Toyota Camry

 XV30 (2002–2006) Service Manual

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

REPLACEMENT

1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT

2. DRAIN ENGINE COOLANT

3. DRAIN ENGINE OIL

4. REMOVE MANIFOLD STAY No.2

5. DISCONNECT EXHAUST MANIFOLD CONVERTER SUB−ASSY No.2

a. Remove the 2 nuts, and disconnect the exhaust manifold converter from the front exhaust pipe.

6. REMOVE V−BANK COVER SUB−ASSY

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

8. REMOVE AIR CLEANER ASSEMBLY WITH HOSE

9. REMOVE INTAKE AIR SURGE TANK

10. DISCONNECT FUEL PIPE SUB−ASSY No.1

11. DISCONNECT HEATER INLET WATER HOSE

12. REMOVE INTAKE MANIFOLD

13. REMOVE RADIATOR HOSE INLET

14. REMOVE WATER OUTLET

15. DISCONNECT RADIATOR HOSE OUTLET

16. REMOVE WATER INLET PIPE

17. REMOVE OIL LEVEL GAGE SUB−ASSY

18. REMOVE OIL LEVEL GAGE GUIDE

19. REMOVE FRONT WHEEL RH

20. REMOVE FRONT FENDER APRON SEAL RH

21. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT No.1

22. REMOVE VANE PUMP V BELT

23. REMOVE ENGINE MOVING CONTROL ROD

24. REMOVE ENGINE MOUNTING STAY No.2 RH

25. REMOVE GENERATOR BRACKET No.2

26. REMOVE CRANKSHAFT PULLEY

27. REMOVE TIMING BELT No.1 COVER

28. REMOVE TIMING BELT No.2 COVER

29. REMOVE ENGINE MOUNTING BRACKET RH

30. REMOVE TIMING BELT GUIDE No.2

31. REMOVE TIMING BELT

32. REMOVE TIMING BELT IDLER SUB−ASSY No.2

33. REMOVE CAMSHAFT TIMING PULLEY

34. REMOVE TIMING BELT No.3 COVER

35. REMOVE IGNITION COIL ASSY

36. REMOVE CYLINDER HEAD COVER SUB−ASSY LH

37. REMOVE No.3 CAMSHAFT SUB−ASSY

38. REMOVE No.4 CAMSHAFT SUB−ASSY

39. REMOVE CYLINDER HEAD LH

1. Disconnect the VVT connector.

2. Disconnect the camshaft timing oil control valve connector.

3. Remove the bolt and disconnect the ground cable.

4. Remove the bolt and the wire harness clamp bracket.

e. Using a socket hexagon wrench 8, remove the hexagon bolt.

f. Uniformly loosen the 8 cylinder head bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.

NOTICE:

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

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

40. REMOVE CYLINDER HEAD GASKET No.2

41. INSPECT CYLINDER HEAD SET BOLT

42. INSTALL CYLINDER HEAD GASKET No.2

a) Place a new cylinder head gasket on the cylinder block with the L mark as shown in the illustration.

NOTICE:

• Remove any oil from the contact surface.

• Be careful of the installation direction.

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

43. INSTALL CYLINDER HEAD LH

NOTICE: The cylinder head bolts are tightened in 2 successive steps.

1. Apply a light coat of engine oil on the threads of the cylinder head bolts.

2. Install the plate washer to the cylinder head bolt.

3. Uniformly install and tighten the 8 cylinder head bolts in the sequence shown in the illustration.

   Torque: 54 N·m (550 kgf·cm, 40 ft·lbf)

4. Mark the front side of each cylinder head bolt head with paint as shown in the illustration.

5. Retighten the cylinder head bolts by 90 in the same sequence as step c..

6. Check that each painted mark is now at a 90 angle to the front.

7. Using a socket hexagon wrench 8, install the hexagon bolt.

   Torque: 19 N·m (189 kgf·cm, 14 ft·lbf)

8. Install the wire harness clamp bracket with the bolt.

   Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)

9. Connect the ground cable with the bolt.

   Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)

44. INSTALL No.4 CAMSHAFT SUB−ASSY

45. INSTALL No.3 CAMSHAFT SUB−ASSY

46. INSTALL CYLINDER HEAD COVER SUB−ASSY LH

47. INSTALL IGNITION COIL ASSY Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf)

48. INSTALL TIMING BELT No.3 COVER

49. INSTALL CAMSHAFT TIMING PULLEY

50. INSTALL TIMING BELT IDLER SUB−ASSY No.2 Torque: 43 N·m (438 kgf·cm, 32 ft·lbf)

51.  INSPECT TIMING BELT

52. INSTALL TIMING BELT

53. INSTALL TIMING BELT TENSIONER ASSY

54. INSTALL TIMING BELT GUIDE No.2

55. INSTALL ENGINE MOUNTING BRACKET RH Torque: 28 N·m (286 kgf·cm, 21 ft·lbf)

56. INSTALL TIMING BELT No.2 COVER

57. INSTALL TIMING BELT No.1 COVER

58. INSTALL CRANKSHAFT PULLEY

59. INSTALL GENERATOR BRACKET No.2 Torque: 28 N·m (286 kgf·cm, 21 ft·lbf)

60. INSTALL ENGINE MOUNTING STAY No.2 RH

61. INSTALL ENGINE MOVING CONTROL ROD

62. INSTALL VANE PUMP V BELT

63. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT No.1

64. INSPECT DRIVE BELT TENSION

65. INSTALL OIL LEVEL GAGE GUIDE

66. INSTALL WATER INLET PIPE

67. INSTALL WATER OUTLET

68. INSTALL INTAKE MANIFOLD

69. CONNECT FUEL PIPE SUB−ASSY No.1

70. INSTALL INTAKE AIR SURGE TANK

71. INSTALL AIR CLEANER ASSEMBLY WITH HOSE

72. CONNECT VACUUM HOSES

73. INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER) Torque: 80 N·m (816 kgf·cm, 59 ft·lbf)

74. INSTALL V−BANK COVER SUB−ASSY

75. INSTALL EXHAUST MANIFOLD CONVERTER SUB−ASSY No.2

a. Install a new gasket and the exhaust manifold converter to the front exhaust pipe. Torque: 62 N·m (633 kgf·cm, 46 ft·lbf)

76. INSTALL MANIFOLD STAY No.2

77. INSTALL FRONT WHEEL RH

78. ADD ENGINE OIL

79. ADD ENGINE COOLANT

80. CHECK FOR ENGINE OIL LEAKS

81. CHECK FOR ENGINE COOLANT LEAKS

82. CHECK FOR FUEL LEAKS

83. CHECK FOR EXHAUST GAS LEAKS

84. INSPECT IGNITION TIMING

85. INSPECT ENGINE IDLE SPEED

86. INSPECT COMPRESSION

87. 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)