Vibe 2003-2005

Cylinder Head

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Right side engine under cover
     
    Right front wheel and tire
     
    Cylinder head cover
     
    Air cleaner assembly with hose
     
    Accelerator control cable
     
    Wire harness clamp and suction hose assembly, 2ZZ-GE engine only
     
    Water bypass hoses
     
    Fuel pipe clamp
     
    Fuel tube sub-assembly
     
    Union-to-connector tube hose
     
    Radiator and heater inlet hoses
     
    Drive belt
     

  6.  
  7. Separate the vane pipe assembly, but do not disconnect the hose, 1ZZ-FE engine.

    Alternator bracket, 2ZZ-GE
     
    Alternator
     

  8.  
  9. Separate the compressor and magnetic clutch, on 2ZZ-GE engines with air conditioning.

    Front exhaust pipe assembly
     
    Power steering pump reservoir and position it aside, 1ZZ-FE engine
     

  10.  
  11. Place a jack with a wooden block under the vehicle for support, then remove the 4 bolts and 2 nuts and remove the right side engine mount.

    Click image to see an enlarged view

    Fig. With the engine supported, remove the right side engine mount-1ZZ-FE engine shown, 2ZZ-GE similar

  12.  
  13. Remove the engine wire, on 1ZZ-FE engines as follows:
    1. Remove the 5 clamps from the brackets.
    2.  
    3. Detach the connectors.
    4.  
    5. Remove the ignition coil connectors.
    6.  
    7. Bolt and nut holding the engine wire.
    8.  

  14.  
  15. Remove or disconnect the following:

    Ignition coil assembly
     
    Positive Crankcase Ventilation (PCV) hoses
     
    Valve (cylinder head) cover sub-assembly
     

  16.  
  17. Set the No. 1 cylinder to Top Dead Center (TDC) of the compressor stroke as follows:
    1. Turn the crankshaft pulley, and align its groove with the -0- timing mark of the timing chain cover.
    2.  
    3. Make sure the point marks of the camshaft timing sprockets and Variable Valve Timing (VVT) timing sprockets are in a straight line as shown. If not, turn the crankshaft 1 complete revolution (360°) and align the marks.

      Click image to see an enlarged view

      Fig. Proper timing mark alignment for TDC

    4.  

  18.  
  19. Remove or disconnect the following:
    NOTE
    In case you turn the camshafts with the timing chain removed, turn the crankshaft 1 / 4 turn for the valve to avoid contact with the pistons.



    Crankshaft pulley, using SST 09960-10010
     
    Belt tensioner
     
    Exhaust manifold stay and head insulator, 2ZZ-GE engine
     
    Water pump pulley and pump
     
    Transverse engine mounting bracket
     
    Crankshaft Position (CKP) sensor
     
    No. 1 chain tensioner assembly, making sure not to revolve the crankshaft without the tensioner
     
    Timing chain or belt cover
     
    Timing gear cover oil seal
     
    CKP sensor plate No. 1
     
    Timing chain tensioner slipper
     
    Timing chain vibration damper No. 1
     



    Timing chain sub-assembly. Remove the chain with the crankshaft gear, using screwdrivers as shown.

    Click image to see an enlarged view

    Fig. Remove the timing chain with the crankshaft gear

     
    Surge tank stay, 2ZZ-GE engine
     
    Intake manifold
     
    Oil level gauge
     
    Water bypass pipe bolts and pipe, 1ZZ-FE engine
     
    Camshafts
     
    Camshaft timing oil control valve, 1ZZ-FE engine
     
    Manifold stay, 1ZZ-FE engine
     
    Cylinder head bolts in sequence. To prevent damage to the cylinder head, loosen each bolt about 1 / 4 of a turn during each pass until the bolts are loose.

    Click image to see an enlarged view

    Fig. Cylinder head bolt loosening sequence

     



    Cylinder head
     

  20.  

To install:

Click image to see an enlarged view

Fig. Position the head gasket correctly on the cylinder head-1.8L (1ZZ-FE) engine



Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-1ZZ-FE and 2ZZ-GE engines

  1. Clean and degrease the surface of the cylinder head and engine block.
  2.  
  3. Check the length of the cylinder head bolts. They should be 5.780-5.835 in. (146.8-148.2mm) long. If they are longer than 5.846 in. (148.5mm), they must be replaced.
  4.  
  5. Install or connect the following:

    New gasket on the engine block with the Lot No. stamp facing up.
     
    Cylinder head
     
    Apply a light coat of oil to cylinder head bolt threads;
     

  6.  
  7. On 1ZZ-FE engines tighten the bolts as follows:
    1. Step 1: 36 ft. lbs. (49 Nm)
    2.  
    3. Step 2: Tighten an additional 90 degrees.
    4.  

  8.  
  9. On 2003-04 2ZZ-GE engines tighten the bolts as follows:
    1. Step 1: 26 ft. lbs. (35 Nm)
    2.  
    3. Step 2: Tighten an additional 180 degrees.
    4.  

  10.  
  11. On 2005 2ZZ-GE engines tighten the bolts as follows:
    1. Step 1: 16 ft. lbs. (25 Nm)
    2.  
    3. Step 2: 36 ft. lbs. (49 Nm)
    4.  
    5. Step 3: 36 ft. lbs. (49 Nm), plus an additional 90 degrees.
    6.  

  12.  
  13. Install or connect the following:
    NOTE
    When installing the tensioner, make sure to set the hook again if the hook releases the plunger.



    Manifold stay, 1ZZ-FE engine. Tighten the bolts to 36 ft. lbs. (49 Nm).
     
    Camshaft timing oil control valve, on 1ZZ-FE engines, and tighten to 80 inch lbs. (9 Nm)
     
    Camshaft
     
    Water by-pass pipe, on 1ZZ-FE engines, and tighten to 80 inch lbs. (9 Nm)
     
    Oil level gauge
     
    Intake manifold
     
    Surge tank stay, 2ZZ-GE engine. Tighten to 18 ft. lbs. (24 Nm).
     
    Timing chain
     
    Timing chain vibration damper. Tighten the bolts to 80 inch lbs. (9 m).
     
    Timing chain tensioner slipper and tighten the bolt to 14 ft. lbs. (19 Nm).
     
    Crankshaft position sensor plate, with the -F- mark facing forward.
     
    Timing gear cover oil seal
     
    Timing cover. For 1ZZ-FE engine, tighten the -A- bolts to 10 ft. lbs. (13 Nm), the -B- bolts to 14 ft. lbs. (19 Nm) and the stud bolt to 84 inch lbs. (9.5 Nm), using a Torx® wrench. For 2ZZ-GE engines, tighten the M8 bolts to 15 ft. lbs. (21 m), the M6 bolts to 8 ft. lbs. (11 Nm) and the stud bolt to 84 inch lbs. (9.5 Nm).
     



    Timing chain tensioner. Torque the nuts to 80 inch lbs. (9 Nm).
     
    CKP sensor and tighten the bolts to 80 inch lbs. (9 Nm)
     
    Transverse engine mounting bracket. Tighten the bolts to 35 ft. lbs. (47 Nm).
     
    Water pump and pulley
     
    Exhaust manifold stay and heat insulator, 2ZZ-GE engine
     
    Belt tensioner. Tighten the nut to 21 ft. lbs. (29 Nm) and the bolt to 51 ft. lbs. (69 Nm) on 1ZZ-FE engines or to 74 ft. lbs. (100 Nm) on 2ZZ-GE engines.
     

  14.  
  15. Install the crankshaft pulley, as follows:
    1. Align the pulley set key with the key groove of the pulley and slide on the pulley.
    2.  
    3. Use SST 09960-11010 to install the bolt and tighten to 102 ft. lbs. (138 Nm) for 1ZZ-FE engine or to 87 ft. lbs. (118 Nm) on 2ZZ-GE engines.
    4.  
    5. Turn the crankshaft counterclockwise and disconnect the plunger knock pin from the hook.
    6.  
    7. Turn the crankshaft clockwise and check that the slipper is pushed by the plunger. If the plunger does not spring out, press the slipper into the chain tensioner with a screwdriver so that the hook is released from the knock pin and the plunder springs out.
    8.  

  16.  
  17. Install or connect the following:

    Cylinder head sub-assembly cover. Install seal packing into the locations shown and install within 3 minutes. Tighten the -A- bolts to 8 ft. lbs. (11 Nm) and the -B- bolts to 80 inch lbs. (9 Nm) for 1ZZ-FE engines. For 2ZZ-GE engines, tighten the bolts to 7 ft. lbs. (10 Nm).

    Click image to see an enlarged view

    Fig. Seal packing installation locations



    Click image to see an enlarged view

    Fig. Cylinder head (valve) cover bolt locations-1ZZ-FE engine

     
    Ignition coil assembly. Torque the bolts to 80 inch lbs. (9 Nm).
     
    Engine wire and tighten to 80 inch lbs. (9 Nm), 1ZZ-FE
     
    Right side engine mount. Tighten to 38 ft. lbs. (52 Nm).
     
    Front exhaust pipe
     
    Vane pump, 1ZZ-FE
     
    Compressor and magnetic clutch, 2ZZ-GE
     
    Alternator bracket, 2ZZ-GE engine
     
    Alternator
     
    Suction hose and wire harness clamp, 2ZZ-GE engine
     
    Air cleaner and hose
     
    Main cylinder head cover and tighten to 62 inch lbs. (7 Nm)
     
    Right front wheel and tire. Tighten the lug nuts to 76 ft. lbs. (103 Nm).
     

  18.  
  19. Fill the cooling system to the proper level.
  20.  
  21. Start the vehicle, check for leaks and repair if necessary.
  22.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Right side engine under cover
     
    Right front wheel and tire
     
    Cylinder head cover
     
    Air cleaner assembly with hose
     
    Accelerator control cable
     
    Wire harness clamp and suction hose assembly, 2ZZ-GE engine only
     
    Water bypass hoses
     
    Fuel pipe clamp
     
    Fuel tube sub-assembly
     
    Union-to-connector tube hose
     
    Radiator and heater inlet hoses
     
    Drive belt
     

  6.  
  7. Separate the vane pipe assembly, but do not disconnect the hose, 1ZZ-FE engine.

    Alternator bracket, 2ZZ-GE
     
    Alternator
     

  8.  
  9. Separate the compressor and magnetic clutch, on 2ZZ-GE engines with air conditioning.

    Front exhaust pipe assembly
     
    Power steering pump reservoir and position it aside, 1ZZ-FE engine
     

  10.  
  11. Place a jack with a wooden block under the vehicle for support, then remove the 4 bolts and 2 nuts and remove the right side engine mount.

    Click image to see an enlarged view

    Fig. With the engine supported, remove the right side engine mount-1ZZ-FE engine shown, 2ZZ-GE similar

  12.  
  13. Remove the engine wire, on 1ZZ-FE engines as follows:
    1. Remove the 5 clamps from the brackets.
    2.  
    3. Detach the connectors.
    4.  
    5. Remove the ignition coil connectors.
    6.  
    7. Bolt and nut holding the engine wire.
    8.  

  14.  
  15. Remove or disconnect the following:

    Ignition coil assembly
     
    Positive Crankcase Ventilation (PCV) hoses
     
    Valve (cylinder head) cover sub-assembly
     

  16.  
  17. Set the No. 1 cylinder to Top Dead Center (TDC) of the compressor stroke as follows:
    1. Turn the crankshaft pulley, and align its groove with the -0- timing mark of the timing chain cover.
    2.  
    3. Make sure the point marks of the camshaft timing sprockets and Variable Valve Timing (VVT) timing sprockets are in a straight line as shown. If not, turn the crankshaft 1 complete revolution (360°) and align the marks.

      Click image to see an enlarged view

      Fig. Proper timing mark alignment for TDC

    4.  

  18.  
  19. Remove or disconnect the following:
    NOTE
    In case you turn the camshafts with the timing chain removed, turn the crankshaft 1 / 4 turn for the valve to avoid contact with the pistons.



    Crankshaft pulley, using SST 09960-10010
     
    Belt tensioner
     
    Exhaust manifold stay and head insulator, 2ZZ-GE engine
     
    Water pump pulley and pump
     
    Transverse engine mounting bracket
     
    Crankshaft Position (CKP) sensor
     
    No. 1 chain tensioner assembly, making sure not to revolve the crankshaft without the tensioner
     
    Timing chain or belt cover
     
    Timing gear cover oil seal
     
    CKP sensor plate No. 1
     
    Timing chain tensioner slipper
     
    Timing chain vibration damper No. 1
     



    Timing chain sub-assembly. Remove the chain with the crankshaft gear, using screwdrivers as shown.

    Click image to see an enlarged view

    Fig. Remove the timing chain with the crankshaft gear

     
    Surge tank stay, 2ZZ-GE engine
     
    Intake manifold
     
    Oil level gauge
     
    Water bypass pipe bolts and pipe, 1ZZ-FE engine
     
    Camshafts
     
    Camshaft timing oil control valve, 1ZZ-FE engine
     
    Manifold stay, 1ZZ-FE engine
     
    Cylinder head bolts in sequence. To prevent damage to the cylinder head, loosen each bolt about 1 / 4 of a turn during each pass until the bolts are loose.

    Click image to see an enlarged view

    Fig. Cylinder head bolt loosening sequence

     



    Cylinder head
     

  20.  

To install:

Click image to see an enlarged view

Fig. Position the head gasket correctly on the cylinder head-1.8L (1ZZ-FE) engine



Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-1ZZ-FE and 2ZZ-GE engines

  1. Clean and degrease the surface of the cylinder head and engine block.
  2.  
  3. Check the length of the cylinder head bolts. They should be 5.780-5.835 in. (146.8-148.2mm) long. If they are longer than 5.846 in. (148.5mm), they must be replaced.
  4.  
  5. Install or connect the following:

    New gasket on the engine block with the Lot No. stamp facing up.
     
    Cylinder head
     
    Apply a light coat of oil to cylinder head bolt threads;
     

  6.  
  7. On 1ZZ-FE engines tighten the bolts as follows:
    1. Step 1: 36 ft. lbs. (49 Nm)
    2.  
    3. Step 2: Tighten an additional 90 degrees.
    4.  

  8.  
  9. On 2ZZ-GE engines tighten the bolts as follows:
    1. Step 1: 16 ft. lbs. (25 Nm)
    2.  
    3. Step 2: 36 ft. lbs. (49 Nm)
    4.  
    5. Step 3: 36 ft. lbs. (49 Nm), plus an additional 90 degrees.
    6.  

  10.  
  11. Install or connect the following:
    NOTE
    When installing the tensioner, make sure to set the hook again if the hook releases the plunger.



    Manifold stay, 1ZZ-FE engine. Tighten the bolts to 36 ft. lbs. (49 Nm).
     
    Camshaft timing oil control valve, on 1ZZ-FE engines, and tighten to 80 inch lbs. (9 Nm)
     
    Camshaft
     
    Water by-pass pipe, on 1ZZ-FE engines, and tighten to 80 inch lbs. (9 Nm)
     
    Oil level gauge
     
    Intake manifold
     
    Surge tank stay, 2ZZ-GE engine. Tighten to 18 ft. lbs. (24 Nm).
     
    Timing chain
     
    Timing chain vibration damper. Tighten the bolts to 80 inch lbs. (9 m).
     
    Timing chain tensioner slipper and tighten the bolt to 14 ft. lbs. (19 Nm).
     
    Crankshaft position sensor plate, with the -F- mark facing forward.
     
    Timing gear cover oil seal
     
    Timing cover. For 1ZZ-FE engine, tighten the -A- bolts to 10 ft. lbs. (13 Nm), the -B- bolts to 14 ft. lbs. (19 Nm) and the stud bolt to 84 inch lbs. (9.5 Nm), using a Torx® wrench. For 2ZZ-GE engines, tighten the M8 bolts to 15 ft. lbs. (21 m), the M6 bolts to 8 ft. lbs. (11 Nm) and the stud bolt to 84 inch lbs. (9.5 Nm).
     



    Timing chain tensioner. Torque the nuts to 80 inch lbs. (9 Nm).
     
    CKP sensor and tighten the bolts to 80 inch lbs. (9 Nm)
     
    Transverse engine mounting bracket. Tighten the bolts to 35 ft. lbs. (47 Nm).
     
    Water pump and pulley
     
    Exhaust manifold stay and heat insulator, 2ZZ-GE engine
     
    Belt tensioner. Tighten the nut to 21 ft. lbs. (29 Nm) and the bolt to 51 ft. lbs. (69 Nm) on 1ZZ-FE engines or to 74 ft. lbs. (100 Nm) on 2ZZ-GE engines.
     

  12.  
  13. Install the crankshaft pulley, as follows:
    1. Align the pulley set key with the key groove of the pulley and slide on the pulley.
    2.  
    3. Use SST 09960-11010 to install the bolt and tighten to 102 ft. lbs. (138 Nm) for 1ZZ-FE engine or to 87 ft. lbs. (118 Nm) on 2ZZ-GE engines.
    4.  
    5. Turn the crankshaft counterclockwise and disconnect the plunger knock pin from the hook.
    6.  
    7. Turn the crankshaft clockwise and check that the slipper is pushed by the plunger. If the plunger does not spring out, press the slipper into the chain tensioner with a screwdriver so that the hook is released from the knock pin and the plunder springs out.
    8.  

  14.  
  15. Install or connect the following:

    Cylinder head sub-assembly cover. Install seal packing into the locations shown and install within 3 minutes. Tighten the -A- bolts to 8 ft. lbs. (11 Nm) and the -B- bolts to 80 inch lbs. (9 Nm) for 1ZZ-FE engines. For 2ZZ-GE engines, tighten the bolts to 7 ft. lbs. (10 Nm).

    Click image to see an enlarged view

    Fig. Seal packing installation locations



    Click image to see an enlarged view

    Fig. Cylinder head (valve) cover bolt locations-1ZZ-FE engine

     
    Ignition coil assembly. Torque the bolts to 80 inch lbs. (9 Nm).
     
    Engine wire and tighten to 80 inch lbs. (9 Nm), 1ZZ-FE
     
    Right side engine mount. Tighten to 38 ft. lbs. (52 Nm).
     
    Front exhaust pipe
     
    Vane pump, 1ZZ-FE
     
    Compressor and magnetic clutch, 2ZZ-GE
     
    Alternator bracket, 2ZZ-GE engine
     
    Alternator
     
    Suction hose and wire harness clamp, 2ZZ-GE engine
     
    Air cleaner and hose
     
    Main cylinder head cover and tighten to 62 inch lbs. (7 Nm)
     
    Right front wheel and tire. Tighten the lug nuts to 76 ft. lbs. (103 Nm).
     

  16.  
  17. Fill the cooling system to the proper level.
  18.  
  19. Start the vehicle, check for leaks and repair if necessary.
  20.  

 
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