Canada - Engine - Cold Start Up Knock/Rattle

Bulletin
TSB3429

Issue Date
August 10, 2010

Market
Canada

Title
BRIEF ENGINE KNOCK/RATTLE NOISE AT COLD STARTUP (1AR/2AR)

Component
ENGINE MECHANICAL

Models
'10-'11 Camry; '09-'10 Highlander; '09-'10 RAV4; '09-'10 Venza

INTRODUCTION:
Immediately following a cold soak startup, some 2009 - 2011 model year vehicles equipped with the 1AR-FE and 2AR-FE engines may exhibit a brief knock/rattle noise from the engine compartment for approximately one second.
Follow the repair procedure below to address this condition.






APPLICABILITY:






WARRANTY INFORMATION:

PRODUCTION CHANGE INFORMATION:







This TSB applies to vehicles produced BEFORE the Production Change Effective VIN shown.






PARTS INFORMATION:






REQUIRED TOOLS & EQUIPMENT:

NOTE:
- Additional Techstream units may be ordered by completing the order form on ETAS and faxing it to (416) 431-8342.
- Additional SSTs may be ordered by calling SPX/OTC at 1-800-933-8335.

REPAIR PROCEDURE:
1. Confirm the customer complaint. See attached video for an example of the engine knock/rattle noise.







2. Remove the cylinder head cover.
A. Relocate the engine harness that lies across the top of the cylinder head cover.
B. Remove the ignition coils.
C. Remove the 16 bolts and cylinder head cover.

3. Remove the chain tensioner.
A. Remove the right front wheel.
B. Remove the front fender apron seal RH.
C. Remove the V-ribbed belt for the vane pump.
D. Rotate the crankshaft clockwise and set the No. 1 cylinder at +10° from the TDC/compression.







E. After the timing marks are aligned on the VVT gear, place paint marks on the chain and both gears.
F. Rotate the crankshaft counterclockwise by 10° and loosen the tension of the chain.
G. Remove the timing chain cover plate.







H. Align the holes of the stopper plate and tensioner, and insert a pin into the stopper plate hole to lock the tensioner.
I. Remove the 2 bolts and chain tensioner.







4. Remove the timing chain guide by removing the bolt.
5. Remove the intake side VVT gear.







A. For Camry ONLY:
Remove the 2 bolts and the No. 2 timing chain cover.







B. Remove the service hole plug.







C. Insert the tool through the service hole and remove the bolt of the intake VVT gear while holding the camshaft stationary with a wrench.

NOTICE:
- Be careful NOT to damage the cylinder head or spark plug tube with the wrench.
- Do NOT disassemble the camshaft timing gear.







D. After the VVT gear is slid in the arrow direction as shown in Figure 8, lower the VVT gear and remove the chain from the VVT gear.
E. Remove the VVT gear from the cam housing.
F. Tie the timing chain to ensure it stays properly aligned with the exhaust and crankshaft timing gear pulleys.







6. Install the intake side VVT gear.
A. Transfer the paint marks from the old gear to the new gear.







B. Confirm the new gear is in the unlocked position prior to installation.

NOTE:
The camshaft timing gear MUST be in the unlocked position when installing on the camshaft to prevent damage to the lock pin during tightening. Please see step E for instructions to unlock the camshaft timing gear.

C. Remove the tie from the timing chain.







D. Insert the tool from the service hole and install the bolt of the intake VVT gear.

NOTICE:
Make sure NOT to lock the camshaft timing gear. If the camshaft timing gear is locked, release the lock according to the following procedure (step E).

E. Inspect the camshaft timing gear lock.
If the camshaft timing gear is locked, release the lock according to the following procedure.







(1). After cleaning and degreasing the intake side VVT oil hole on the No. 1 camshaft bearing cap, completely seal the oil hole with adhesive tape or equivalent as shown in Figure 12 to prevent air from leaking.

NOTICE:
Be sure to seal the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.

(2). Make a hole in the adhesive tape covering the oil hole as shown in Figure 12.







(3). Apply approximately 200 kPa (2.0 kgf/cm2, 29 psi) of air pressure to the hole made in the preceding step, then forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).

CAUTION:
Cover the oil passages with a piece of cloth when applying pressure to keep oil from splashing.

NOTICE:
- If air leaks out, reattach the adhesive tape.
- Do NOT allow the camshaft timing gear assembly to lock. If it locks, release the lock pin again.

HINT:
- The camshaft timing gear assembly may be turned in the advance direction without applying any force.
- If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.

(4). Remove the adhesive tape on the VVT hole.

F. Tighten the bolt of the intake VVT gear.
Torque: 85 N-m (867 kgf-cm, 63 ft-lbf)

G. Lock the gear by rotating the camshaft timing gear assembly clockwise.







7. Install the service hole plug with a new gasket.
Torque: 30 N-m (306 kgf-cm, 22 ft-lbf)







8. For Camry ONLY:
Install the No. 2 timing chain cover with the 2 bolts.
Torque: 10 N-m (102 kgf-cm, 7 ft-lbf)







9. Install the timing chain guide with the bolt.
Torque: 21 N-m (214 kgf-cm, 15 ft-lbf)







10. Install the chain to the VVT gear.

NOTICE:
Align the marks that were placed on the gears and chain.

11. Install the chain tensioner.







A. Install the chain tensioner to the service hole.
Torque: 10 N-m (102 kgf-cm, 7 ft-lbf)

B. When installing the tensioner, pull out the pin and release the tensioner.
C. Install the timing chain cover plate.
Install a new gasket and the timing chain cover plate with the 4 bolts.
Torque: 10 N-m (102 kgf-cm, 7 ft-lbf)

12. Install the cylinder head cover sub-assembly.
A. Apply a light coat of engine oil to 3 new gaskets.







B. Install the 3 gaskets to the camshaft bearing caps.
C. Install a new gasket to the cylinder head cover.

NOTICE:
Remove any oil from the contact surface.







D. Apply FIPG sealant as shown in Figure 20.
FIPG Sealant: Three Bond 1281, or equivalent
Standard Seal Diameter: 3.0 to 6.0 mm (0.118 to 0.236 in.)
Application Width A: 5.0 mm (0.197 in.)

NOTICE:
- Remove any oil from the contact surface.
- Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying FIPG sealant.







E. Align the cylinder head cover with pin A. Then align the cylinder head cover with pin B and install the cylinder head cover.
F. Install the 16 bolts and then tighten the bolts in the order shown in Figure 21.
Torque: 12 N-m (122 kgf-cm, 9 ft-lbf)

NOTICE:
Do NOT apply oil for at least 4 hours after the installation.

13. Confirm the repair.

NOTE:
Issue of this Technical Service Bulletin is to ensure that proper repair information is available. IT DOES NOT CONSTITUTE AN AUTHORIZATION FOR REPAIR. Normal provisions of the formal warranty policy, as applicable, will apply.