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Home >> Toyota >> 2007 >> Camry L4-2.4L (2AZ-FE) >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Cylinder Head Assembly >> Service and Repair >> Removal and Replacement >> Removal and Installation

Removal and Installation

CYLINDER HEAD

COMPONENTS:
























REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. REMOVE ENGINE UNDER COVER LH
4. REMOVE ENGINE UNDER COVER RH
5. REMOVE FRONT FENDER APRON SEAL RH
6. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY
7. DRAIN ENGINE COOLANT
8. DRAIN ENGINE OIL
9. REMOVE WINDSHIELD WIPER LINK ASSEMBLY
10. REMOVE COWL TOP PANEL OUTER SUB-ASSEMBLY
11. REMOVE AIR CLEANER INLET ASSEMBLY
12. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
13. REMOVE AIR CLEANER CASE SUB-ASSEMBLY
14. REMOVE BATTERY
15. REMOVE THROTTLE BODY ASSEMBLY
16. DISCONNECT FUEL TUBE SUB-ASSEMBLY
17. REMOVE FUEL DELIVERY PIPE WITH INJECTOR
18. REMOVE INTAKE MANIFOLD
19. REMOVE INTAKE AIR CONTROL VALVE (For PZEV)
20. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR
21. REMOVE FRONT EXHAUST PIPE ASSEMBLY
22. REMOVE NO. 2 ENGINE MOUNTING STAY RH
23. REMOVE ENGINE MOVING CONTROL ROD SUB-ASSEMBLY
24. REMOVE NO. 2 ENGINE MOUNTING BRACKET RH
25. REMOVE V-RIBBED BELT
26. REMOVE GENERATOR ASSEMBLY
27. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY
28. REMOVE OIL LEVEL GAUGE GUIDE
29. REMOVE MANIFOLD STAY
30. REMOVE NO. 2 MANIFOLD STAY
31. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
32. REMOVE CHAIN SUB-ASSEMBLY





33. REMOVE NO. 2 CAMSHAFT
(a) Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.
(b) Remove the 5 bearing caps and No. 2 camshaft.





34. REMOVE CAMSHAFT
(a) Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.
(b) Remove the 5 bearing caps and camshaft.
35. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
36. DISCONNECT RADIATOR HOSE INLET





37. DISCONNECT ENGINE WIRE
(a) Disconnect the radio setting condenser connector.
(b) Disconnect the engine oil pressure switch connector.
(c) Disconnect the engine coolant temperature sensor connector.
(d) Disconnect the camshaft position sensor connector.
(e) Remove the bolt and ground cable.





38. REMOVE NO. 2 CAMSHAFT BEARING
(a) Remove the No. 2 camshaft bearing.





39. REMOVE CYLINDER HEAD SUB-ASSEMBLY
(a) Using several steps, uniformly loosen and remove the 10 cylinder head bolts and 10 plate washers with a 10 mm bi-hexagon wrench in the sequence shown in the illustration.

NOTICE: Head warpage or cracking could result from removing the bolts in the wrong order.





(b) Using a screwdriver with its tip wrapped with tape, pry between the cylinder head and cylinder block, and remove the cylinder head.

NOTICE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block.





40. REMOVE CYLINDER HEAD GASKET
(a) Remove the cylinder head gasket.

INSTALLATION





1. INSTALL CYLINDER HEAD GASKET
(a) Place a new gasket on the cylinder block surface with the Lot No. stamp facing upward.

NOTICE:
- Remove any oil from the contact surface.
- Make sure that the gasket is installed in the correct direction.

2. INSTALL CYLINDER HEAD SUB-ASSEMBLY

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

(a) Apply a light coat of engine oil to the bolt threads and the area beneath the bolt heads that come in contact with the washers.
(b) Install the bolts and plate washers to the cylinder head.

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





(c) Using several steps, uniformly install and tighten the 10 cylinder head set bolts and plate washers with a 10 mm bi-hexagon wrench in the order shown in the illustration.
Torque: 70 Nm (714 kgf-cm, 52 ft. lbs.)





(d) Mark the front side of the cylinder head bolt with paint.
(e) Retighten the cylinder head bolts 90° in the sequence shown in the illustration.
(f) Check that the paint mark is now at a 90° angle to the front.





3. CONNECT ENGINE WIRE
(a) Connect the ground cable with the bolt.
Torque: 8.4 Nm (86 kgf-cm, 74 inch lbs.)
(b) Connect the camshaft position sensor connector.
(c) Connect the engine coolant temperature sensor connector.
(d) Connect the engine oil pressure switch connector.
(e) Connect the radio setting condenser connector.
4. CONNECT RADIATOR HOSE INLET





5. INSTALL NO. 2 CAMSHAFT BEARING
(a) Install the No. 2 camshaft bearing.
6. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
7. INSTALL CAMSHAFTS
(a) Apply a light coat of engine oil to the journal portion of the camshaft.





(b) Place the 2 camshafts on the cylinder head with the No. 1 cam lobes facing the directions shown in the illustration.





(c) Examine the front marks and numbers, and check that the order is as shown in the illustration. Then install the bearing caps onto the cylinder head.
(d) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.





(e) Using several steps, uniformly tighten the 20 bearing cap bolts in the sequence shown in the illustration.
Torque:
No. 1 and No. 2 bearing cap 30 Nm (301 kgf-cm, 22 ft. lbs.)
No. 3 bearing cap 9.0 Nm (92 kgf-cm, 80 inch lbs.)
8. INSTALL CHAIN SUB-ASSEMBLY
9. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
10. INSTALL NO. 2 MANIFOLD STAY
11. INSTALL MANIFOLD STAY
12. INSTALL OIL LEVEL GAUGE GUIDE
13. INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY
14. INSTALL GENERATOR ASSEMBLY
15. INSTALL V-RIBBED BELT
16. INSTALL NO. 2 ENGINE MOUNTING BRACKET RH
17. INSTALL ENGINE MOVING CONTROL ROD SUB-ASSEMBLY
18. INSTALL NO. 2 ENGINE MOUNTING STAY RH
19. INSTALL FRONT EXHAUST PIPE ASSEMBLY
20. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR
21. INSTALL INTAKE AIR CONTROL VALVE (For PZEV)
22. INSTALL INTAKE MANIFOLD
23. INSTALL FUEL DELIVERY PIPE WITH INJECTOR
24. CONNECT FUEL TUBE SUB-ASSEMBLY
25. INSTALL THROTTLE BODY ASSEMBLY
26. INSTALL BATTERY
27. REMOVE AIR CLEANER CASE SUB-ASSEMBLY
28. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
29. INSTALL AIR CLEANER INLET ASSEMBLY
30. INSTALL COWL TOP PANEL OUTER SUB-ASSEMBLY
31. INSTALL WINDSHIELD WIPER LINK ASSEMBLY
32. CONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
33. ADD ENGINE OIL
34. CHECK FOR FUEL LEAKS
35. ADD COOLANT
36. CHECK FOR ENGINE COOLANT LEAKS
37. CHECK FOR ENGINE OIL LEAKS
38. CHECK FOR EXHAUST GAS LEAKS
39. INSPECT IGNITION TIMING
40. INSPECT IDLE SPEED
41. INSPECT COMPRESSION
42. INSPECT CO/HC
43. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY
44. INSTALL FRONT FENDER APRON SEAL RH
45. INSTALL ENGINE UNDER COVER LH
46. INSTALL ENGINE UNDER COVER RH
47. INSTALL FRONT WHEEL RH

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