T-SB-0041-13

@TOYOTA
T-SB-0041-13
Technical Service Bulletin
March 15, 2013
Brief Engine Knock/Rattle Noise at Cold Startup
(1AR/2AR)
Service
Category
Engine/Hybrid System
Section
Engine Mecha nical
Market
USA
Toyota Supports ~
ASE Certification ~
Applicability
YEAR(S)
MODEL(S)
ADDITIONAL INFORMATION
20 10 - 2012
Camry
VDS(s): BF1 FK, BF3EK
WMl(s): 4T1 , 4T4, JTN
2009 - 2013
Highlander
VDS(s): DA41A, ZA3EH
WM l(s): 5TD
2009 - 201 2
RAV4
VDS(s): BF31V, BF32V, BF33V, BF34V, BF35V,
BF4DV, BF9DV, DF4DV, DF9DV, EF4DV,JF4DV,
KF4DV , KF9DV,RF4DV , WF4DV,XF4DV,YF4DV,
YK9DV,ZF31V, ZF32V, ZF33V,ZF34V, ZF35V,
ZF4DV,ZF9DV
WM l(s): 2T3, JTM
201 1 - 2013
Sienna
VDS(s): KA3 DC
WMl(s): 5TD
2009 - 2013
Venza
VDS(s): BA3BB, BE 11 A, ZA3BB
WMl(s): 4T3
SUPERSESSION NOTICE
The information contained in this bulletin supersedes SB No. T-SB-0146-10 .
• Applicability has been updated to include 2012 - 2013 model year vehicles.
Service Bulletin No. T-SB-0146-10 is Obsolete and any printed versions should be discarded. Be
sure to review the entire content of this bulletin before proceeding.
Introduction
Immediately following a cold soak startup, some 2009 - 201 3 model year vehicles eq uipped w ith the
1AR-FE and 2AR-FE engines may exhibit a bri ef knock/rattle no ise from the e ngi ne compa rtment for
approximate ly one second. Fo llow the repair procedure below to add ress this condition.
© 2013 Toyota Motor Sales, USA
Page 1 of 16
@TOYOTA
T-S B-0041-13
Ma rch 15, 2013
Page 2 o f 16
Brief Engine Knock/Rattle Noise at Cold Startup (1AR/2AR)
Prod uction Change Information
This bulletin applies to :
•
A ll 20 10 - 201 2 MY T sutsumi produced Ca mry vehicles.
•
Vehicles produced BEFORE the Production C hange Effective VI Ns shown below.
MODEL
PLANT
DRIVETRAIN
PRODUCTION CHAN GE EFFECTIVE VIN
TMMK Line 1
Camry
TMMK Line 2
SIA
Highlander
4T1BF1FK#CU631600
2WO
4T4BF1FK#CR267530
5TDKA3DC#DS016895
TMM I
Shokki
RAV4
4T1BF1FK#CU193768
Tahara
TMMC
Sienna
TMMI
Venza
TM MK
2WD
JTMZF4DV#BD031671
4WD
JTMBF4DV#BD043071
2WD
JTMWF4DV#B5042326
4WO
JTMRF4DV#B50487 12
2WD
2T3YF4DV#CW 153020
4WD
2T3BF4DV#CW264373
2WD
5TDZA3EH#DS035562
2WD
4T3ZA3BB#DU070721
4WD
4T3BA3BB#DU039056
Warranty Information
OP CODE
140021
DESCRIPTION
R & R Camshaft Timing
Gear Assembly
MODEL
MODEL YEAR
TIME
Camry
2010 - 2012
2.6
Highlander
2009 - 2013
2.6
RAV4
2009 - 2012
2.4
Sienna
20 11 - 2013
2.8
Venza
2009 - 2013
2.7
OFP
T1
T2
13050-0V010
06
40
APPLICABLE WARRANTY
• This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60
months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
• Warranty application is limited to oc currence of the specified c ondition described in this
bulletin .
© 201 3 Toyota Motor Sales, USA
@TOYOTA
March 15, 2013
T-SB-0041-13
Page 3 of 16
Brief Engine Knock/Rattle Noise at Cold Startup (1AR/2AR)
Parts Information
MODEL
PREVIOUS PART
NUMBER
CURRENT PART
NUMBER
PART NAME
Camry
Highlander
RAV4
{from April '1 1)
Sienna
13050-0V010
13050-0V011
13050-36010
13050-3601 1
13050-0V030
13050-0V040
Gear Assembly, Camshaft Timing
Venza
RAV4
(from '09 MY until
end of March '11)
ALL
QTY
- 11
1
-1
-1
-
13050-0V010
13050-360 10
13050-3601 1
13050-0VO 11
11213-36020
Same
Gasket, Cylinder Head Cover
1
111 59-36010
11159-3601 1
111 59-0V010
111 59-0V011
Gasket, Camshaft Bearing Cap
Oil Hole No. 1
2
90430-10024
90430-A000 1
Gasket, Camshaft Bearing Cap
Oil Hole No. 2
1
11328-36020
11328-0V010
Gasket, Timing Chain Tensioner
1
11 329-36010
Same
Gasket, Timing Chain Cover, No. 2
1
13552-36010
13552-0V010
Gasket (for Chain Tensioner)
1
© 2013 Toyota Motor Sales, USA
1
@TOYOTA
T-SB-0041-13
March 15, 2013
Page 4of16
Brief Engine Knock/Rattle Noise at Cold Startup (1AR/2AR)
Required Tools & Equipment
REQUIRED EQUIPMENT
SUPPLIER
Techstream 2.0*
TIS Techstream
PART NUMBER
QTY
TS2UNIT
ADE
Techstream Lite
TSPKG1
1
TSLITEDLR01
SPECIAL SERVICE TOOLS (SST)
PART NUMBER
QTY
Torque Wrench Adapter*
09249-63010-01
1
REQUIRED MATERIALS
QTY
FIPG Sealant: Three Bond 12078 , or Equivalent
As Needed
NOTE
• Only ONE of the Techstream units listed above is required.
• Software version 8.00.034 or later is required .
• Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE) at
1-800-368-6787.
• Additional SSTs may be ordered by calling 1-800-933-8335.
• Essential SST.
© 2013 Toyota Motor Sales, USA
@TOYOTA
T-SB-0041-13
March 15, 2013
Page 5of16
Brief Engine Knock/Rattle Noise at Cold Startup (1AR/2AR)
Repair Procedure
1. Confirm the brief knock/rattle noise condition. See attached video for an ex ample of the engine
knock/rattle noise:
Eng ine Knock/Rattle Noise Example (1AR/2AR)
2. Remove the cylinder head cover.
Fig ure 1.
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
gea r, place paint marks on the chain and both
gea rs.
Figu re 2.
~--------------~
1
2
© 2013 Toyota Motor Sales, USA
I
P•iot M"''
Timi ng Marks
@TOYOTA
March 15, 2013
T-SB-0041-13
Page 6 of 16
Brief Engine Knock/Rattle Noise at Cold Startup (1AR/2AR)
Repair Procedure (Continued)
F. Rotate the crankshaft counterclockwise by 10° and loosen the tension of the chain .
G. Remove the timing chain cover plate.
H. Al ign the holes of the stopper plate and
tensioner, and insert a pin into the stopper
plate hole to lock the tensioner.
Figure 3.
1
Stopper Plate
2
Timing Tensioner
I. Remove the 2 bolts and chain tensioner.
4 . Remove the timing chain guide by removing the
bolt.
Figure 4.
~--------------~
© 2013 Toyota Motor Sales, USA
@TOYOTA
T-SB-0041-13
March 15, 2013
Brief Engine Knock/Rattle Noise at Cold Startup (1AR/2AR)
Repair Procedure (Continued)
5. Remove t he intake side W T gear.
A. For Camry ONLY:
Remove the 2 bolts and the No. 2 timing
chain cover.
Figure 5.
B. Remove the service hole plug.
Figure 6.
1
© 2013 Toyota Motor Sales, USA
I
Service Hole Plug
Page 7 of 16
@TOYOTA
T-SB-0041-13
March 15, 2013
Page 8 of 16
Brief Engine Knock/Rattle Noise at Cold Startup (1AR/2AR)
Repair Procedure (Continued)
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.
Figure 1.
~--------------~
NOTICE
•
Be careful NOT to damage the cylinder
head or spark plug tube with the
wrench.
•
Do NOT disassemble the cam s haft
timing gear.
D. After the VVT gear is slid in the arrow direction
as shown in Figure 8, lower the WT gea r and
remove the chain from the VVT gear.
Figure
a.
~--------------~
© 2013 Toyota Motor Sales, USA
@TOYOTA
T-SB-0041-13
March 15, 2013
Page 9 of 16
Brief Engine Knock/Rattle Noise at Cold Startup (1AR/2AR)
Repair Procedure (Continued)
E. Remove the W T gear from the cam housing.
F. Tie the timing chain to ensure it stays properly aligned w ith the exhaust and crankshaft
timing gear pulleys.
NOTICE
The WT gear bolts may interfere with the
housing during remova l. After the WT
gear slides out from the camshaft, carefully
Figure 9.
~--------------~
rotate the WT gear to the position shown in
Figure 9 to avoid interference and remove
it in the arrow direction shown .
© 2013 Toyota Motor Sales, USA
@TOYOTA
T-SB-0041-13
March 15, 2013
Page 10 of 16
Brief Engine Knock/Rattle Noise at Cold Startup (1AR/2AR)
Repair Procedure (Continued)
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.
Figure 10.
©
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.
0
1
Advanced (Unlocked) Position
2
Retarded (L ocked) Position
3
Knock Pin Hole
4
A lignment Mark
C. Remove the tie from the timing chain.
© 2013 Toyota Motor Sales, USA
@TOYOTA
March 15, 2013
T-SB-0041-13
Page 11 of 16
Brief Engine Knock/Rattle Noise at Cold Startup (1AR/2AR)
Repair Procedure (Continued)
D. Insert the tool from the service hole and install
the bolt of the intake VVT gear.
Figu re 11.
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 sea l the oil hole
with adhesive tape or equivalent as
shown in Figure 12 to prevent air from
leaking.
Figure 12.
....---------------------.
NOTICE
Be sure to seal the oil hole completely
because air leaks due to insufficient
sealing will prevent the lock pin from
being released .
1
Adhesive Tape
2
Adhesive Tape Sealing Area
3
Poke a Hole
(2) Make a hole in the adhesive tape covering the oil hole as shown in Figure 12.
© 2013 Toyota Motor Sales, USA
@TOYOTA
T-SB-0041-13
March 15, 2013
Page 12 of 16
Brief Engine Knock/Rattle Noise at Cold Startup (1AR/2AR)
Repair Procedure (Continued)
(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).
Figure 13.
.--- - - - - - - - - - - - -------,
CAUTION
Cover the oil passages with a piece of
cloth when applying pres sure to keep
oil from splashing.
NOTIC E
• If air leaks out, reattach the
adhesive tape.
1
I
Co m pressed A ir
• 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) Re move the adhesive tape on the W T hole.
F. Tighten the bolt of the intake W T gear.
Torque: 85 N*m (867 kgf*cm , 63 ft*lbf)
G. Lock the gear by rotating the camshaft timing gear assembly clockwise.
© 2013 Toyota Motor Sales, USA
@TOYOTA
T-SB-0041-13
March 15, 2013
Brief Engine Knock/Rattle Noise at Cold Startup (1AR/2AR)
Repair Procedure (Continued)
7. Install the service hole plug with a new gasket.
Figure 14.
Torque: 30 N*m (306 kgf*cm, 22 ft*lbf)
1
8. For Camry ONLY:
I
Service Hole Plug
Figure 15.
Install the No. 2 timing chain cover with the
2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft*lbf)
9. Install the chain to the W T gear.
Figure 16.
NOTICE
Align the marks that w ere placed on the gears
and chain.
1
2
© 2013 Toyota Motor Sales, USA
I
P•lot M" ' '
Timing Marks
Page 13 of 16
@TOYOTA
March 15, 2013
T-SB-0041-13
Brief Engine Knock/Rattle Noise at Cold Startup (1AR/2AR)
Repair Procedu re (Continued)
10. Install the timing chain guide with the bolt.
Figure 17.
Torque: 21 N*m (214 kgf*cm , 15 ft*lbf)
11 . Install the chain tensioner.
Figure 18.
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 tim ing chain cover
plate with the 4 bolts.
Torque : 10 N*m (102 kgf*cm, 7 ft*lbf)
1
Stopper Plate
2
T imi ng Tensioner
12. Install the cylinder head cover sub-assembly.
A. Apply a light coat of engine oil to 3 new gaskets.
© 2013 Toyota Motor Sales, USA
Page 14 of 16
@TOYOTA
T-SB-0041-13
March 15, 2013
Brief Engine Knock/Rattle Noise at Cold Startup (1AR/2AR)
Repair Procedure (Continued)
B. Install the 3 gaskets to the camshaft bearing
caps.
Figure 19.
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.
Figure 20.
FIPG Sealant: Three Bond 12078, 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 wi thin
3 minutes and tighten the bolts within
15 minutes after applying FIPG sealant.
1
FIPG Sealant
2
Timing Chain Cover
3
Camshaft Housing
4
3.0 to 6.0 mm
A
Application Width "A"
© 2013 Toyota Motor Sales, USA
Page 15 of 16
@TOYOTA
T-SB-0041-13
March 15, 2013
Page 16 of 16
Brief Engine Knock/Rattle Noise at Cold Startup (1AR/2AR)
Repair Procedure (Continued)
E. Align the cylinder head cover with pin A.
Then align the cylinder head cover with pin B
and install the cylinder head cover.
Figure 21.
.-------- - - - - - - - - - - - - .
6
A
B
Ip;,
5, 18
17
A
Pin B
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.
© 2013 Toyota Motor Sales, USA