1976 Jeep CJ7 4.2L 1BL OHV 6cyl - Repair Guides - Engine Mechanical Components - Cylinder Head - AutoZone
1976 Jeep CJ7 4.2L 1BL OHV 6cyl - Repair Guides - Engine Mechanical Components - Cylinder Head - AutoZone
1976 Jeep CJ7 4.2L 1BL OHV 6cyl - Repair Guides - Engine Mechanical Components - Cylinder Head - AutoZone
com
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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