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ToyotaMatrix200306

REMOVAL&INSTALLATION

CylinderHead
Removal&Installation

1.Beforeservicingthevehicle,refertothePrecautionssection.
2.Drainthecoolingsystem.
3.Removeordisconnectthefollowing:

Rightsideengineundercover

Rightfrontwheelandtire

Cylinderheadcover

Aircleanerassemblywithhose

Acceleratorcontrolcable

Wireharnessclampandsuctionhoseassembly,2ZZGEengineonly

Waterbypasshoses

Fuelpipeclamp

Fueltubesubassembly

Uniontoconnectortubehose

Radiatorandheaterinlethoses

Drivebelt


4.Separatethevanepipeassembly,butdonotdisconnectthehose,1ZZFEengine.

Alternatorbracket,2ZZGE

Alternator


5.Separatethecompressorandmagneticclutch,on2ZZGEengineswithairconditioning.

Frontexhaustpipeassembly

Powersteeringpumpreservoirandpositionitaside,1ZZFEengine


6.Placeajackwithawoodenblockunderthevehicleforsupport,thenremovethe4boltsand2nutsandremovetherightsideenginemount.
7.Removetheenginewire,on1ZZFEenginesasfollows:

A.Removethe5clampsfromthebrackets.
B.Detachtheconnectors.
C.Removetheignitioncoilconnectors.
D.Boltandnutholdingtheenginewire.

8.Removeordisconnectthefollowing:

Ignitioncoilassembly

PositiveCrankcaseVentilation(PCV)hoses

Valve(cylinderhead)coversubassembly
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Valve(cylinderhead)coversubassembly

9.SettheNo.1cylindertoTopDeadCenter(TDC)ofthecompressorstrokeasfollows:

A.Turnthecrankshaftpulley,andalignitsgroovewiththe0timingmarkofthetimingchaincover.
B.MakesurethepointmarksofthecamshafttimingsprocketsandVariableValveTiming(VVT)timingsprocketsareinastraightlineasshown.Ifnot,turnthe
crankshaft1completerevolution(360)andalignthemarks.

10.Removeordisconnectthefollowing:

Crankshaftpulley,usingSST0996010010

Belttensioner

Exhaustmanifoldstayandheadinsulator,2ZZGEengine

Waterpumppulleyandpump

Transverseenginemountingbracket

CrankshaftPosition(CKP)sensor

No.1chaintensionerassembly,makingsurenottorevolvethecrankshaftwithoutthetensioner

Timingchainorbeltcover

Timinggearcoveroilseal

CKPsensorplateNo.1

Timingchaintensionerslipper

TimingchainvibrationdamperNo.1


Fig.Withtheenginesupported,removetherightsideenginemount1ZZFEengineshown,2ZZGEsimilar

Withtheenginesupported,removetherightsideenginemount1ZZFEengineshown,2ZZGEsimilar

Fig.PropertimingmarkalignmentforTDC

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PropertimingmarkalignmentforTDC


NOTE
1
Incaseyouturnthecamshaftswiththetimingchainremoved,turnthecrankshaft /4turnforthevalvetoavoidcontactwiththepistons.


Timingchainsubassembly.Removethechainwiththecrankshaftgear,usingscrewdriversasshown.

Fig.Removethetimingchainwiththecrankshaftgear

Removethetimingchainwiththecrankshaftgear

Surgetankstay,2ZZGEengine

Intakemanifold

Oillevelgauge

Waterbypasspipeboltsandpipe,1ZZFEengine

Camshafts

Camshafttimingoilcontrolvalve,1ZZFEengine

Manifoldstay,1ZZFEengine
1
Cylinderheadboltsinsequence.Topreventdamagetothecylinderhead,looseneachboltabout 4

Fig.Cylinderheadboltlooseningsequence

Cylinderheadboltlooseningsequence

Cylinderhead

Toinstall:

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Fig.Positiontheheadgasketcorrectlyonthecylinderhead1.8L(1ZZFE)engine

Positiontheheadgasketcorrectlyonthecylinderhead1.8L(1ZZFE)engine

Fig.Cylinderheadbolttighteningsequence1ZZFEand2ZZGEengines

Cylinderheadbolttighteningsequence1ZZFEand2ZZGEengines

1.Cleananddegreasethesurfaceofthecylinderheadandengineblock.
2.Checkthelengthofthecylinderheadbolts.Theyshouldbe5.7805.835in.(146.8148.2mm)long.Iftheyarelongerthan5.846in.(148.5mm),theymustbereplaced.
3.Installorconnectthefollowing:

NewgasketontheengineblockwiththeLotNo.stampfacingup.

Cylinderhead

Applyalightcoatofoiltocylinderheadboltthreadsandtighteninsequence,inseveralpasses,to36ft.lbs.(49Nm)for1ZZFEenginesorto26ft.lbs.(35Nm)for2ZZ
GEengines.

Tighteneachheadbolt,insequence,anadditional90degreeturnfor1ZZFEengines,or180degreeturnfor2ZZGEengines.

Manifoldstay,1ZZFEengine.Tightentheboltsto36ft.lbs.(49Nm).

Camshafttimingoilcontrolvalve,on1ZZFEengines,andtightento80inchlbs.(9Nm)

Camshaft

Waterbypasspipe,on1ZZFEengines,andtightento80inchlbs.(9Nm)

Oillevelgauge

Intakemanifold

Surgetankstay,2ZZGEengine.Tightento18ft.lbs.(24Nm).

Timingchain

Timingchainvibrationdamper.Tightentheboltsto80inchlbs.(9Nm).

Timingchaintensionerslipperandtightentheboltto14ft.lbs.(19Nm).

Crankshaftpositionsensorplate,withtheFmarkfacingforward.

Timinggearcoveroilseal

Timingcover.For1ZZFEengine,tightentheAboltsto10ft.lbs.(13Nm),theBboltsto14ft.lbs.(19Nm)andthestudboltto84inchlbs.(9.5Nm),usingaTorx
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Timingcover.For1ZZFEengine,tightentheAboltsto10ft.lbs.(13Nm),theBboltsto14ft.lbs.(19Nm)andthestudboltto84inchlbs.(9.5Nm),usingaTorx
wrench.For2ZZGEengines,tightentheM8boltsto15ft.lbs.(21Nm),theM6boltsto8ft.lbs.(11Nm)andthestudboltto84inchlbs.(9.5Nm).


NOTE
Wheninstallingthetensioner,makesuretosetthehookagainifthehookreleasestheplunger.


Timingchaintensioner.Torquethenutsto80inchlbs.(9Nm).

CKPsensorandtightentheboltsto80inchlbs.(9Nm)

Transverseenginemountingbracket.Tightentheboltsto35ft.lbs.(47Nm).

Waterpumpandpulley

Exhaustmanifoldstayandheatinsulator,2ZZGEengine

Belttensioner.Tightenthenutto21ft.lbs.(29Nm)andtheboltto51ft.lbs.(69Nm)on1ZZFEenginesorto74ft.lbs.(100Nm)on2ZZGEengines.

1.Installthecrankshaftpulley,asfollows:

A.Alignthepulleysetkeywiththekeygrooveofthepulleyandslideonthepulley.
B.UseSST0996011010toinstalltheboltandtightento102ft.lbs.(138Nm)for1ZZFEengineorto87ft.lbs.(118Nm)on2ZZGEengines.
C.Turnthecrankshaftcounterclockwiseanddisconnecttheplungerknockpinfromthehook.
D.Turnthecrankshaftclockwiseandcheckthattheslipperispushedbytheplunger.Iftheplungerdoesnotspringout,presstheslipperintothechaintensionerwitha
screwdriversothatthehookisreleasedfromtheknockpinandtheplungerspringsout.

2.Installorconnectthefollowing:

Cylinderheadsubassemblycover.Installsealpackingintothelocationsshownandinstallwithin3minutes.TightentheAboltsto8ft.lbs.(11Nm)andtheBboltsto
80inchlbs.(9Nm)for1ZZFEengines.For2ZZGEengines,tightentheboltsto7ft.lbs.(10Nm).

Fig.Sealpackinginstallationlocations

Sealpackinginstallationlocations

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Fig.Cylinderhead(valve)coverboltlocations1ZZFEengine

Cylinderhead(valve)coverboltlocations1ZZFEengine

Ignitioncoilassembly.Torquetheboltsto80inchlbs.(9Nm).

Enginewireandtightento80inchlbs.(9Nm),1ZZFE

Rightsideenginemount.Tightento38ft.lbs.(52Nm).

Frontexhaustpipe

Vanepump,1ZZFE

Compressorandmagneticclutch,2ZZGE

Alternatorbracket,2ZZGEengine

Alternator

Suctionhoseandwireharnessclamp,2ZZGEengine

Aircleanerandhose

Maincylinderheadcoverandtightento62inchlbs.(7Nm)

Rightfrontwheelandtire.Tightenthelugnutsto76ft.lbs.(103Nm).

3.Fillthecoolingsystemtotheproperlevel.
4.Startthevehicle,checkforleaksandrepairifnecessary.

1.Beforeservicingthevehicle,refertotheprecautionssection.
2.Drainthecoolingsystem.
3.Removeordisconnectthefollowing:

Rightsideengineundercover

Rightfrontwheelandtire

Cylinderheadcover

Aircleanerassemblywithhose

Acceleratorcontrolcable

Wireharnessclampandsuctionhoseassembly,2ZZFEENGINEonly

Waterbypasshoses

Fuelpipeclamp

Fueltubesubassembly

Uniontoconnectortubehose

Radiatorandheaterinlethoses

Drivebelt

4.Separatethevanepipeassembly,butdonotdisconnectthehose,1ZZFEengine.

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Alternatorbracket,2ZZGE

Alternator

5.Separatethecompressorandmagneticclutch,on2ZZFEEngineswithairconditioning.

Frontexhaustpipeassembly

Powersteeringpumpreservoirandpositionitaside,1ZZFEengine

6.Placeajackwithawoodenblockunderthevehicleforsupport,thenremovethe4boltsand2nutsandremovetherightsideenginemount.

Fig.Withtheenginesupported,removetherightsideenginemount1ZZFEengineshown,2ZZFEsimilar

Withtheenginesupported,removetherightsideenginemount1ZZFEengineshown,2ZZFEsimilar
7.Removetheenginewire,on1ZZFEenginesasfollows:

A.Removethe5clampsfromthebrackets.
B.Detachtheconnectors.
C.Removetheignitioncoilconnectors.
D.Boltandnutholdingtheenginewire.

8.Removeordisconnectthefollowing:

Ignitioncoilassembly

PositiveCrankcaseVentilation(PCV)hoses

Valve(cylinderhead)coversubassembly

9.SettheNo.1cylindertoTopDeadCenter(TDC)ofthecompressorstrokeasfollows:

A.Turnthecrankshaftpulley,andalignitsgroovewiththe0timingmarkofthetimingchaincover.
B.MakesurethepointmarksofthecamshafttimingsprocketsandVariableValveTiming(VVT)timingsprocketsareinastraightlineasshown.Ifnot,turnthe
crankshaft1completerevolution(360)andalignthemarks.

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Fig.PropertimingmarkalignmentforTDC

PropertimingmarkalignmentforTDC

10.Removeordisconnectthefollowing:
NOTE
1
Incaseyouturnthecamshaftswiththetimingchainremoved,turnthecrankshaft /4turnforthevalvetoavoidcontactwiththepistons.

Crankshaftpulley,usingSST0996010010

Belttensioner

Exhaustmanifoldstayandheadinsulator,2ZZFEENGINE

Waterpumppulleyandpump

Transverseenginemountingbracket

CrankshaftPosition(CKP)sensor

No.1chaintensionerassembly,makingsurenottorevolvethecrankshaftwithoutthetensioner

Timingchainorbeltcover

Timinggearcoveroilseal

CKPsensorplateNo.1

Timingchaintensionerslipper

TimingchainvibrationdamperNo.1


Timingchainsubassembly.Removethechainwiththecrankshaftgear,usingscrewdriversasshown.

Fig.Removethetimingchainwiththecrankshaftgear

Removethetimingchainwiththecrankshaftgear

Surgetankstay,2ZZFEENGINE

Intakemanifold

Oillevelgauge
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Oillevelgauge

Waterbypasspipeboltsandpipe,1ZZFEengine

Camshafts

Camshafttimingoilcontrolvalve,1ZZFEengine

Manifoldstay,1ZZFEengine

1
Cylinderheadboltsinsequence.Topreventdamagetothecylinderhead,looseneachboltabout /4ofaturnduringeachpassuntiltheboltsareloose.

Fig.Cylinderheadboltlooseningsequence

Cylinderheadboltlooseningsequence

Cylinderhead

Toinstall:

Fig.Positiontheheadgasketcorrectlyonthecylinderhead1.8L(1ZZFE)engine

Positiontheheadgasketcorrectlyonthecylinderhead1.8L(1ZZFE)engine

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Fig.Cylinderheadbolttighteningsequence1ZZFEand2ZZFEEngines

Cylinderheadbolttighteningsequence1ZZFEand2ZZFEEngines

1.Cleananddegreasethesurfaceofthecylinderheadandengineblock.
2.Checkthelengthofthecylinderheadbolts.Theyshouldbe5.7805.835in.(146.8148.2mm)long.Iftheyarelongerthan5.846in.(148.5mm),theymustbereplaced.
3.Installorconnectthefollowing:

NewgasketontheengineblockwiththeLotNo.stampfacingup.

Cylinderhead

Applyalightcoatofoiltocylinderheadboltthreads

4.On1ZZFEenginestightentheboltsasfollows:

A.Step1:36ft.lbs.(49Nm)
B.Step2:Tightenanadditional90degrees.

5.On2003042ZZFEEnginestightentheboltsasfollows:

A.Step1:26ft.lbs.(35Nm)
B.Step2:Tightenanadditional180degrees.

6.On2005062ZZFEEnginestightentheboltsasfollows:

A.Step1:16ft.lbs.(25Nm)
B.Step2:36ft.lbs.(49Nm)
C.Step3:36ft.lbs.(49Nm),plusanadditional90degrees.

7.Installorconnectthefollowing:
NOTE
Wheninstallingthetensioner,makesuretosetthehookagainifthehookreleasestheplunger.

Manifoldstay,1ZZFEengine.Tightentheboltsto36ft.lbs.(49Nm).

Camshafttimingoilcontrolvalve,on1ZZFEengines,andtightento80inchlbs.(9Nm)

Camshaft

Waterbypasspipe,on1ZZFEengines,andtightento80inchlbs.(9Nm)

Oillevelgauge

Intakemanifold

Surgetankstay,2ZZFEENGINE.Tightento18ft.lbs.(24Nm).

Timingchain

Timingchainvibrationdamper.Tightentheboltsto80inchlbs.(9Nm).

Timingchaintensionerslipperandtightentheboltto14ft.lbs.(19Nm).

Crankshaftpositionsensorplate,withtheFmarkfacingforward.

Timinggearcoveroilseal

Timingcover.For1ZZFEengine,tightentheAboltsto10ft.lbs.(13Nm),theBboltsto14ft.lbs.(19Nm)andthestudboltto84inchlbs.(9.5Nm),usingaTorx
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Timingcover.For1ZZFEengine,tightentheAboltsto10ft.lbs.(13Nm),theBboltsto14ft.lbs.(19Nm)andthestudboltto84inchlbs.(9.5Nm),usingaTorx
wrench.For2ZZFEEngines,tightentheM8boltsto15ft.lbs.(21Nm),theM6boltsto8ft.lbs.(11Nm)andthestudboltto84inchlbs.(9.5Nm).


Timingchaintensioner.Torquethenutsto80inchlbs.(9Nm).

CKPsensorandtightentheboltsto80inchlbs.(9Nm)

Transverseenginemountingbracket.Tightentheboltsto35ft.lbs.(47Nm).

Waterpumpandpulley

Exhaustmanifoldstayandheatinsulator,2ZZFEENGINE

Belttensioner.Tightenthenutto21ft.lbs.(29Nm)andtheboltto51ft.lbs.(69Nm)on1ZZFEenginesorto74ft.lbs.(100Nm)on2ZZFEEngines.

8.Installthecrankshaftpulley,asfollows:

A.Alignthepulleysetkeywiththekeygrooveofthepulleyandslideonthepulley.
B.UseSST0996011010toinstalltheboltandtightento102ft.lbs.(138Nm)for1ZZFEengineorto87ft.lbs.(118Nm)on2ZZFEEngines.
C.Turnthecrankshaftcounterclockwiseanddisconnecttheplungerknockpinfromthehook.
D.Turnthecrankshaftclockwiseandcheckthattheslipperispushedbytheplunger.Iftheplungerdoesnotspringout,presstheslipperintothechaintensionerwitha
screwdriversothatthehookisreleasedfromtheknockpinandtheplungerspringsout.

9.Installorconnectthefollowing:

Cylinderheadsubassemblycover.Installsealpackingintothelocationsshownandinstallwithin3minutes.TightentheAboltsto8ft.lbs.(11Nm)andtheBboltsto
80inchlbs.(9Nm)for1ZZFEengines.For2ZZFEEngines,tightentheboltsto7ft.lbs.(10Nm).

Fig.Sealpackinginstallationlocations

Sealpackinginstallationlocations

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Fig.Cylinderhead(valve)coverboltlocations1ZZFEengine

Cylinderhead(valve)coverboltlocations1ZZFEengine

Ignitioncoilassembly.Torquetheboltsto80inchlbs.(9Nm).

Enginewireandtightento80inchlbs.(9Nm),1ZZFE

Rightsideenginemount.Tightento38ft.lbs.(52Nm).

Frontexhaustpipe

Vanepump,1ZZFE

Compressorandmagneticclutch,2ZZGE

Alternatorbracket,2ZZFEENGINE

Alternator

Suctionhoseandwireharnessclamp,2ZZFEENGINE

Aircleanerandhose

Maincylinderheadcoverandtightento62inchlbs.(7Nm)

Rightfrontwheelandtire.Tightenthelugnutsto76ft.lbs.(103Nm).

10.Fillthecoolingsystemtotheproperlevel.
11.Startthevehicle,checkforleaksandrepairifnecessary.

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