RM36D0EC _51 Engine / Hybrid System _083059 M20D-FKS ENGINE MECHANICAL _0403042 CAMSHAFT A

M20D-FKS ENGINE MECHANICAL  CAMSHAFT  INSTALLATION  


CAUTION / NOTICE / HINT

NOTICE:

This procedure includes the installation of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION


PROCEDURE

Hide 1.INSTALL CAMSHAFT

HINT:

Perform Inspection After Repair after replacing the intake camshaft sub-assembly, exhaust camshaft sub-assembly, camshaft timing gear assembly and camshaft timing exhaust gear assembly.

Click hereEngine / Hybrid System>M20D-FKS (ENGINE CONTROL)>SFI SYSTEM>INITIALIZATION


a.
A445970C02
1.844,1.698 2.01,1.698 2.01,1.698 2.198,1.313 true 2.271,1.417 2.479,1.646 2.479,1.646 2.656,1.646 true 2.677,1.542 2.875,1.75 0.198,0.208 10 true *a 1.656,1.594 1.854,1.792 0.198,0.198 10 true *b
*a "0" Timing Mar
*b Timing Mark


Turn the crankshaft clockwise to align the timing mark (cutout) on the crankshaft pulley with the "0" timing mark on the No. 2 timing chain cover assembly.


b.
A400400C05
2.531,0.906 2.896,0.906 false 1.885,0.406 2.052,0.24 2.052,0.24 2.208,0.24 false 0.677,0.76 1.042,0.76 false 2.25,0.146 2.438,0.344 0.188,0.198 10 false *1 2.938,0.823 3.125,1.031 0.188,0.208 10 false *2 0.49,0.656 0.677,0.854 0.188,0.198 10 false *3
*1 No. 1 Valve Rocker Arm Sub-assembly
*2 Valve Lash Adjuster Assembly
*3 Valve Stem Cap


Check that the No. 1 valve rocker arm sub-assembly is correctly installed as shown in the illustration.


c.

Clean the camshaft housing sub-assembly and the cams and journals of the intake camshaft sub-assembly and exhaust camshaft sub-assembly, and then apply engine oil to them.


d.

Apply a light coat of engine oil to the journals of the intake camshaft sub-assembly and install the intake camshaft sub-assembly to the camshaft housing sub-assembly.


e.

Apply a light coat of engine oil to the journals of the exhaust camshaft sub-assembly and install the exhaust camshaft sub-assembly to the camshaft housing sub-assembly.


f.
A445967C04
0.219,0.833 0.5,0.833 true 1.198,0.823 1.365,0.823 true 1.417,1.385 1.417,1.25 1.417,1.25 1.75,1.115 true 2,1.385 2,1.25 2,1.25 2.333,1.104 true 2.667,0.844 2.833,0.844 true 0,0.75 0.208,0.938 0.208,0.188 10 true *1 1.406,0.74 1.604,0.927 0.198,0.188 10 true *2 1.323,1.406 1.531,1.594 0.208,0.188 10 true *3 2.469,0.76 2.667,0.948 0.198,0.188 10 true *4 0.844,0.031 1.052,0.208 0.208,0.177 10 true 12 3.188,0 3.406,0.177 0.219,0.177 10 true 10 0.833,2 1.052,2.177 0.219,0.177 10 true 11 0.885,0.75 1.094,0.917 0.208,0.167 10 true 13 2.521,1.427 2.646,1.625 0.125,0.198 10 true 7 2.458,0.042 2.583,0.24 0.125,0.198 10 true 4 1.844,0.031 2,0.208 0.156,0.177 10 true 2 1.438,1.979 1.563,2.177 0.125,0.198 10 true 5 2.865,0.031 3.01,0.177 0.146,0.146 10 true 8 1.302,0.031 1.427,0.229 0.125,0.198 10 true 6 3.208,1.521 3.344,1.698 0.135,0.177 10 true 9 2.615,1.979 2.74,2.177 0.125,0.198 10 true 3 2.021,1.969 2.146,2.167 0.125,0.198 10 true 1 1.906,1.406 2.115,1.594 0.208,0.188 10 true *3
*1 No. 1 Camshaft Bearing Cap
*2 No. 2 Camshaft Bearing Cap
*3 No. 3 Camshaft Bearing Cap
*4 No. 4 Camshaft Bearing Cap


Set the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, 2 No. 3 camshaft bearing caps and No. 4 camshaft bearing cap as shown in the illustration.


g.

Uniformly tighten the 13 camshaft bearing cap bolts in the order shown in the illustration.

Torque:
28.5 N*m (291 kgf*cm, 21 ft.*lbf)


h.
A445966N04
2.052,1.396 2.208,1.594 0.156,0.198 10 true 1 2.083,0.667 2.24,0.865 0.156,0.198 10 true 2 2.667,1.396 2.813,1.563 0.146,0.167 10 true 3 2.688,0.646 2.833,0.813 0.146,0.167 10 true 4 1.458,1.396 1.615,1.594 0.156,0.198 10 true 5 1.458,0.698 1.594,0.875 0.135,0.177 10 true 6 3.188,1.833 3.323,2 0.135,0.167 10 true 7 3.24,0.896 3.375,1.083 0.135,0.188 10 true 8 0.896,1.417 1.052,1.615 0.156,0.198 10 true 9

Uniformly tighten the 9 camshaft bearing cap bolts in the order shown in the illustration.

Torque:
16 N*m (163 kgf*cm, 12 ft.*lbf)


i.
A445971

Set the camshaft timing gear assembly and camshaft timing exhaust gear assembly to the timing chain sub-assembly in order as shown in the illustration.


j.
A445972C02
2.104,0.49 2.396,0.208 2.396,0.208 2.573,0.208 true 2.073,1.031 2.073,0.688 true 2,1.052 2.208,1.271 0.208,0.219 10 true *a 2.594,0.104 2.802,0.313 0.208,0.208 10 true *b
*a Paint Mark
*b Timing Mark


Align the timing mark on the camshaft timing gear assembly with the paint mark on the timing chain sub-assembly.


k.
A445973C02
2.115,0.958 2.115,0.75 2.115,0.75 1.75,0.583 true 1.24,0.927 1.24,0.74 1.24,0.74 1.677,0.438 true 1.156,0.948 1.365,1.156 0.208,0.208 10 true *a 2.042,0.969 2.25,1.188 0.208,0.219 10 true *b
*a Paint Mark
*b Timing Mark


Align the timing mark on the camshaft timing exhaust gear assembly with the paint mark on the timing chain sub-assembly.


l.
A445974C02
1.531,1.354 1.531,1.125 1.531,1.125 1.656,0.896 true 1.469,1.375 1.677,1.604 0.208,0.229 10 true *a
*a Knock Pin


Using the hexagonal portion of the intake camshaft sub-assembly, install the camshaft timing gear assembly to the intake camshaft sub-assembly.


m.

Check that the knock pin matches the pin hole from the No. 2 timing chain cover sub-assembly side.


n.

Using a bi-hexagon socket wrench (10 mm), temporarily install the camshaft timing gear assembly with the bolt.

HINT:

Temporarily install the bolt enough that the camshaft timing gear assembly does not detach from the knock pin of the intake camshaft sub-assembly.



o.
A445975

Using the hexagonal portion of the exhaust camshaft sub-assembly, install the camshaft timing exhaust gear assembly to the exhaust camshaft sub-assembly.


p.

Temporarily install with the 2 bolts.

HINT:

The 2 bolts can only be installed as shown in the illustration if the knock pin on the exhaust camshaft sub-assembly and the pin hole on the camshaft timing exhaust gear assembly match. If the 2 bolts cannot be installed, the knock pin and pin hole do not match.



q.
A445976C02
1.844,0.948 2.552,1.115 2.552,1.115 2.74,1.115 true 2.76,1.01 2.948,1.229 0.188,0.219 10 false *1
*1 No. 1 Chain Vibration Damper


Check the status of the camshaft timing gear assembly and camshaft timing exhaust gear assembly temporarily installed to each camshaft.

i.

Camshaft timing gear assembly side:

Check that the timing chain sub-assembly does not overlap the No. 1 chain vibration damper as shown in the illustration.

NOTICE:

If the timing chain sub-assembly overlaps the No. 1 chain vibration damper, install it again.



ii.
A445977C02
1.406,0.573 1.615,0.573 1.615,0.573 2.156,0.771 true 1.219,0.49 1.417,0.677 0.198,0.188 10 false *1
*1 Chain Tensioner Slipper


Camshaft timing exhaust gear assembly side:

Check that the timing chain sub-assembly does not overlap the chain tensioner slipper as shown in the illustration.

NOTICE:

If the timing chain sub-assembly overlaps the chain vibration slipper, install it again.




r.
A445978C02
2.313,0.219 2.521,0.427 0.208,0.208 10 true *a
*a Hold


Using the hexagonal portion of the intake camshaft sub-assembly, hold the intake camshaft sub-assembly.

NOTICE:
·

Do not damage the camshaft housing sub-assembly, cylinder head sub-assembly and spark plug tube.

·

Do not disassemble the camshaft timing gear assembly.




s.

Using a bi-hexagon socket wrench (10 mm), tighten the bolt on the camshaft timing gear assembly.

Torque:
86 N*m (877 kgf*cm, 63 ft.*lbf)


t.
A445975C02
3.146,0.042 3.365,0.25 0.219,0.208 10 true *a
*a Hold


Using the hexagonal portion of the exhaust camshaft sub-assembly, hold the exhaust camshaft sub-assembly.

NOTICE:
·

Do not damage the camshaft housing sub-assembly, cylinder head sub-assembly and spark plug tube.

·

Do not disassemble the camshaft timing gear assembly.




u.

Using a hexagon wrench (5 mm), tighten the 2 bolts.

Torque:
19 N*m (194 kgf*cm, 14 ft.*lbf)


v.
A445979C02
0.833,1.417 0.833,1.208 0.833,1.208 1.063,0.938 true 0.771,0.479 0.969,0.479 0.969,0.479 1.125,0.708 true 1.438,1.385 1.25,1.385 1.25,1.385 1.125,1.052 true 2.656,0.938 2.781,1.448 2.781,1.448 2.979,1.448 true 2.698,0.781 2.938,0.625 2.938,0.625 3.104,0.625 true 2.677,0.729 2.917,0.281 2.917,0.281 3.073,0.281 true 0.76,1.438 0.958,1.656 0.198,0.219 10 true *a 0.573,0.365 0.771,0.573 0.198,0.208 10 true *b 1.469,1.302 1.667,1.51 0.198,0.208 10 true *b 3.125,0.531 3.323,0.74 0.198,0.208 10 true *b 3.094,0.167 3.292,0.375 0.198,0.208 10 true *b 3,1.333 3.198,1.552 0.198,0.219 10 true *a
*a Paint Mark
*b Timing Mark


Check that the paint marks and timing marks are positioned as shown in the illustration.


w.

Using the hexagonal portion of the intake camshaft sub-assembly, check that the timing chain sub-assembly slackens when the intake camshaft sub-assembly is moved in the direction shown in the illustration.

A445980C02
5.948,0.115 6.198,0.323 0.25,0.208 10 false *a
*a Hold - -
V113147

Turn - -


NOTICE:

If the timing chain sub-assembly remains tight and does not slacken, the chain tensioner slipper and No. 1 chain vibration damper may overlap the timing chain sub -assembly, so install them again.



x.

Remove the pin from the No. 1 chain tensioner assembly.


Hide 135A0A 8.INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (EXHAUST CAMSHAFT TIMING GEAR BOLT ASSEMBLY)

Click hereEngine / Hybrid System>M20D-FKS (ENGINE CONTROL)>CAMSHAFT OIL CONTROL VALVE>INSTALLATION

Hide 82121 12.CONNECT ENGINE WIRE

a.
A445956

Attach the 2 clamps and connect the engine wire.


b.

Connect the 6 connectors.


c.
A451175

Install the purge valve (purge VSV) to the purge VSV bracket with the bolt.

Torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)


d.

Connect the purge valve (purge VSV) connector.


e.
A457653

Attach the clamp.


f.

Connect the 2 connectors.


g.
A457652

Connect the engine wire with the bolt and 2 nuts.

Torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)


h.

Connect the connector.