Toyota Camry

 XV30 (2002–2006) Service Manual

Engine mechanical
Cylinder head gasket (1MZ−FE/3MZ−FE)

REPLACEMENT

1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT

2. DRAIN ENGINE COOLANT

3. DRAIN ENGINE OIL

4. REMOVE EXHAUST PIPE No.1 SUPPORT BRACKET

5. REMOVE EXHAUST PIPE ASSY FRONT

6. REMOVE EXHAUST MANIFOLD SUB−ASSY RH

7. REMOVE V−BANK COVER SUB−ASSY

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

9. REMOVE AIR CLEANER ASSEMBLY WITH HOSE

10. REMOVE INTAKE AIR SURGE TANK

11. DISCONNECT FUEL PIPE SUB−ASSY No.1

12. DISCONNECT HEATER INLET WATER HOSE

1. Lock the hose clamp as shown in the illustration.

2. Disconnect the heater inlet water hose.

Disconnect heater inlet water hose

13. REMOVE INTAKE MANIFOLD

1. Remove the nut and disconnect the ground cable.

2.  Disconnect the 6 fuel injector connectors.

 

c. Uniformly loosen and remove the intake manifold’s 9 bolts and 2 nuts in the sequence shown in the illustration. Remove the intake manifold.

14. DISCONNECT RADIATOR HOSE INLET

15. REMOVE WATER OUTLET

1. Disconnect the radiator hose inlet.

2. Disconnect the engine coolant temperature connector.

3. Remove the clamp.

4. Remove the 2 bolts, 2 nuts and 2 washers.

5. Lock the hose clamp as shown in the illustration and remove the water outlet together with the water by−pass hose No. 1.

6. Remove the 2 gaskets from the 2 cylinder heads.

16. REMOVE FRONT WHEEL RH

17. REMOVE FRONT FENDER APRON SEAL RH

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

19. REMOVE VANE PUMP V BELT

20. REMOVE ENGINE MOVING CONTROL ROD

21. REMOVE ENGINE MOUNTING STAY No.2 RH

22. REMOVE GENERATOR BRACKET No.2

23. REMOVE CRANKSHAFT PULLEY

24. REMOVE TIMING BELT No.1 COVER

25. REMOVE TIMING BELT No.2 COVER

26. REMOVE ENGINE MOUNTING BRACKET RH

27. REMOVE TIMING BELT GUIDE No.2

28. REMOVE TIMING BELT

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

30. REMOVE CAMSHAFT TIMING PULLEY

31. REMOVE TIMING BELT No.3 COVER

32. REMOVE VANE PUMP ASSY

33. REMOVE IGNITION COIL ASSY

34. REMOVE CYLINDER HEAD COVER SUB−ASSY

35. REMOVE CAMSHAFT

36. REMOVE No.2 CAMSHAFT

37. REMOVE CYLINDER HEAD SUB−ASSY

1. Disconnect the VVT connector.

2. Disconnect the camshaft timing oil control valve connector.

3. Remove the nut and disconnect the engine wire harness clamp.

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

e. 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.

38. REMOVE CYLINDER HEAD GASKET

39. INSPECT CYLINDER HEAD SET BOLT

a. Using a vernier caliper, measure the tension portion diameter of the bolt.

Specified outside diameter: 8.75 to 9.05 mm (0.3445 to 0.3563 in.)

If the diameter is less than the minimum, replace the bolt.

Inspect cylinder head set bolt

40. INSTALL CYLINDER HEAD GASKET

a. Place a new cylinder head gasket on the cylinder block with the R mark upside down, 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.

41. INSTALL CYLINDER HEAD SUB−ASSY

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 washers to the cylinder head bolts.

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. Connect the engine wire harness clamp with the nut.

   Torque: 8.4 N·m (85 kgf·cm, 74 in.·lbf)

1. INSTALL No.2 CAMSHAFT

2. INSTALL CAMSHAFT

3. INSTALL CYLINDER HEAD COVER SUB−ASSY

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

5. INSTALL VANE PUMP ASSY

6. INSTALL TIMING BELT No.3 COVER

7. INSTALL CAMSHAFT TIMING PULLEY

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

9. INSPECT TIMING BELT

10. INSTALL TIMING BELT

11. INSTALL TIMING BELT TENSIONER ASSY

12. INSTALL TIMING BELT GUIDE No.2

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

14. INSTALL TIMING BELT No.2 COVER

15. INSTALL TIMING BELT No.1 COVER

16. INSTALL CRANKSHAFT PULLEY

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

18. INSTALL ENGINE MOUNTING STAY No.2 RH

19. INSTALL ENGINE MOVING CONTROL ROD

20. INSTALL VANE PUMP V BELT

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

22. INSPECT DRIVE BELT TENSION

23. INSTALL WATER OUTLET

1. Install 2 new gaskets to the 2 cylinder heads.

2. Install the water outlet together the with water by−pass hose No. 1 and unlock the hose clamp.

3. Tighten the 2 bolts, 2 nuts and 2 washers.

   Torque: 15 N·m (153 kgf·cm, 11 ft·lbf)

4. Install the clamp.

5. Connect the engine coolant temperature connector.

6.  Connect the radiator hose inlet.

65. INSTALL INTAKE MANIFOLD

1. Install the intake manifold with the 9 bolts, 2 nuts and 2 washers. Uniformly tighten the bolts and nuts in the sequence shown in the illustration.

   Torque: 15 N·m (153 kgf·cm, 11 ft·lbf)

2. Retighten the water outlet mounting bolts and nuts.

   Torque: 15 N·m (153 kgf·cm, 11 ft·lbf)

3. Install the ground cable with the nut.

   Torque: 8.4 N·m (86 kgf·cm, 74 in.·lbf)

4. Connect the heater inlet water hose.

Install intake manifold

66. CONNECT FUEL PIPE SUB−ASSY No.1

67. INSTALL INTAKE AIR SURGE TANK

68. INSTALL AIR CLEANER ASSEMBLY WITH HOSE

69. CONNECT VACUUM HOSES

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

71. INSTALL V−BANK COVER SUB−ASSY

72. INSTALL EXHAUST MANIFOLD SUB−ASSY RH

73. INSTALL EXHAUST PIPE ASSY FRONT

74. INSTALL EXHAUST PIPE No.1 SUPPORT BRACKET

75. INSTALL FRONT WHEEL RH

76. ADD ENGINE OIL

77. ADD ENGINE COOLANT

78. CHECK FOR ENGINE OIL LEAKS

79. CHECK FOR ENGINE COOLANT LEAKS

80. CHECK FOR FUEL LEAKS

81. CHECK FOR EXHAUST GAS LEAKS

82. INSPECT IGNITION TIMING

83. INSPECT ENGINE IDLE SPEED

84. INSPECT COMPRESSION

85. 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)