engine TOYOTA CAMRY 2000 Service Manual Online

20. CALIFORNIA:
REMOVE AIR TUBE
(a) Disconnect the following hoses:
(1) w/ A/C:
A/C hose (from ASV) from air tube
(2) 2 air hoses (from PS pump) from air tube
(3) California only:
2 vacuum hoses from VSV (for fuel pressure
control)
(4) Vacuum hose from air intake chamber
(b) Remove the 3 bolts, wire clamp and air tube.
21. DISCONNECT 2 ENGINE WIRE GROUND STRAPS
FROM INTAKE MANIFOLD
22. DISCONNECT KNOCK SENSOR AND VSV (FOR
EGR) CONNECTORS
23. CALIFORNIA ONLY:
DISCONNECT VSV (FOR FUEL PRESSURE CON±
TROL) CONNECTOR
24. REMOVE VSV OR VSV ASSEMBLY
25. REMOVE INTAKE MANIFOLD
(a) Remove the 4 bolts, wire bracket, No.1 air intake
chamber and manifold stays.
(b) Remove the bolt, vacuum hose bracket, and discon±
nect the engine wire.
(c) Remove the6 bolts, 2 nuts, intake manifold and
gasket.
± 5S±FE ENGINEENGINE MECHANICALEG1±47

(d) Remove the 2 bolts and delivery pipe together with
the 4 injectors.
NOTICE: Be careful not to drop the injectors when rem±
oving the delivery pips.
(e) Remove the 4 insulators (except California) and 2
spacers from the cylinder head.
(f) Pull out the 4 injectors from the delivery pipe. 26. REMOVE DELIVERY PIPE AND INJECTORS
(a) Disconnect the injector connectors.
(b) Loosen the pulsation damper, and disconnect the fuel
inlet hose.
(c) Disconnect fuel return hose.
(g) California:
Remove the 2 O±rings, insulator and grommet from
each injector.
(h) Except California:
Remove the 0±ring and grommet from each injector. (d) Disconnect the 2 wire clamps from the wire brackets
on the intake manifold.
± 5S±FE ENGINEENGINE MECHANICALEG1±48

NOTICE:
wSupport the timing belt, :o the meshing of crank±
shaft timing pulley and timing belt does not shift.
wBe careful not to drop anything inside the timing
belt cover.
wDo not allow the belt to come into correct with oil,
water or dust.
30. REMOVE ENGINE HANGERS
Remove the bolt and engine hanger. Remove the 2
engine hangers. Remove the ground strap.
31. REMOVE GENERATOR BRACKET
Remove the 3 bolts and generator bracket.
32. REMOVE OIL PRESSURE SWITCH 27. REMOVE CAMSHAFT TIMING PULLEY
(See steps 2 to 15 on pages EG1±26 to 28)
28. REMOVE NO. 1 IDLER PULLEY AND TENSION
SPRING
Remove the bolt, pulley and tension spring.
33. REMOVE CYLINDER HEAD COVER
Remove the 4 nuts, grommets, head cover and gasket.29. REMOVE NO.3 TIMING BELT COVER
Remove the 4 bolts and timing and cover.
± 5S±FE ENGINEENGINE MECHANICALEG1±49

(b) Secure the exhaust camshaft sub gear to drive gear
with a service bolt.
Recommended service bolt:
Thread diameter6 mm
Thread pitch 1.0 mm
Bolt length 16±20 m m (0.63±0.79 in.)
HINT: When removing the camshaft, make sure that
the torsional spring force of the sub gear has been
eliminated by the above operation. 35. REMOVE CAMSHAFTS
NOTICE: Since the thrust clearance of the camshaft is
small, the camshaft must be kept level while it is being
removed. If the camshaft is not kept level, the portion of
the cylinder head receiving the shaft thrust may crack or
be damaged, causing the camshaft to seize or break. To
avoid this, the following steps should be carried out.
A. Remove exhaust camshaft
(a) Set the knock pin of the intake camshaft at 10±455
BTDC of camshaft position.
HINT: The above angle allows No.2 and No.4 cylinder
cam lobes of the exhaust camshaft to push their valve
lifters evenly.HINT: Arrange the grommets in correct order, so that
they can be reinstalled into their original positions.
This minimizes any possibility of oil leakage due to
reuse of grommets.
34. REMOVE HIGH ± TENSION CORDS CLAMP AND
PCV VALVE
± 5S±FE ENGINEENGINE MECHANICALEG1±50

(f) Alternately loosen and remove the 2 bolts on the No.
3 bearing cap.
HINT:
wAs the 2 No.3 bearing cap bolts are loosened, make
sure that the camshaft is lifted out straight and level.
wIf the camshaft is not being lifted out straight and
level, retighten the 2 No.3 bearing cap bolts. Then
reverse the order of above steps from (f) to (a) and
reset the knock pin of the intake camshaft at 10±45

BTDC, and repeat steps from
(b) to
(f) once again.
NOTICE: Do not pry on or attempt to force the camshaft
with a tool or other object.
(g) Remove the No.3 bearing cap and exhaust camshaft.(d) Uniformly loosen and remove the6 bolts on the No. 1,
No.2 and No.4 bearing caps in several passes in the
sequence shown.
NOTICE: Do not remove the No.3 bearing cap bolts at this
stage.
(e) Remove the No. 1, No.2 and No.4 bearing caps.
B. Remove intake camshaft
(a) Set the knock pin of the intake camshaft at 80±115

BTDC of camshaft angle.
HINT: The above angle allows the No.1 and No.3
cylinder cam lobes of intake camshaft to push their
valve lifters evenly.(c) Remove the 2 bolts and rear bearing cap.
± 5S±FE ENGINEENGINE MECHANICALEG1±51

(e) Alternately loosen and remove the 2 bolts on the No.
2 bearing cap.
HINT:
wAs the 2 No.2 bearing cap bolts are loosened, make
sure that the camshaft is lifted out straight and level,
after breaking adhesion on the front bearing cap.
wIf the camshaft is not being lifted out straight and
level, retighten the 2 No.2 bearing cap bolts. Reverse
the order of above steps from (e) to (a) and reset the
knock pin of the intake camshaft at 80±115*6TDC,
and repeat steps from (b) to (e) once again.
NOTICE: Do not pry on or attempt to force the camshaft
with a tool or other object.
(f) Remove the No.2 bearing cap and camshaft. (c) Uniformly loosen and remove the6 bolts on the No.1,
No.3 and No.4 bearing caps in several passes in the
sequence shown.
NOTICE: Do not remove the No.2 bearing cap bolts at this
stage.
(d) Remove the No. 1, No.3 and No.4 bearing caps.
36. DISASSEMBLE EXHAUST CAMSHAFT
(a) Mount the hexagon wrench head portion of the cam±
shaft in a vise.
NOTICE: Be careful not to damage the camshaft.
(b) Remove the 2 bolts, front bearing cap and oil seal.
± 5S±FE ENGINEENGINE MECHANICALEG1±52

37. REMOVE CYLINDER HEAD
(a) Using SST, uniformly loosen and remove the 10 cylin±
der head bolts in several passes, in the sequence
shown.
SST 09011± 38121
NOTICE: Cylinder head warpage or cracking could result
from removing bolts in incorrect order.
(b) Insert a service bolt (A) into the service hole of the
camshaft sub gear.
(c) Using a screwdriver, turn the sub gear clockwise, and
remove the service bolt (B).
NOTICE: Be careful not to damage the camshaft.
(e) Remove the following parts:
(1) Wave washer
(2) Camshaft sub gear
(3) Camshaft gear spring (d) Using snap ring pliers, remove the snap ring.
± 5S±FE ENGINEENGINE MECHANICALEG1±53

(b) Lift the cylinder head from the dowels on the cylinder
block, and place the cylinder head on wooden blocks
on a bench.
HINT: If the cylinder head is difficult to lift off, pry
between the cylinder head and cylinder block with a
screwdriver.
NOTICE: Be careful not to damage the contact surfaces
of the cylinder head and cylinder block.
2. REMOVE VALVES
(a) Using SST, compress the valve spring and remove the
2 keepers.
SST 09202 ± 70010
(b) Remove the spring retainer, valve spring, valve and
spring seat.
CYLINDER HEAD DISASSEMBLY
(See Components for Removal and Installation)
1. REMOVE VALVE LIFTERS AND SHIMS
HINT: Arrange the valves, valve springs, spring seats
and spring retainers in correct order. HINT: Arrange the valve lifters and shims in correct
order.
± 5S±FE ENGINEENGINE MECHANICALEG1±54

CYLINDER HEAD COMPONENTS
INSPECTION, CLEANING AND REPAIR
1. CLEAN TOP SURFACES OF PISTONS AND
CYLINDER BLOCK
(a) Turn the crankshaft, and bring each piston to top dead
center (TDC). Using a gasket scraper, remove all the
carbon from the piston top surface.
(b) Using a gasket scraper, remove all the gasket material
from the cylinder block surface.
(c) Using compressed air, blow carbon and oil from the
bolt holes.
CAUTION: Protect your eyes when using high pressure
compressed air.
2. CLEAN CYLINDER HEAD
A. Remove gasket material
Using a gasket scraper, remove all the gasket material
from the cylinder block contact surface.
NOTICE: Be careful not to scratch the cylinder block
contact surface.
B. Clean combustion chambers
Using a wire brush, remove all the carbon from the
combustion chambers.
NOTICE: Be careful not to scratch the cylinder block
contact surface.
(c) Using needle±nose pliers, remove the oil seal.
± 5S±FE ENGINEENGINE MECHANICALEG1±55

3. INSPECT CYLINDER HEAD
A. Inspect for flatness
Using a precision straight edge and thickness gauge,
measure the surfaces contacting the cylinder block
and the manifolds for warpage.
Maximum warpage:
Cylinder block side
0.05 mm (0.0020 in.)
Manifold side
0.08 mm (0.0031 in.)
If warpage is greater than maximum, replace the cylin±
der head.
B. Inspect for cracks
Using a dye penetrant, check the combustion cham±
bers, intake ports, exhaust ports and cylinder block
surface for cracks.
If cracked, replace the cylinder head. D. Clean cylinder head
Using a soft brush and solvent, thoroughly clean the
cylinder head. C. Clean valve guide bushings
Using a valve guide bushing brush and solvent, clean
all the guide bushings.
± 5S±FE ENGINEENGINE MECHANICALEG1±56