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Home >> Toyota >> 2007 >> Matrix L4-1.8L (1ZZ-FE) >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Cylinder Head Assembly >> Service and Repair >> Removal and Replacement

Removal and Replacement

CYLINDER HEAD

COMPONENTS (Part 1):




COMPONENTS (Part 2):




COMPONENTS (Part 3):




COMPONENTS (Part 4):




COMPONENTS (Part 5):




COMPONENTS (Part 6):





REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
(a) Discharge the fuel system pressure.
2. DISCONNECT BATTERY NEGATIVE TERMINAL
3. REMOVE FRONT WHEEL RH
4. REMOVE ENGINE UNDER COVER RH
5. REMOVE CYLINDER HEAD COVER NO.2
(a) Remove the cylinder head cover No. 2.
6. DRAIN ENGINE COOLANT
(a) Drain the engine coolant.
7. SEPARATE EXHAUST PIPE ASSEMBLY FRONT
(a) Separate the exhaust pipe assembly front.
8. REMOVE MANIFOLD STAY
(a) Remove the manifold stay.
9. REMOVE FAN AND GENERATOR V BELT
(a) Remove the fan and generator V belt.
10. SEPARATE VANE PUMP ASSEMBLY
(a) Separate the vane pump assembly.
11. REMOVE GENERATOR ASSEMBLY
(a) Remove the generator assembly.
12. REMOVE ENGINE MOUNTING INSULATOR RH
(a) Remove the engine mounting insulator RH.
13. REMOVE IGNITION COIL ASSEMBLY
(a) Remove the ignition coil assembly.
14. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
(a) Remove the cylinder head cover sub-assembly.
15. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
(a) Remove the V-ribbed belt tensioner assembly.
16. REMOVE ENGINE MOUNTING BRACKET RH
(a) Remove the engine mounting bracket RH.
17. REMOVE WATER PUMP ASSEMBLY
(a) Remove the water pump assembly.
18. SEPARATE CRANKSHAFT POSITION SENSOR
(a) Separate the crankshaft position sensor.
19. SET NO. 1 CYLINDER TO TDC / COMPRESSION
(a) Set the No. 1 cylinder to the TCD/compression.
20. REMOVE CRANKSHAFT PULLEY
(a) Remove the crankshaft pulley.
SST 09960-10010 (09962-01000, 09963-01000)
21. REMOVE CHAIN TENSIONER ASSEMBLY NO.1
(a) Remove the chain tensioner assembly No. 1.
22. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
(a) Remove the timing chain or belt cover sub-assembly.
23. REMOVE TIMING CHAIN OR BELT COVER OIL SEAL
(a) Remove the timing chain or belt cover oil seal.
24. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1
(a) Remove the crankshaft position plate No. 1.
25. REMOVE CHAIN TENSIONER SLIPPER
(a) Remove the chain tensioner slipper.
26. REMOVE CHAIN SUB-ASSEMBLY
(a) Remove the chain sub-assembly.
27. REMOVE CHAIN VIBRATION DAMPER NO.1
(a) Remove the chain vibration damper No. 1.





28. REMOVE AIR CLEANER HOSE NO.1
(a) Disconnect the VSV connector [A].
(b) Remove the clamp [B] of the engine wire.
(c) Disconnect the fuel vapor feed hose No. 1 [C] from the VSV.
(d) Disconnect the fuel vapor feed hose No. 3 [C] from the VSV.





(e) Loosen the 2 hose clamp bolts, then remove the air cleaner hose No. 1.
29. REMOVE OIL LEVEL GAGE SUB-ASSEMBLY





30. REMOVE INTAKE MANIFOLD
(a) Remove the 2 clamps of the engine wire from the clamp bracket.





(b) Disconnect the throttle control motor connector.





(c) Disconnect the water by-pass hose [C] from the throttle body.
(d) Disconnect the water by-pass hose No. 2 [D] from the throttle body.





(e) Disconnect the union to check valve hose from the intake manifold.





(f) Remove the 4 bolts, 2 nuts and 2 clamp brackets.
(g) Remove the intake manifold and throttle body.
(h) Remove the gasket from the intake manifold.





31. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(a) Remove the bolt, then remove the camshaft timing oil control valve.





32. REMOVE CAMSHAFT
(a) Using several steps, uniformly loosen and remove the 19 bearing cap bolts in the sequence shown in the illustration.
(b) Remove the 9 bearing caps, then remove the 2 camshafts from the cylinder head.
33. DISCONNECT FUEL TUBE SUB-ASSEMBLY
(a) Disconnect the fuel tube sub-assembly.
SST 09268-21010





34. REMOVE CYLINDER HEAD SUB-ASSEMBLY
(a) Disconnect the engine wire.
(1) Disconnect the 4 fuel injector connectors.





(2) Disconnect the oil pressure switch connector.





(3) Disconnect the crankshaft position sensor connector [A].
(4) Disconnect the knock sensor connector [B].





(5) Disconnect the camshaft position sensor connector.





(6) Disconnect the engine coolant temperature sensor connector [C].
(7) Disconnect the radio setting condenser connector [D].
(8) Disconnect the 2 engine earths [E].
(9) Remove the clamp [F] from the clamp bracket.
(10) Disconnect the heated oxygen sensor connector [G].





(b) Disconnect the radiator hose inlet [H].
(c) Disconnect the heater inlet water hose [I].
(d) Remove the bolt [J], then separate the water bypass pipe No. 1.





(e) Using several steps, uniformly loosen and remove the 10 cylinder head bolts with a bi-hexagon wrench 10 mm in the sequence shown in the illustration. Remove the 10 cylinder head bolts and 10 plate washers.

NOTICE:
^ Be careful not to drop the plate washers into the cylinder head.
^ Head warpage or cracking could result from removing the bolts in the wrong order.

(f) Remove the cylinder head.
35. REMOVE CYLINDER HEAD GASKET

INSTALLATION





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

NOTICE:
^ Make sure that the cylinder head gasket is mounted in the correct direction.
^ Place the cylinder head gently in order to avoid damaging the gasket.

2. INSTALL CYLINDER HEAD SUB-ASSEMBLY

HINT: The cylinder head bolts should be tightened in 2 successive steps.

(a) Apply a light coat of engine oil to the threads of the cylinder head bolts.





(b) Using several steps, uniformly install and tighten the 10 cylinder head bolts and plate washers with a bi-hexagon wrench 10 mm in the sequence shown in the illustration (Procedure "A").
Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)





(c) Mark the front of the cylinder head bolts with paint.
(d) Retighten the cylinder head bolts 90° in the same sequence as procedure "A".
(e) Check that the paint mark of each bolt is at a 90° angle to the front.
(f) Install the water by-pass pipe No. 1 with the bolt.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
(g) Connect the heater inlet water hose.
(h) Connect the radiator hose inlet.
(i) Connect the engine wire.
(1) Connect the heated oxygen sensor connector.
(2) Install the clamp onto the clamp bracket.
(3) Connect the 2 engine earths.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
(4) Connect the radio setting condenser connector.
(5) Connect the engine coolant temperature sensor connector.
(6) Connect the camshaft position sensor connector.
(7) Connect the knock sensor connector.
(8) Connect the crankshaft position sensor connector.
(9) Connect the oil pressure switch connector.
(10) Connect the 4 fuel injector connectors.
3. CONNECT FUEL TUBE SUB-ASSEMBLY
(a) Connect the fuel tube sub-assembly.
4. INSTALL CAMSHAFT
(a) Apply a light coat of engine oil to the camshaft journals.





(b) Place the 2 camshafts on the cylinder head as shown in the illustration.





(c) Examine the front marks and numbers and check that the sequence order is as shown in the illustration. Then tighten the bolts.
Torque:
Bearing cap No. 1 23 N*m (235 kgf*cm, 17 ft.*lbf)
Bearing cap No. 3 13 N*m (133 kgf*cm, 10 ft.*lbf)

HINT:
^ Bearing cap No. 1 is used for bearings numbered from 9 to 11 in the illustration.
^ Bearing cap No. 3 is used for bearings numbered from 1 to 8 in the illustration.

5. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(a) Apply a light coat of engine oil to a new O-ring, then install it onto the camshaft timing oil control valve.





(b) Install the camshaft timing oil control valve with the bolt.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
6. INSTALL INTAKE MANIFOLD
(a) Install a new gasket onto the intake manifold.





(b) Install the intake manifold and throttle body with the 2 brackets, 4 bolts and 2 nuts.
Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)
(c) Connect the union to check valve hose to the intake manifold.
(d) Connect the water by-pass hose No. 2 to the throttle body.
(e) Connect the water by-pass hose to the throttle body.
(f) Connect the throttle control motor connector.
(g) Install the 2 clamps of the engine wire onto the clamp bracket.
7. INSTALL OIL LEVEL GAGE SUB-ASSEMBLY
8. INSTALL AIR CLEANER HOSE NO.1
(a) Install the air cleaner hose No. 1 with the 2 hose clamp bolts.
(b) Connect the fuel vapor feed hose No. 3 to the VSV.
(c) Connect the fuel vapor feed hose No. 1 to the VSV.
(d) Install the clamp of the engine wire.
(e) Connect the VSV connector.
9. INSTALL CHAIN VIBRATION DAMPER NO.1
(a) Install the chain vibration damper No. 1.
10. INSTALL CHAIN SUB-ASSEMBLY
(a) Install the chain sub-assembly.
SST 09223-22010
11. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper.
12. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1
(a) Install the crankshaft position sensor plate No. 1.
13. INSTALL TIMING CHAIN OR BELT COVER OIL SEAL
(a) Install the timing chain or belt cover oil seal.
SST 09223-22010
14. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
(a) Install the timing chain or belt cover sub-assembly.
15. INSTALL CHAIN TENSIONER ASSEMBLY NO.1
(a) Install the chain tensioner assembly No. 1.
16. INSTALL CRANKSHAFT PULLEY
(a) Install the crankshaft pulley.
SST 09960-10010 (09962-01000, 09963-01000)
17. INSTALL CRANKSHAFT POSITION SENSOR
(a) Install the crankshaft position sensor.
18. INSTALL WATER PUMP ASSEMBLY
(a) Install the water pump assembly.
19. INSTALL ENGINE MOUNTING BRACKET RH
(a) Install the engine mounting bracket RH.
20. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
(a) Install the V-ribbed belt tensioner assembly.
21. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(a) Install the cylinder head cover sub-assembly.
22. INSTALL IGNITION COIL ASSEMBLY
(a) Install the ignition coil assembly.
23. INSTALL ENGINE MOUNTING INSULATOR RH
(a) Install the engine mounting insulator RH.
24. INSTALL GENERATOR ASSEMBLY
(a) Install the generator assembly.
25. INSTALL VANE PUMP ASSEMBLY
(a) Install the vane pump assembly.
26. INSTALL FAN AND GENERATOR V BELT
27. INSTALL MANIFOLD STAY
(a) Install the manifold stay.
28. INSTALL EXHAUST PIPE ASSEMBLY FRONT
(a) Install the exhaust pipe assembly front.
29. ADD ENGINE COOLANT
(a) Add the engine coolant.
30. INSTALL BATTERY NEGATIVE TERMINAL
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
31. INSPECT FOR ENGINE COOLANT LEAK
(a) Check for the engine coolant leakage.
32. INSPECT FOR ENGINE OIL LEAK
33. INSPECT FOR FUEL LEAK
34. INSPECT FOR EXHAUST GAS LEAK
35. INSPECT IGNITION TIMING
(a) Inspect the ignition timing.
SST 09843-18040
36. INSPECT ENGINE IDLING SPEED
(a) Inspect the engine idling speed.
37. INSPECT COMPRESSION
(a) Inspect the compression.
SST 09992-00500
38. INSPECT CO/HC
(a) Inspect the CO/HC.
39. INSTALL CYLINDER HEAD COVER NO.2
(a) Install the cylinder head cover No. 2.
40. INSTALL ENGINE UNDER COVER RH
41. INSTALL FRONT WHEEL RH
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)

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