Toyota Camry

 XV30 (2002–2006) 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

9. REMOVE INTAKE MANIFOLD RUNNER VALVE ASSY

10. DISCONNECT ENGINE WIRE

11. REMOVE INTAKE MANIFOLD INSULATOR No.1

12. REMOVE EXHAUST MANIFOLD HEAT INSULATOR No.1

13. 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.

14. REMOVE CHAIN SUB−ASSY

15. REMOVE No.2 CAMSHAFT

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

   Then remove the 5 bearings.

2.  Remove the camshaft.

Remove No.2 Camshaft

16. REMOVE CAMSHAFT

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

   Then remove the 5 bearings.

2. Remove the camshaft.

Remove camshaft

17. REMOVE CAMSHAFT BEARING No.2

18. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY

19. 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

20. REMOVE CYLINDER HEAD GASKET

21. 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

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 10 bolts in the sequence shown in the illustration.

Torque: 79 N·m (806 kgf·cm, 58 ft·lbf)

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

24. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY Torque: 9.0 N·m (92 kgf·cm, 80 in.·lbf)

25. INSTALL CAMSHAFT BEARING No.2

26. 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 N·m (301 kgf·cm, 22 ft·lbf) for bearing cap No. 1 9.0 N·m (92 kgf·cm, 80 in.·lbf) for bearing cap No. 3

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 N·m (301 kgf·cm, 22 ft·lbf) for bearing cap No.2 9.0 N·m (92 kgf·cm, 80 in.·lbf) for bearing cap No.3

Install No.2 Camshaft

28. INSTALL CHAIN SUB−ASSY

29. INSTALL EXHAUST MANIFOLD CONVERTER SUB−ASSY

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

Torque: 37 N·m (378 kgf·cm, 27 ft·lbf)

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

Torque: 44 N·m (449 kgf·cm, 32 ft·lbf)

30. INSTALL EXHAUST MANIFOLD HEAT INSULATOR No.1 Torque: 12 N·m (122 kgf·cm, 9 ft·lbf)

31. INSTALL INTAKE MANIFOLD RUNNER VALVE ASSY

32. INSTALL INTAKE MANIFOLD

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

Torque: 30 N·m (306 kgf·cm, 22 ft·lbf)

Install intake manifold

33. CONNECT FUEL TUBE SUB−ASSY

34. ADD ENGINE OIL

35. ADD ENGINE COOLANT

36. CHECK FOR ENGINE OIL LEAKS

37. CHECK FOR ENGINE COOLANT LEAKS

38. INSPECT FOR FUEL LEAKS

39. INSPECT CHECK IDLE SPEED AND IGNITION TIMING

40. INSPECT CO/HC

Engine (2AZ−FE) (From July, 2003)

Timing gear case or timing chain case oil seal (2AZ−FE)(From July, 2003)

Engine rear oil seal (2AZ−FE)(From July, 2003)

Cylinder head assy (2AZ−FE) (From July, 2003)

Cylinder block assy (2AZ−FE)(From July, 2003)

Engine (1MZ−FE/3MZ−FE)

Drive belt (1MZ−FE/3MZ−FE)

Valve clearance (1MZ−FE/3MZ−FE)

Partial engine assy (1MZ−FE/3MZ−FE)

Partial engine assy (2AZ−FE)(From July, 2003)

Partial engine assy (1MZ−FE/3MZ−FE)

Timing belt (1MZ−FE/3MZ−FE)

Camshaft (RH BANK) (1MZ−FE/3MZ−FE)

Camshaft (LH BANK) (1MZ−FE/3MZ−FE)

Cylinder head gasket (1MZ−FE/3MZ−FE)

Cylinder head gasket No.2 (1MZ−FE/3MZ−FE)

Oil pump seal (1MZ−FE/3MZ−FE)

Engine rear oil seal (1MZ−FE/3MZ−FE)

Cylinder head assy (1MZ−FE/3MZ−FE)

Cylinder block assy (1MZ−FE/3MZ−FE)

Partial engine assy (2AZ−FE)(From July, 2003)

Drive belt (2AZ−FE)(From July, 2003)

Valve clearance (2AZ−FE)

Chain (2AZ−FE)(From July, 2003)

Camshaft (2AZ−FE)(From July, 2003)

Cylinder head gasket (2AZ−FE)(From July, 2003)