a new O-ring, then install the nozzle and end cover
34. Install the cam chain auto-tensioner in the cylinder head with new O-ring
35. Remove the maintenance bolt from the cylinder head
36. Remove the set pin from the cam chain auto-tensioner. Reinstall the maintenance bolt with new washer
37. Install the rocker arm assembly.
38. Check the alignment of the TDC marks on the cam chain sprocket with the cylinder head surface
39. Align the TDC marks on the intake camshaft gear and the exhaust camshaft gear, and install the camshafts
40. Apply engine oil to the bolt threads of all the camshaft holder bolts.
41. Put the camshaft holders on the cylinder head, then tighten all bolts to 22 N.m (2.2 kgf.m, 16 lbf.ft)
42. Make sure the camshaft gears are at TDC.
43. Adjust the valve clearance.
44. Install the cylinder head cover
45. Install the exhaust manifold using new gaskets and new self-locking nuts
46. Install the exhaust manifold bracket. Make sure the smooth sides of the washers face the exhaust manifold bracket
47. Put the exhaust manifold cover on the exhaust manifold.
48. Install the heat shield
49. Tighten the four bolts securing the exhaust manifold cover
50. Install the water bypass hose, and tighten the two bolts securing the intake manifold bracket
51. Install the water outlet cover
52. Install the air hose, and tighten the bolt securing the intake manifold bracket
53. Install the evaporative emission (EVAP) control canister hose
54. Install the fuel feed hose, fuel return hose and brake booster hose
55. Install the idler pulley base, then install the idler pulley.
56. Install the alternator
57. Install the auto-tensioner.
58. Install the water pump pulley.
59. Install the water bypass hose, and tighten the three bolts securing the water bypass tube.
60. Install the alternator-compressor belt.
61. Install the vacuum tank.
62. Install the air cleaner housing/intake air duct assembly, then install the vacuum hoses. Connect the air control solenoid valve connector.
63. Install the throttle cable, then adjust it.
64. After installation, check that all tubes, hoses, and connectors are installed correctly.
65. After assembly, wait at least 30 minutes before filling the engine with oil.
66. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open
67. Inspect for fuel leaks. Turn ON (II) the ignition switch (do not operate the starter) so that the fuel pump runs for about 2 seconds and pressurizes the fuel line. Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
68. Inspect the idle speed
69. Inspect the ignition timing
70. Connect the negative battery cable first, then connect the positive cable.
71. Enter the anti-theft code for the radio, then enter the customer's radio station presets.
To see the original article with images check it out here: Honda S2000 F20C Cam Chain Removal and Installation. Garage411.com
REMOVAL
TOOLS NEEDED
* Holder handle 07JAB-001020B
* Holder attachment, 50 mm 07JAB-001040A
* Socket, 19 mm 07JAA-001020A or a commercially available 19 mm socket
TIP
* Use fender covers to avoid damaging painted surfaces.
* To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
* To avoid damaging the cylinder head, wait until the engine coolant temperature drops below 100°F (38°C) before loosening the cylinder head bolts.
* Mark all wiring and hoses to avoid misconnection. Also, be sure that they do not contact other wiring or hoses, or interfere with other parts.
* Keep the cam chain away from magnets. A magnetized cam chain may misfire or cause false DTCs.
1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons.
2. Disconnect the negative cable from the battery, then disconnect the positive cable.
3. Drain the engine coolant.
4. Drain the engine oil.
5. Disconnect the air control solenoid valve connector, then remove the vacuum hoses and the air cleaner housing/intake air duct assembly.
6. Remove the vacuum tank.
7. Loosen the water pump pulley bolts.
8. Move the auto-tensioner to remove tension from the alternator-compressor belt, then remove the alternator-compressor belt.
9. Remove the water bypass hose, then remove the three bolts securing the water bypass tube.
10. Remove the water pump pulley.
11. Remove the auto-tensioner.
12. Remove the alternator.
13. Remove the idler pulley, then remove the idler pulley base.
14. Remove the throttle cable.
15. Relieve fuel pressure.
16. Remove the fuel feed hose, fuel return hose, and brake booster vacuum hose
17. Remove the evaporative emission (EVAP) canister hose
18. Remove the bolt securing the intake manifold bracket, and remove the air hose
19. Remove the water outlet cover
20. Remove the two bolts securing the intake manifold bracket, and remove the water bypass hose
21. Remove the engine wire harness connectors and wire harness clamps from the cylinder head and intake manifold.
* Four fuel injector connectors
* Intake air temperature (IAT) sensor connector
* Idle air control (IAC) valve connector
* Throttle position (TP) sensor connector
* Manifold absolute pressure (MAP) sensor connector
* Engine coolant temperature (ECT) sensor connector
* Primary heated oxygen sensor (primary HO2S) connector
* VTEC solenoid valve connector
* VTEC pressure switch connector
* Crankshaft position (CKP) sensor connector
22. Remove the four bolts securing the exhaust manifold cover
23. Remove the heat shield
24. Remove the exhaust manifold cover, then remove the exhaust manifold bracket and exhaust manifold
25. Remove the dipstick, Positive Crankcase Ventilation (PCV) hose and breather hose
26. Remove the ignition coil cover, then remove the ignition coils
27. Remove the cylinder head cover
28. Set the No. 1 piston at top dead center (TDC)
29. Remove the end cover and nozzle from the cam chain auto-tensioner
30. Thread a nut onto the 5 x 0.8 mm bolt, then thread the bolt into the maintenance hole in the cam chain auto-tensioner (see step 25 on Cylinder Head Removal ).
31. Turn the bolt clockwise to compress the cam chain auto-tensioner, and lock the bolt with the nut (see step
26 on Cylinder Head Removal ).
32. Remove the cam chain auto-tensioner
33. Loosen the rocker arm adjusting screws
34. Remove the camshaft holders and camshafts.
35. Remove the rocker arm assembly
36. Remove the idler gear/idler gear collar/washer assembly. Do not drop the washer into the chain case (see step 31 on Cylinder Head Removal ).
37. Remove the cylinder head bolts (see step 32 on Cylinder Head Removal ). To prevent warpage, unscrew the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened.
38. Remove the cylinder head.
39. Remove the oil pan.
40. Hold the pulley with holder handle and holder attachment.
41. Remove the bolt with a heavy duty 19 mm socket and breaker bar.
42. Remove the chain case.
43. Remove the oil pump chain guide.
44. Remove the cam chain.
INSTALLATION
TOOLS NEEDED
* Holder handle 07JAB-001020B
* Holder attachment, 50 mm 07JAB-001040A
* Socket, 19 mm 07JAA-001020A or a commercially available 19 mm socket
1. Set the crankshaft sprocket so that the No. 1 piston is at top dead center (TDC). Align the key on the sprocket and crankshaft with the pointer on the cylinder block.
2. Install the cam chain with the colored piece aligned with the punch mark on the crankshaft sprocket.
3. Install the oil pump chain guide.
4. Remove any old liquid gasket from the chain case mating surfaces, bolts, and bolt holes.
5. Clean and dry the chain case mating surfaces.
6. Apply liquid gasket, PN 08718-0009, evenly to the cylinder block mating surface of the chain case and to the inner threads of the bolt holes.
TIP: Do not install the parts if 4 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing the old residue.
7. Install the dowel pins and chain case using a new O-ring.
8. Remove any old liquid gasket from the oil pan mating surfaces, bolts, and bolt holes.
9. Clean and dry the oil pan mating surfaces.
10. Apply liquid gasket, PN 08718-0009, evenly to the cylinder block mating surface of the oil pan and to the inner threads of the bolt holes. Install the oil pan. Do not install the parts if 4 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing the old residue.
11. Tighten the bolts in two or three steps. In the final step, tighten all bolts, in sequence, to 12 N.m (1.2 kgf.m, 8.7 lbf.ft).
12. Clean the bolt, washer, pulley and crankshaft. Lubricate with new engine oil as shown.
13. Install the crankshaft pulley, and tighten the bolt to 245 N.m (25.0 kgf.m, 181 lbf.ft). Do not use an impact wrench.
14. Measure the diameter of each cylinder head bolt at point A and point B (see step 1 on Camshaft Gear Installation). If either diameter is less than 11.5 mm (0.45 in.), replace the cylinder head bolt.
15. Clean the cylinder head and engine block surfaces.
16. Apply liquid gasket, PN 08718-0009, to the shaded areas of the cylinder head gasket mating surface of the block and chain case.
17. Install the dowel pins and new cylinder head gasket.
18. Apply liquid gasket, PN 08718-0009, to the cylinder head mating surface of the engine block and chain case within 5 mm from the edge of the cylinder head gasket.
19. Install the cylinder head on the block.
20. Apply engine oil to the threads and under the heads of all the cylinder head bolts.
21. Tighten the cylinder head bolts in sequence to 29 N.m (3.0 kgf.m, 22 lbf.ft). Use a beam-type torque wrench. When using a preset-type torque wrench, be sure to tighten slowly and do not overtighten. If a bolt makes any noise while you are torquing it, loosen the bolt and retighten it
22. Tighten all cylinder head bolts in two steps (90° per step). If you are using a new cylinder head bolt, tighten the bolt an extra 90°
23. Tighten the 8 mm bolts to 22 N.m (2.2 kgf.m, 16 lbf.ft).
24. Make sure the crankshaft pulley is at TDC.
25. Place the idler gear/cam chain sprocket assembly into the cylinder head.
26. Install the cam chain on the sprocket with the punch mark aligned with the center of the two colored pieces.
27. Fit the cam chain sprocket assembly into the cylinder head.
28. Turn the assembly counterclockwise to relieve cam chain free play, and check alignment of the TDC marks on the cam chain sprocket with the cylinder head surface. If the cam chain sprocket is not positioned at TDC, remove the assembly from the cylinder head and reposition the cam chain to bring the cam chain sprocket to TDC.
29. Apply engine oil to the idler gear center bolt threads. Install a new O-ring on the bolt.
30. Install the washer on the idler gear, and tighten the idler gear center bolt
31. Clamp the cam chain auto-tensioner in a soft-jawed vise.
32. Turn the 5 x 0.8 mm bolt clockwise to compress the bottom of the auto-tensioner, then insert the set pin
33. Remove the 5 x 0.8 mm bolt from the maintenance hole. Install a new O-ring, then install the nozzle and end cover
34. Install the cam chain auto-tensioner in the cylinder head with new O-ring
35. Remove the maintenance bolt from the cylinder head
36. Remove the set pin from the cam chain auto-tensioner. Reinstall the maintenance bolt with new washer
37. Install the rocker arm assembly.
38. Check the alignment of the TDC marks on the cam chain sprocket with the cylinder head surface
39. Align the TDC marks on the intake camshaft gear and the exhaust camshaft gear, and install the camshafts
40. Apply engine oil to the bolt threads of all the camshaft holder bolts.
41. Put the camshaft holders on the cylinder head, then tighten all bolts to 22 N.m (2.2 kgf.m, 16 lbf.ft)
42. Make sure the camshaft gears are at TDC.
43. Adjust the valve clearance.
44. Install the cylinder head cover
45. Install the exhaust manifold using new gaskets and new self-locking nuts
46. Install the exhaust manifold bracket. Make sure the smooth sides of the washers face the exhaust manifold bracket
47. Put the exhaust manifold cover on the exhaust manifold.
48. Install the heat shield
49. Tighten the four bolts securing the exhaust manifold cover
50. Install the water bypass hose, and tighten the two bolts securing the intake manifold bracket
51. Install the water outlet cover
52. Install the air hose, and tighten the bolt securing the intake manifold bracket
53. Install the evaporative emission (EVAP) control canister hose
54. Install the fuel feed hose, fuel return hose and brake booster hose
55. Install the idler pulley base, then install the idler pulley.
56. Install the alternator
57. Install the auto-tensioner.
58. Install the water pump pulley.
59. Install the water bypass hose, and tighten the three bolts securing the water bypass tube.
60. Install the alternator-compressor belt.
61. Install the vacuum tank.
62. Install the air cleaner housing/intake air duct assembly, then install the vacuum hoses. Connect the air control solenoid valve connector.
63. Install the throttle cable, then adjust it.
64. After installation, check that all tubes, hoses, and connectors are installed correctly.
65. After assembly, wait at least 30 minutes before filling the engine with oil.
66. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open
67. Inspect for fuel leaks. Turn ON (II) the ignition switch (do not operate the starter) so that the fuel pump runs for about 2 seconds and pressurizes the fuel line. Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
68. Inspect the idle speed
69. Inspect the ignition timing
70. Connect the negative battery cable first, then connect the positive cable.
71. Enter the anti-theft code for the radio, then enter the customer's radio station presets.
To see the original article with images check it out here: Honda S2000 F20C Cam Chain Removal and Installation. Garage411.com
Last edited by Master23; 07-01-2009 at 05:54 PM.
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