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Home >> Toyota >> 2007 >> Corolla CE, Automatic >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical (1ZZ-FE) >> Cylinder Head, Intake Manifold, Exhaust Manifold >> Removal

Cylinder Head, Intake Manifold, Exhaust Manifold: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE 
    1. Discharge the fuel system pressure (See PRECAUTION )
  2. DISCONNECT BATTERY NEGATIVE TERMINAL 
  3. REMOVE FRONT WHEEL RH 
  4. REMOVE ENGINE UNDER COVER RH 
  5. REMOVE CYLINDER HEAD COVER NO.2 
    1. Remove the cylinder head cover No. 2 (See )REMOVAL .
  6. DRAIN ENGINE COOLANT 
    1. Drain the engine coolant (See ON-VEHICLE INSPECTION ).
  7. SEPARATE EXHAUST PIPE ASSEMBLY FRONT 
    1. Separate the exhaust pipe assembly front (See REMOVAL ).
  8. REMOVE MANIFOLD STAY 
    1. Remove the manifold stay (See )REMOVAL .
  9. REMOVE FAN AND GENERATOR V BELT 
    1. Remove the fan and generator V belt (See )ENGINE .
  10. SEPARATE VANE PUMP ASSEMBLY 
    1. Separate the vane pump assembly (See REMOVAL ).
  11. REMOVE GENERATOR ASSEMBLY 
    1. Remove the generator assembly (See REMOVAL ).
  12. REMOVE ENGINE MOUNTING INSULATOR RH 
    1. Remove the engine mounting insulator RH (See )REMOVAL .
  13. REMOVE IGNITION COIL ASSEMBLY 
    1. Remove the ignition coil assembly (See )REMOVAL .
  14. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Remove the cylinder head cover sub-assembly (See )REMOVAL .
  15. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY 
    1. Remove the V-ribbed belt tensioner assembly (See )REMOVAL .
  16. REMOVE ENGINE MOUNTING BRACKET RH 
    1. Remove the engine mounting bracket RH (See )REMOVAL .
  17. REMOVE WATER PUMP ASSEMBLY 
    1. Remove the water pump assembly (See REMOVAL ).
  18. SEPARATE CRANKSHAFT POSITION SENSOR 
    1. Separate the crankshaft position sensor (See )REMOVAL .
  19. SET NO. 1 CYLINDER TO TDC / COMPRESSION 
    1. Set the No. 1 cylinder to the TCD/compression (See )REMOVAL .
  20. REMOVE CRANKSHAFT PULLEY 
    1. Remove the crankshaft pulley (See )REMOVAL .

      SST 09960-10010 (09962-01000, 09963-01000) 

  21. REMOVE CHAIN TENSIONER ASSEMBLY NO.1 
    1. Remove the chain tensioner assembly No. 1 (See )REMOVAL .
  22. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY 
    1. Remove the timing chain or belt cover sub-assembly (See )REMOVAL .
  23. REMOVE TIMING CHAIN OR BELT COVER OIL SEAL 
    1. Remove the timing chain or belt cover oil seal (See )REMOVAL .
  24. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1 
    1. Remove the crankshaft position plate No. 1 (See )REMOVAL .
  25. REMOVE CHAIN TENSIONER SLIPPER 
    1. Remove the chain tensioner slipper (See )REMOVAL .
  26. REMOVE CHAIN SUB-ASSEMBLY 
    1. Remove the chain sub-assembly (See )REMOVAL .
  27. REMOVE CHAIN VIBRATION DAMPER NO.1 
    1. Remove the chain vibration damper No. 1 (See DISASSEMBLY ).
  28. REMOVE AIR CLEANER HOSE NO.1 
    1. Disconnect the VSV connector [A].
    2. Remove the clamp [B] of the engine wire.
    3. Disconnect the fuel vapor feed hose No. 1 [C] from the VSV.
    4. Disconnect the fuel vapor feed hose No. 3 [C] from the VSV.
      Fig 1: Locating Fuel Vapor Feed Hose No. 3
      G05192846Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Loosen the 2 hose clamp bolts, then remove the air cleaner hose No. 1.
  29. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY 
    Fig 2: Locating Air Cleaner Hose Clamp Bolts
    G05192847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE INTAKE MANIFOLD 
    1. Remove the 2 clamps of the engine wire from the clamp bracket.
      Fig 3: Locating Clamps Of Engine Wire
      G05192848Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the throttle control motor connector.
      Fig 4: Locating Throttle Control Motor Connector
      G05192849Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the water bypass hose [C] from the throttle body.
    4. Disconnect the water bypass hose No. 2 [D] from the throttle body.
      Fig 5: Locating Water bypass Hose Clamp
      G05192850Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the union to check valve hose from the intake manifold.
      Fig 6: Locating Union Of Check Valve Hose
      G05192851Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 4 bolts, 2 nuts and 2 clamp brackets.
    7. Remove the intake manifold and throttle body.
    8. Remove the gasket from the intake manifold.
    Fig 7: Locating Bolts, Nuts And Clamp Brackets
    G05192852Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 
    1. Remove the bolt, then remove the camshaft timing oil control valve.
    Fig 8: Locating Camshaft Timing Oil Control Valve Bolt
    G05192853Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE CAMSHAFT 
    1. Using several steps, uniformly loosen and remove the 19 bearing cap bolts in the sequence shown in the illustration.
    2. Remove the 9 bearing caps, then remove the 2 camshafts from the cylinder head.
  33. DISCONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Disconnect the fuel tube sub-assembly (See REMOVAL ).

      SST 09268-21010 

    Fig 9: Identifying Bearing Cap Bolts Loosening Sequence
    G05192854Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE CYLINDER HEAD SUB-ASSEMBLY 
    1. Disconnect the engine wire.
      1. Disconnect the 4 fuel injector connectors.
        Fig 10: Locating Fuel Injector Connectors
        G05192855Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Disconnect the oil pressure switch connector.
        Fig 11: Locating Oil Pressure Switch Connector
        G05192856Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Disconnect the crankshaft position sensor connector [A].
      4. Disconnect the knock sensor connector [B].
        Fig 12: Locating Knock Sensor Connector
        G05192857Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      5. Disconnect the camshaft position sensor connector.
        Fig 13: Locating Camshaft Position Sensor Connector
        G05192858Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      6. Disconnect the engine coolant temperature sensor connector [C].
      7. Disconnect the radio setting condenser connector [D].
      8. Disconnect the 2 engine earth [E].
      9. Remove the clamp [F] from the clamp bracket.
      10. Disconnect the heated oxygen sensor connector [G].
      Fig 14: Locating Heated Oxygen Sensor Connector [G]
      G05192859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the radiator hose inlet [H].
    3. Disconnect the heater inlet water hose [I].
    4. Remove the bolt [J], then separate the water bypass pipe No. 1.
      Fig 15: Locating Heater Inlet Water Hose Clamp
      G05192860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. 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.
      NOTE:
      • 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.
    6. Remove the cylinder head.
    Fig 16: Identifying Cylinder Head Bolts Loosening Sequence
    G05192861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE CYLINDER HEAD GASKET 
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