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HOMESERVICE MANUALSTOYOTA2004MATRIX XR, FWD, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT VARIANT/TRIMSECTION 9 (ENGINE MECHANICAL (2ZZ-GE))PARTIAL ENGINE ASSEMBLY (2ZZ-GE)OVERHAUL

2004 Toyota Matrix XR, FWD, Standard

Partial Engine Assembly (2ZZ-GE): Overhaul

2004 Toyota Matrix XR, FWD, StandardSECTION Overhaul

WARNING: This page is about a different variant/trim than selected.

REMOVE OIL FILLER CAP SUB-ASSY
REMOVE OIL FILLER CAP GASKET
1. Using a screwdriver, remove the gasket from the oil filler cap.
  
  Fig 1: Removing Oil Filler Cap Gasket Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE VENTILATION VALVE SUB-ASSY
REMOVE SPARK PLUG
REMOVE CYLINDER HEAD COVER SUB-ASSY
1. Remove the 9 bolts and cylinder head cover.
2. Remove the spark plug tube gasket and O-ring.
Fig 2: Removing Spark Plug Tube Gasket & O-Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER HEAD COVER GASKET
REMOVE WATER PUMP PULLEY
1. Using SST, remove the water pump pulley.
  
  Fig 3: Removing Water Pump Pulley Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09960-10010 (09962-01000, 09963-00600)
REMOVE WATER PUMP ASSY

Fig 4: Removing Water Pump Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 6 bolts and water pump.
2. Remove the O-ring from the timing chain cover.
REMOVE TRANSVERSE ENGINE MOUNTING BRACKET

Fig 5: Removing Transverse Engine Mounting Bracket
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 4 bolts and engine mounting bracket.
SET NO. 1 CYLINDER TO TDC/COMPRESSION
1. Turn the crankshaft pulley, then align its groove with the timing mark "0" of the timing chain cover.
2. Check that the point marks of the camshaft timing sprocket and the VVT timing sprocket are in a straight line on the timing chain cover surface as shown in Fig 6 .
  
  Fig 6: Checking Point Marks Of Camshaft Timing Sprocket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE: If not, turn the crankshaft 1 revolution (360°) and align the marks as above.
REMOVE CRANKSHAFT PULLEY
1. Using SST, remove the pulley bolt.
  
  Fig 7: Removing Crankshaft Pulley Bolt Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09213-70011 (09213-70020), 09330-00021
2. Using SST, remove the crankshaft pulley.
  
  Fig 8: Removing Crankshaft Pulley Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
REMOVE CHAIN TENSIONER ASSY No. 1

Fig 9: Removing Chain Tensioner Assembly No. 1
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 2 nuts and chain tensioner assy No. 1.
NOTE: Be sure not to revolve the crankshaft without the chain tensioner.
REMOVE TIMING CHAIN OR BELT COVER SUB-ASSY

Fig 10: Removing Timing Chain Or Belt Cover Sub-Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 13 bolts and timing chain cover.
2. Remove the 2 gaskets from the timing chain cover.
NOTE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder head and cylinder block.
REMOVE TIMING CHAIN OR BELT COVER OIL SEAL
1. Using a screwdriver, remove the oil seal.
Fig 11: Removing Oil Seal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CRANKSHAFT POSITION SENSOR PLATE No. 1
REMOVE CHAIN TENSIONER SLIPPER
1. Remove the bolt and chain tensioner slipper.
REMOVE CHAIN VIBRATION DAMPER No. 1
1. Remove the 2 bolts and chain vibration damper No. 1.
REMOVE CHAIN SUB-ASSY

Fig 12: Removing Chain Sub-Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using 2 screwdrivers, ply out the timing chain together with the crankshaft timing gear as shown in Fig 12 .
NOTE:
- Put a shop rag to protect the engine.
- In case of revolving the camshafts with the chain off the sprockets, turn the crankshaft 1/4 revolution to prevent contact of the valves with the pistons.
REMOVE OIL PUMP ASSY

Fig 13: Removing Oil Pump Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 5 bolts and oil pump.
2. Remove the gasket from the cylinder block.
REMOVE CAMSHAFT

Fig 14: Removing Camshaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Uniformly loosen and remove the 20 bearing cap bolts, in several passes in the sequence shown in Fig 14. Then remove the 9 bearing caps, intake and exhaust camshafts.
REMOVE CAMSHAFT TIMING GEAR OR SPROCKET

Fig 15: Removing Camshaft Timing Gear Or Sprocket
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Clamp the No. 2 camshaft in a vise, then remove the camshaft timing gear.
NOTE: Be careful not to damage the camshaft.
INSPECT CAMSHAFT TIMING GEAR ASSY
1. Check the lock of camshaft timing gear.
  1. Clamp the camshaft in a vise, then confirm the camshaft timing gear is locked.
  NOTE: Be careful not to damage the camshaft.
2. Release the lock pin.
  1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in Fig 16 .
    NOTE: Two advance side paths are provided in the groove of the camshaft. Plug one of the path with a rubber piece.
  2. Puncture the tape for the advance side path and retard side path on the opposite side of the groove.
    
    Fig 16: View Of Advance Side Path & Retard Side Path
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Put air pressure into the two broken paths (the advance side path and retard side path) with about 150 kPa {1.5 kgf/cm² }.
    CAUTION: Cover the paths with a shop rag to avoid oil splashing.