1D
Camshaft and Tappet Removal and Installation
Reference: Camshaft and Tappet Components:K9K
Removal
1) Remove engine assembly from vehicle referring to Engine Assembly Removal and Installation:K9K .
2) Remove timing belt referring to Timing Belt and Belt Tensioner Removal and Installation:K9K .
3) Remove special tool (A).
Special Tool
(A) : 09919–58120
4) Remove camshaft pulley as follows.
a) Fix camshaft pulley using special tool.
Special Tool
(A) : 09917–68221
b) Loosen camshaft pulley nut, and remove camshaft pulley.
5) Remove cylinder head cover referring to Cylinder Head Cover Removal and Installation:K9K .
6) Disconnect vacuum pump oil hose (1) from camshaft cover (2).
7) Remove camshaft cover (2).
8) Loosen camshaft housing bolts in numerical order (“1” to “12”) as indicated in the figure, and remove them.
9) Remove camshaft housing and camshaft from cylinder head.
10) Remove tappet (1) from cylinder head.
CAUTION:
Note original position in which each tappet was installed when valve lash (clearance) adjustment is not necessary. If each tappet is not installed to original position, engine will spoil its original performance.
Installation
Reference: Camshaft and Tappet Inspection:K9K
1) Apply engine oil around tappet (1), and then install it to cylinder head.
2) Remove oil, old sealant and dust from sealing surfaces. After cleaning, apply sealant “A” to cylinder head (1) sealing surface area as shown in the figure.
“A” : Sealant ( Loctite 5181® )
“a”: 1 mm (0.04 in.)
3) Install camshaft to cylinder head as follows.
a) Direct key groove (2) upward by turning crankshaft (1) clockwise.
b) Install camshaft pulley (1) to camshaft with aligning key (3) of camshaft pulley to key groove (4) of camshaft (2), and then tighten camshaft pulley nut to temporary.
c) Apply engine oil to sliding surface of each camshaft and camshaft journal.
d) Fit camshaft to cylinder head and install special tool into holes of timing belt pulley (1) and cylinder head as shown in the figure.
Special Tool
(A) : 09919–58120
4) Install camshaft housing to cylinder head as follows.
a) Fit camshaft housing to cylinder head in specified position as shown.
b) Tighten camshaft housing bolts temporarily by hand.
c) Tighten camshaft housing bolts in numerical order as indicated in the figure a little at a time till they are tightened to specified torque.
Tightening torque
Camshaft housing bolt ( a ): Tighten 10 N·m (1.0 kgf-m, 7.5 lbf-ft) by the specified procedure
5) Install camshaft cover (1) with new gasket.
Tightening torque
Camshaft cover bolt ( b ): Tighten 5 N·m (0.5 kgf-m, 4.0 lbf-ft) and 12 N·m (1.2 kgf-m, 9.0 lbf-ft) by the specified procedure
6) Connect vacuum pump oil hose (2) to rear camshaft (1) cover with new gasket.
Tightening torque
Vacuum pump oil hose union bolt ( c ): 16 N·m ( 1.6 kg-m, 12.0 lb-ft)
7) Remove camshaft pulley and special tool.
8) Install new oil seal (1)  together with protector (2) using special tool with plastic hammer until special tool comes into contact with cylinder head.
CAUTION:
Do not touch oil seal (1) so that it is extremely fragile. Be sure to install new oil seal using special tool (A) and protector (2) supplied with new oil seal. If it doesn't follow the above-mentioned service, it may cause oil leak from oil seal.
Special Tool
(A) : 09911–98120
9) Install cylinder head cover referring to Cylinder Head Cover Removal and Installation:K9K .
10) Install camshaft pulley (1) to camshaft (2) as follows.
a) Install camshaft pulley to camshaft with aligning key (3) of camshaft pulley with key groove (4) of camshaft.
b) Fix camshaft pulley using special tool.
Special Tool
(A) : 09917–68221
c) Tighten new camshaft pulley nut to 30 N·m (3.0 kgf-m, 22.0 lbf-ft).
d) Retighten camshaft pulley nut 85°.
Tightening torque
Camshaft pulley nut ( a ): Tighten 30 N·m (3.0 kgf-m, 22.0 lbf-ft) and 85° by the specified procedure
11) Install special tool into timing belt pulley (1) and cylinder head hole.
Special Tool
(A) : 09919–58120
12) Install timing belt referring to Timing Belt and Belt Tensioner Removal and Installation:K9K .
13) Check valve lash (clearance) referring to Valve Lash (Clearance) Inspection:K9K .
14) Install engine assembly to vehicle referring to Engine Assembly Removal and Installation:K9K .