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Home >> Toyota >> 2007 >> Camry L4-2.4L (2AZ-FXE) Hybrid >> 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 (Part 1):




COMPONENTS (Part 2):




COMPONENTS (Part 3):




COMPONENTS (Part 4):




COMPONENTS (Part 5):




COMPONENTS (Part 6):




COMPONENTS (Part 7):





REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER
3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
4. REMOVE ENGINE UNDER COVER LH
5. REMOVE ENGINE UNDER COVER RH
6. REMOVE FRONT FENDER APRON SEAL RH
7. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY
8. DRAIN ENGINE COOLANT
9. DRAIN ENGINE OIL
10. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH
11. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH
12. REMOVE FRONT FENDER TO COWL SIDE SEAL LH
13. REMOVE FRONT FENDER TO COWL SIDE SEAL RH
14. REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY
15. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
16. SEPARATE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY
17. REMOVE COWL TOP PANEL OUTER SUBASSEMBLY
18. REMOVE AIR CLEANER INLET ASSEMBLY
19. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
20. REMOVE AIR CLEANER CASE SUB-ASSEMBLY
21. REMOVE THROTTLE BODY ASSEMBLY
22. DISCONNECT FUEL TUBE SUB-ASSEMBLY
23. REMOVE FUEL DELIVERY PIPE WITH INJECTOR
24. REMOVE INTAKE MANIFOLD
25. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR
26. REMOVE FRONT EXHAUST PIPE ASSEMBLY
27. REMOVE NO. 2 ENGINE MOUNTING STAY RH
28. REMOVE ENGINE MOVING CONTROL ROD SUBASSEMBLY
29. REMOVE NO. 2 ENGINE MOUNTING BRACKET RH
30. REMOVE V-RIBBED BELT TENSIONER COVER SUBASSEMBLY
31. REMOVE V-RIBBED BELT
32. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY
33. REMOVE OIL LEVEL GAUGE GUIDE
34. REMOVE MANIFOLD STAY
35. REMOVE NO. 2 MANIFOLD STAY
36. REMOVE EXHAUST MANIFOLD CONVERTER SUBASSEMBLY
37. REMOVE CHAIN SUB-ASSEMBLY





38. 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.





39. 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.

40. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
41. DISCONNECT RADIATOR HOSE INLET





42. 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.





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





44. 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.





45. 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 SUBASSEMBLY
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 V-RIBBED BELT
15. INSTALL V-RIBBED BELT TENSIONER COVER SUBASSEMBLY
16. INSTALL NO. 2 ENGINE MOUNTING BRACKET RH
17. INSTALL ENGINE MOVING CONTROL ROD SUBASSEMBLY
18. INSTALL NO. 2 ENGINE MOUNTING STAY RH
19. INSTALL FRONT EXHAUST PIPE ASSEMBLY
20. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR
21. INSTALL INTAKE MANIFOLD
22. INSTALL FUEL DELIVERY PIPE WITH INJECTOR
23. CONNECT FUEL TUBE SUB-ASSEMBLY
24. INSTALL THROTTLE BODY ASSEMBLY
25. INSTALL AIR CLEANER CASE SUB-ASSEMBLY
26. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
27. INSTALL AIR CLEANER INLET ASSEMBLY
28. INSTALL COWL TOP PANEL OUTER SUBASSEMBLY
29. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY
30. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
31. INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY
32. INSTALL FRONT FENDER TO COWL SIDE SEAL LH
33. INSTALL FRONT FENDER TO COWL SIDE SEAL RH
34. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH
35. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH
36. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
37. INSTALL LUGGAGE TRIM SERVICE HOLE COVER
38. ADD ENGINE OIL
39. CHECK FOR FUEL LEAKS
40. ADD COOLANT
41. CHECK FOR ENGINE COOLANT LEAKS
42. CHECK FOR ENGINE OIL LEAKS
43. CHECK FOR EXHAUST GAS LEAKS
44. INSPECT IGNITION TIMING
45. INSPECT IDLE SPEED
46. INSPECT COMPRESSION
47. INSPECT CO/HC
48. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY
49. INSTALL FRONT FENDER APRON SEAL RH
50. INSTALL ENGINE UNDER COVER LH
51. INSTALL ENGINE UNDER COVER RH
52. INSTALL FRONT WHEEL RH
53. PERFORM INITIALIZATION
(a) Perform initialization procedure.

HINT: Some vehicle systems require initialization after reconnecting the cable to the negative battery terminal.
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