Camry 2008-2009

Cylinder Head

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Removal & Installation



2.4L Hybrid Engine

Specific to:

Toyota Camry 2009-2010

  1. Discharge the fuel system pressure.
  2.  
  3. Remove the luggage trim service hole cover.
  4.  
  5. Disconnect the cable from the negative battery terminal.
  6.  
  7. Remove the engine under covers.
  8.  
  9. Remove the front fender apron seal RH.
  10.  
  11. Remove the No. 1 engine cover sub assembly.
  12.  
  13. Drain the engine coolant.
  14.  
  15. Drain the engine oil.
  16.  
  17. Remove the wiper arms and blade assemblies.
  18.  
  19. Remove the front fender to cowl side seals.
  20.  
  21. Remove the cowl top ventilator louver sub assembly.
  22.  
  23. Remove the windshield wiper motor and link assembly.
  24.  
  25. Separate the brake master cylinder reservoir sub assembly.
  26.  
  27. Remove the cowl top panel outer sub assembly.
  28.  
  29. Remove the air cleaner inlet assembly.
  30.  
  31. Remove the air cleaner cap sub assembly.
  32.  
  33. Remove the air cleaner case sub assembly.
  34.  
  35. Remove the throttle body assembly.
  36.  
  37. Disconnect the fuel tube sub assembly.
  38.  
  39. Remove the fuel delivery pipe with the injector.
  40.  
  41. Remove the intake manifold.
  42.  
  43. Remove the No. 1 intake manifold insulator.
  44.  
  45. Remove the front exhaust pipe assembly.
  46.  
  47. Remove the No. 2 engine mounting stay RH.
  48.  
  49. Remove the engine moving control rod sub assembly.
  50.  
  51. Remove the No. 2 engine mounting bracket RH.
  52.  
  53. Remove the V-ribbed belt tensioner cover sub assembly.
  54.  
  55. Remove the V-ribbed belt.
  56.  
  57. Remove the oil level gage sub assembly.
  58.  
  59. Remove the oil level gauge guide.
  60.  
  61. Remove the manifold stay.
  62.  
  63. Remove the No. 2 manifold stay.
  64.  
  65. Remove the exhaust manifold converter sub assembly.
  66.  
  67. Remove the chain sub assembly.
  68.  
  69. Remove the No. 2 camshaft.
    1. Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown.

      Click image to see an enlarged view

      Fig. Removing the bearing cap bolts in sequence

    2.  
    3. Remove the 5 bearing caps and No. 2 camshaft.
    4.  

  70.  
  71. Remove the camshaft.
    1. Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown.

      Click image to see an enlarged view

      Fig. Removing the 10 bearing cap bolts

    2.  
    3. Remove the 5 bearing caps and camshaft.
    4.  

  72.  
  73. Remove the camshaft timing oil control valve assembly.
  74.  
  75. Disconnect the radiator hose inlet.
  76.  
  77. Disconnect the engine wire.
    1. Disconnect the radio setting condenser connector.
    2.  
    3. Disconnect the engine oil pressure switch connector.
    4.  
    5. Disconnect the engine coolant temperature sensor connector.
    6.  
    7. Disconnect the camshaft position sensor connector.
    8.  
    9. Remove the bolt and disconnect the ground cable.
    10.  

  78.  
  79. Remove the No. 2 camshaft bearing.

    Click image to see an enlarged view

    Fig. Removing the No. 2 camshaft bearing

  80.  
  81. Remove the cylinder head sub assembly.
    1. 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.
      NOTE
      Head warpage or cracking could result from removing the bolts in the wrong order.



      Click image to see an enlarged view

      Fig. Removing the 10 cylinder head bolts

    2.  
    3. Using a screwdriver with its tip wrapped with protective tape, pry between the cylinder head and cylinder block, and remove the cylinder head.
      NOTE
      Be careful not to damage the contact surfaces between the cylinder head and cylinder block.



      Click image to see an enlarged view

      Fig. Removing the cylinder head

    4.  

  82.  
  83. Remove the cylinder head gasket.

    Click image to see an enlarged view

    Fig. Removing the cylinder head gasket

  84.  

To install:

  1. Install the cylinder head gasket.
    1. Place a new gasket on the cylinder block surface with the Lot No. stamp facing upward.
      NOTE
      Remove any oil from the contact surfaces.


      NOTE
      Make sure that the gasket is installed in the correct direction.

    2.  

  2.  
  3. Install the cylinder head sub assembly.
    1. Install the cylinder head on the cylinder block.
      NOTE
      The cylinder head bolts are tightened in 2 progressive steps.

    2.  
    3. 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.
    4.  
    5. Install the bolts and plate washers to the cylinder head.
      NOTE
      Do not drop the washers into the cylinder head.

    6.  
    7. 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. Tighten to 52 ft. lbs. (70 Nm).

      Click image to see an enlarged view

      Fig. Installing the cylinder head bolts

    8.  
    9. Mark the front side of the cylinder head bolts with paint.

      Click image to see an enlarged view

      Fig. Marking the cylinder head bolts

    10.  
    11. Retighten the cylinder head bolts 90°in the sequence shown.
    12.  
    13. Check that the paint mark is now at a 90°angle from the front.
    14.  

  4.  
  5. Connect the engine wire.
    1. Connect the ground cable with the bolt. Tighten the bolt to 74 inch lbs. (8.4 Nm).
    2.  
    3. Connect the camshaft position sensor connector.
    4.  
    5. Connect the engine coolant temperature sensor connector.
    6.  
    7. Connect the engine oil pressure switch connector.
    8.  
    9. Connect the radio setting condenser connector.
    10.  

  6.  
  7. Connect the radiator hose inlet.
  8.  
  9. Install the No. 2 camshaft bearing.
    1. Install the No. 2 camshaft bearing.
    2.  

  10.  
  11. Install the camshaft timing oil control valve assembly.
  12.  
  13. Install the camshaft.
    1. Apply a light coat of engine oil to the journal portion of the camshaft.
    2.  
    3. Place the 2 camshafts on the cylinder head with the No. 1 cam lobes facing the directions shown.

      Click image to see an enlarged view

      Fig. Placing the camshafts on the cylinder head

    4.  
    5. 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.

      Click image to see an enlarged view

      Fig. Examining the front marks and numbers

    6.  
    7. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.
    8.  
    9. Using several steps, uniformly tighten the 20 bearing cap bolts in the sequence shown. Tighten the No.1 and No. 2 bearing cap to 22 ft. lbs. (30 Nm). Tighten the No. 3 bearing cap to 80 inch lbs. (9 Nm).

      Click image to see an enlarged view

      Fig. Identifying the bearing cap tightening sequence

    10.  

  14.  
  15. Install the chain sub assembly.
  16.  
  17. Install the exhaust manifold converter sub assembly.
  18.  
  19. Install the No. 2 manifold stay.
  20.  
  21. Install the manifold stay.
  22.  
  23. Install the oil level gauge guide.
  24.  
  25. Install the oil level gauge sub assembly.
  26.  
  27. Install the V-ribbed belt.
  28.  
  29. Install the V-ribbed belt tensioner cover sub assembly.
  30.  
  31. Install the No. 2 engine mounting bracket RH.
  32.  
  33. Install the engine moving control rod sub assembly.
  34.  
  35. Install the No. 2 engine mounting stay RH.
  36.  
  37. Install the front exhaust pipe assembly.
  38.  
  39. Install the No. 1 intake manifold insulator.
  40.  
  41. Install the intake manifold.
  42.  
  43. Install the fuel delivery pipe with the injector.
  44.  
  45. Connect the fuel tube sub assembly.
  46.  
  47. Install the throttle body assembly.
  48.  
  49. Install the air cleaner case sub assembly.
  50.  
  51. Install the air cleaner cap sub assembly.
  52.  
  53. Install the air cleaner inlet assembly.
  54.  
  55. Install the cowl top panel outer sub assembly.
  56.  
  57. Install the brake master cylinder reservoir sub assembly.
  58.  
  59. Install the windshield wiper motor and link assembly.
  60.  
  61. Install the cowl top ventilator louver sub assembly.
  62.  
  63. Install the front fender to the cowl side seals.
  64.  
  65. Install the front wiper arm and blade assemblies.
  66.  
  67. Connect the cable to the negative battery terminal.
  68.  
  69. Install the luggage trim service hole cover.
  70.  
  71. Add engine oil.
  72.  
  73. Inspect for fuel leak.
  74.  
  75. Inspect for exhaust gas leak.
  76.  
  77. Inspect the ignition timing.
  78.  
  79. Inspect the idle speed.
  80.  
  81. Inspect the compression.
  82.  
  83. Inspect CO/HC.
  84.  
  85. Install the No. 1 engine cover sub assembly.
  86.  
  87. Install the front fender apron seal RH.
  88.  
  89. Install the engine under covers.
  90.  
  91. Install the front wheel RH.
  92.  
  93. Perform initialization.
  94.  

2.4L Non-Hybrid Engine

Specific to:

Toyota Camry 2009

  1. Discharge the fuel system pressure.
  2.  
  3. Disconnect the cable from the negative battery terminal.
  4.  
  5. Remove the engine under covers.
  6.  
  7. Remove the front fender apron seal RH.
  8.  
  9. Remove the No. 1 engine cover sub assembly.
  10.  
  11. Drain the engine coolant.
  12.  
  13. Drain the engine oil.
  14.  
  15. Remove the windshield wiper link assembly.
  16.  
  17. Remove the cowl top panel outer sub assembly.
  18.  
  19. Remove the air cleaner inlet assembly.
  20.  
  21. Remove the air cleaner cap sub assembly.
  22.  
  23. Remove the air cleaner case sub assembly.
  24.  
  25. Remove the battery.
  26.  
  27. Remove the throttle body assembly.
  28.  
  29. Disconnect the fuel tube sub assembly.
  30.  
  31. Remove the fuel delivery pipe with the injectors.
  32.  
  33. Remove the intake manifold.
  34.  
  35. Remove the intake air control valve (PZEV).
  36.  
  37. Remove the No. 1 intake manifold insulator.
  38.  
  39. Remove the front exhaust pipe assembly.
  40.  
  41. Remove the No. 2 engine mounting stay RH.
  42.  
  43. Remove the engine moving control rod sub assembly.
  44.  
  45. Remove the No. 2 engine mounting bracket RH.
  46.  
  47. Remove the v-ribbed belt.
  48.  
  49. Remove the generator assembly.
  50.  
  51. Remove the oil level gauge sub assembly.
  52.  
  53. Remove the oil level gauge guide.
  54.  
  55. Remove the manifold stay.
  56.  
  57. Remove the No. 2 manifold stay.
  58.  
  59. Remove the exhaust manifold converter sub assembly.
  60.  
  61. Remove the No. 2 camshaft.
  62.  
  63. Remove the camshaft.
  64.  
  65. Remove the camshaft timing oil control valve assembly.
  66.  
  67. Disconnect the radiator hose inlet.
  68.  
  69. Disconnect the engine wire.
    1. Disconnect the radio setting condenser connector.
    2.  
    3. Disconnect the engine oil pressure switch connector.
    4.  
    5. Disconnect the engine coolant temperature sensor connector.
    6.  
    7. Disconnect the camshaft position sensor connector.
    8.  
    9. Remove the bolt and ground cable.
    10.  

  70.  
  71. Remove the No. 2 camshaft bearing.

    Click image to see an enlarged view

    Fig. Removing the No. 2 camshaft bearing

  72.  
  73. Remove the cylinder head sub assembly.
    1. 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.
      NOTE
      Head warpage or cracking could result from removing the bolts in the wrong order.



      Click image to see an enlarged view

      Fig. Identifying the cylinder head bolt and plate washer removal sequence

    2.  
    3. Using a screwdriver with its tip wrapped with tape, pry between the cylinder head and cylinder block, and remove the cylinder head.
      NOTE
      Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

    4.  

  74.  
  75. Remove the cylinder head gasket.

    Click image to see an enlarged view

    Fig. Removing the cylinder head gasket

  76.  

To install:

  1. Install the cylinder head gasket.
    1. Place a new gasket on the cylinder block surface with the Lot No. stamp facing upward.
      NOTE
      Remove any oil from the contact surfaces.


      NOTE
      Make sure that the gasket is installed in the correct direction.

    2.  

  2.  
  3. Install the cylinder head sub assembly.
    1. Install the cylinder head on the cylinder block.
      NOTE
      The cylinder head bolts are tightened in 2 progressive steps.

    2.  
    3. 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.
    4.  
    5. Install the bolts and plate washers to the cylinder head.
      NOTE
      Do not drop the washers into the cylinder head.

    6.  
    7. 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. Tighten to 52 ft. lbs. (70 Nm).

      Click image to see an enlarged view

      Fig. Identifying the cylinder head set bolts and plate washer installation order

    8.  
    9. Mark the front side of the cylinder head bolt with paint.
    10.  
    11. Retighten the cylinder head bolts 90°in the same sequence provided before.
    12.  
    13. Check that the paint mark is now at a 90°angle to the front.
    14.  

  4.  
  5. Connect the engine wire.
    1. Connect the ground cable with the bolt and tighten to 74 inch lbs. (8.4 Nm).
    2.  
    3. Connect the camshaft position sensor connector.
    4.  
    5. Connect the engine coolant temperature sensor connector.
    6.  
    7. Connect the engine oil pressure switch connector.
    8.  
    9. Connect the radio setting condenser connector.
    10.  

  6.  
  7. Connect the radiator hose inlet.
  8.  
  9. Install the No. 2 camshaft bearing.
  10.  
  11. Install the camshaft timing oil control valve assembly.
  12.  
  13. Install the camshafts.
    1. Apply a light coat of engine oil to the camshaft journals.
    2.  
    3. Place the 2 camshafts on the cylinder head with the No. 1 cam lobes facing the directions shown in the illustration.

      Click image to see an enlarged view

      Fig. Placing the camshafts on the cylinder head

    4.  
    5. 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.

      Click image to see an enlarged view

      Fig. Examining front marks and numbers

    6.  
    7. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.
    8.  
    9. Using several steps, uniformly tighten the 20 bearing cap bolts in the sequence shown in the illustration. Tighten the No. 1 and No. 2 bearing caps to 22 ft. lbs. (30 Nm). Tighten the No. 3 bearing cap to 80 inch lbs. (9 Nm).

      Click image to see an enlarged view

      Fig. Bearing cap installation sequence

    10.  

  14.  
  15. To complete installation, reverse the remaining removal procedure.
  16.  

Hybrid

Specific to:

Toyota Camry 2007-2008


CAUTION
Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, take safety precautions, such as wearing insulated gloves and removing the service plug grip to prevent electrical shocks. Make sure to turn the power switch off before removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the or disconnect the following:


    1. Left hand and right hand engine under cover.
    2.  
    3. Right hand front fender apron seal.
    4.  
    5. Plastic engine cover.
    6.  

  6.  
  7. Drain and recycle the engine coolant.
  8.  
  9. Drain engine oil
  10.  
  11. Remove the or disconnect the following:


    1. Nut and the front wiper arm and blade assembly.
    2.  
    3. Cowl top panel outer assembly: 4 bolts, 4 nuts and cowl top panel outer sub-assembly.
    4.  
    5. Air cleaner inlet, cap and case assembly.
    6.  
    7. Battery.
    8.  
    9. Throttle body assembly.
    10.  
    11. Fuel delivery pipe with injector.
    12.  
    13. Intake manifold.
    14.  
    15. Intake air control valve (PZEV).
    16.  
    17. Intake manifold insulator.
    18.  
    19. Front exhaust pipe assembly.
    20.  
    21. Right hand engine mounting stay.
    22.  
    23. Engine mount.
    24.  
    25. Right hand engine mounting bracket.
    26.  
    27. Drive belt.
    28.  
    29. Generator assembly.
    30.  
    31. Oil level gauge assembly with guide.
    32.  
    33. Exhaust manifold/catalytic converter stays.
    34.  
    35. Exhaust manifold converter sub-assembly.
    36.  
    37. Valve cover.
    38.  
    39. No. 2 and No.1 camshafts.
    40.  
    41. Radio setting condenser connector.

      Click image to see an enlarged view

      Fig. Disconnecting the radio setting condenser, engine oil pressure switch, ECT and camshaft position sensor connectors-2.4L

    42.  
    43. Engine oil pressure switch connector.
    44.  
    45. Engine coolant temperature sensor connector.
    46.  
    47. Camshaft position sensor connector.
    48.  
    49. Bolt and ground cable.
    50.  
    51. No. 2 camshaft bearing.
      NOTE
      Head warpage or cracking could result from removing the bolts in the wrong order.



      Click image to see an enlarged view

      Fig. Removing cylinder head bolts in sequence

    52.  

  12.  
  13. Using several steps, uniformly loosen and remove the 10 cylinder head bolts and 10 plate washers with a 10 mm bi-hexagon wrench in sequence.
    NOTE
    Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

  14.  
  15. Using a screwdriver with its tip wrapped with tape, pry between the cylinder head and cylinder block, and remove the cylinder head.
  16.  
  17. Remove the cylinder head gasket.
  18.  

To install:


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

  1. Place a new gasket on the cylinder block surface with the Lot No. stamp facing upward.
    NOTE
    The cylinder head bolts are tightened in 2 progressive steps.


    NOTE
    Do not drop the washers into the cylinder head.

  2.  
  3. 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. Install the bolts and plate washers to the cylinder head.

    Click image to see an enlarged view

    Fig. Installing cylinder head bolts in sequence-2.4L

  4.  
  5. Using several steps, uniformly install and tighten the 10 cylinder head set bolts and plate washers with a 10 mm bi-hexagon wrench in sequence. Tighten the bolts to 52 ft. lbs. (70 Nm).
  6.  
  7. Mark the front side of the cylinder head bolt with paint. Retighten the cylinder head bolts 90° in sequence. Check that the paint mark is now at a 90° angle to the front.

    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening procedure

  8.  
  9. To complete installation, reverse removal procedure.
  10.  
  11. Add engine oil and check for leaks.
  12.  
  13. Check for fuel leaks.
  14.  
  15. Add coolant and check for coolant leaks.
  16.  
  17. Check for exhaust gas leaks
  18.  
  19. Inspect ignition timing.
  20.  
  21. Inspect idle speed.
  22.  
  23. Inspect compression.
  24.  
  25. Inspect CO/HC.
  26.  

 
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