Toyota Camry manuals

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Toyota Camry
 Service Manual
Engine mechanical
Cylinder head gasket (2AZ−FE)(From July, 2003)

REPLACEMENT

  1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT

  2. REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER)

  3. DRAIN COOLANT

  4. DISCONNECT RADIATOR HOSE OUTLET

  5. DISCONNECT UNION TO CONNECTOR TUBE HOSE

  6. SCONNECT HEATER INLET WATER HOSE

  7. DISCONNECT FUEL TUBE SUB−ASSY

  8. REMOVE INTAKE MANIFOLD

  1. Disconnect the 2 Ωater by−pass hoses of the throttle body.
  2.  Remove the 5 bolts, 2 nuts, intake manifold and gasket.

Remove intake manifold Remove intake manifold

  1. REMOVE INTAKE MANIFOLD RUNNER VALVE ASSY

  2. DISCONNECT ENGINE WIRE

  3. REMOVE INTAKE MANIFOLD INSULATOR No.1

  4. REMOVE EXHAUST MANIFOLD HEAT INSULATOR No.1

  5. REMOVE EXHAUST MANIFOLD CONVERTER SUB−ASSY

a. Remove the 3 bolts, 2 nuts, No. 1 and No. 2 exhaust manifold stays.

b. Remove the 5 nuts, exhaust manifold and gasket.

b. Remove the 5 nuts, exhaust manifold and gasket.

  1. REMOVE CHAIN SUB−ASSY

  2. REMOVE No.2 CAMSHAFT

  1. Uniformly loosen and remove the No. 2 camshafts 10 bearing cap bolts in the sequence shown in the illustration.

    Then remove the 5 bearings.

  2.  Remove the camshaft.

Remove No.2 Camshaft Remove No.2 Camshaft

16. REMOVE CAMSHAFT

  1. Uniformly loosen and remove the No. 2 camshafts 10 bearing cap bolts in the sequence shown in the illustration.

    Then remove the 5 bearings.

  2. Remove the camshaft.

Remove camshaft Remove camshaft

  1. REMOVE CAMSHAFT BEARING No.2

  2. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY

  3. REMOVE CYLINDER HEAD SUB−ASSY

a. Using a 10 mm bi−hexagon wrench, uniformly loosen the 10 bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.

NOTICE:

  • Be careful not to drop washers into the cylinder head.

  • Head warpage or cracking could result from removing bolts in an incorrect order.

Remove cylinder head sub-assy Remove cylinder head sub-assy

  1. REMOVE CYLINDER HEAD GASKET

  2. INSPECT CYLINDER HEAD SET BOLT

a. Using a vernier caliper, measure the length of the head bolts from the seat to the end.

Specified bolt length:

161.3 to 164.2 mm (6.350 to 6.465 in.)

If the length is greater than the maximum, replace the bolt.

Inspect cylinder head set bolt Inspect cylinder head set bolt

22. INSTALL CYLINDER HEAD GASKET

a. Place a new gasket on the cylinder block surface with the Lot No. stamp upward.

NOTICE:

  • Remove any oil from contact surface.

  • Be careful of the installation direction.

  • To avoid damage to the gasket, place the cylinder head on the gasket carefully.

23. INSTALL CYLINDER HEAD SUB−ASSY

HINT: The cylinder head bolts are tightened in 2 progressive steps.

  1. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
  2. Install the bolts and plate washers to the cylinder head.

NOTICE: Do not drop the washers into the cylinder head.

c. Using a 10 mm bi−hexagon wrench, uniformly tighten the

c. Using a 10 mm bi−hexagon wrench, uniformly tighten the 10 bolts in the sequence shown in the illustration.

Torque: 79 Nm (806 kgfcm, 58 ftlbf)

  1. Mark the front side of the cylinder head bolt with paint.
  2. Retighten the cylinder head bolts by 90 in the sequence shown in the illustration.
  3. Check that the painted mark is now at a 90 angle to the front.

  1. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY Torque: 9.0 Nm (92 kgfcm, 80 in.lbf)

  2. INSTALL CAMSHAFT BEARING No.2

  3. INSTALL CAMSHAFT

a. Examine the front marks and numbers of the 5 bearing caps and install them. Then install the 10 bearing cap bolts. Uniformly tighten the bolts in the sequence shown in the illustration.

Torque: 30 Nm (301 kgfcm, 22 ftlbf) for bearing cap No. 1 9.0 Nm (92 kgfcm, 80 in.lbf) for bearing cap No. 3

Install camshaft Install camshaft

27. INSTALL No.2 CAMSHAFT

a. Examine the front marks and numbers of the 5 bearing caps and install them. Then install the 10 bearing cap bolts. Uniformly tighten the bolts in the sequence shown in the illustration.

Torque: 30 Nm (301 kgfcm, 22 ftlbf) for bearing cap No.2 9.0 Nm (92 kgfcm, 80 in.lbf) for bearing cap No.3

Install No.2 Camshaft Install No.2 Camshaft

  1. INSTALL CHAIN SUB−ASSY

  2. INSTALL EXHAUST MANIFOLD CONVERTER SUB−ASSY

a. Install a new gasket and the exhaust manifold with the 5 nuts.

Torque: 37 Nm (378 kgfcm, 27 ftlbf)

b. Install the No. 1 and No. 2 exhaust manifold stays with the

b. Install the No. 1 and No. 2 exhaust manifold stays with the 3 bolts and 2 nuts.

Torque: 44 Nm (449 kgfcm, 32 ftlbf)

  1. INSTALL EXHAUST MANIFOLD HEAT INSULATOR No.1 Torque: 12 Nm (122 kgfcm, 9 ftlbf)

  2. INSTALL INTAKE MANIFOLD RUNNER VALVE ASSY

  3. INSTALL INTAKE MANIFOLD

a Install a new gasket and the intake manifold with the 5 bolts and 2 nuts.

Torque: 30 Nm (306 kgfcm, 22 ftlbf)

Install intake manifold Install intake manifold

  1. CONNECT FUEL TUBE SUB−ASSY

  2. ADD ENGINE OIL

  3. ADD ENGINE COOLANT

  4. CHECK FOR ENGINE OIL LEAKS

  5. CHECK FOR ENGINE COOLANT LEAKS

  6. INSPECT FOR FUEL LEAKS

  7. INSPECT CHECK IDLE SPEED AND IGNITION TIMING

  8. INSPECT CO/HC

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    Toyota Camry Service Manual / Engine mechanical / Cylinder head gasket (2AZ−FE)(From July, 2003)

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