Engine - Knock/Rattle On Cold Start Up
S-SB-0010-13
February 28, 2013
Brief Engine Knock/Rattle Noise at Cold Startup
Service Category
Engine/Hybrid System
Section
Engine Mechanical
Market
USA
Applicability
Introduction
Immediately following a cold soak startup some 2011 - 2012 model year vehicles equipped with the 2AR-FE engine may exhibit a brief knock/rattle noise from the engine compartment for approximately one second. Follow the repair procedure below to address this condition.
Production Change Information
This bulletin applies to vehicles produced BEFORE the Production Change Effective VIN shown.
Warranty Information
Parts Information
Required Tools & Equipment
Repair Procedure
1. Confirm the brief knock/rattle noise condition. See 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. Remove the service hole plug.
B. Insert the tool through the service hole and remove the bolt of the intake VVT gear while holding the camshaft stationary with a wrench.
C. After the VVT gear is slid in the arrow direction as shown in Figure 7 lower the VVT gear and remove the chain from the VVT gear.
D. Remove the VVT gear from the cam housing.
E. 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.
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.
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 11 to prevent air from leaking.
(2) Make a hole in the adhesive tape covering the oil hole as shown in Figure 11.
(3) Apply approximately 200 kPa (2.0 kgflcm2 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).
(4) Remove the adhesive tape on the VVT hole.
F. Tighten the bolt of the intake VVT gear.
Torque: 85 N*m (867 kg*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. Install the chain to the VVT gear.
9. Install the timing chain guide with the bolt.
Torque: 21 N*m (214 kgf*cm, 15 ft*lbf)
10. Install the chain tensioner.
A. Install a new gasket and 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)
11. 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 18.
FIPG Sealant: Three Bond 1207B, 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.)
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 19.
Torque: 12 N*m (122 kgf*cm, 9 ft*lbf)
NOTICE
Do NOT apply oil for at least 4 hours after the installation.
12. Confirm the repair.
© 2013 Toyota Motor Sales, USA