T-SB-0041-13 Rev

T-SB-0041-13
Rev1
March 15, 2013
Brief Engine Knock/Rattle Noise at Cold Startup
(1AR/2AR)
Service
Category
Engine/Hybrid System
Section
Engine Mechanical
Market
USA
Applicability
YEAR(S)
MODEL(S)
ADDITIONAL INFORMATION
2010 – 2012
Camry
VDS(s): BF1FK, BF3EK
WMI(s): 4T1, 4T4, JTN
2009 – 2013
Highlander
VDS(s): DA41A, ZA3EH
WMI(s): 5TD
2009 – 2012
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
WMI(s): 2T3, JTM
2011 – 2013
Sienna
VDS(s): KA3DC
WMI(s): 5TD
2009 – 2013
Venza
VDS(s): BA3BB, BE11A, ZA3BB
WMI(s): 4T3
REVISION NOTICE
October 24, 2013 Rev1:
• Warranty Information has been updated.
Any previous printed versions of this bulletin should be discarded.
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Service Bulletin No. T-SB-0146-10 is Obsolete and any printed versions should be discarded.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.
© 2013 Toyota Motor Sales, USA
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Brief Engine Knock/Rattle Noise at Cold Startup (1AR/2AR)
Introduction
Immediately following a cold soak startup, some 2009 – 2013 model year vehicles equipped with
1AR-FE or 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.
Production Change Information
This bulletin applies to:
• All 2010 – 2012 MY Tsutsumi produced Camry vehicles.
• Vehicles produced BEFORE the Production Change Effective VINs shown below.
MODEL
PLANT
DRIVETRAIN
PRODUCTION CHANGE EFFECTIVE VIN
TMMK Line 1
Camry
TMMK Line 2
SIA
Highlander
4T1BF1FK#CU631600
2WD
4T4BF1FK#CR267530
TMMI
Shokki
RAV4
4T1BF1FK#CU193768
Tahara
TMMC
Sienna
TMMI
Venza
TMMK
5TDKA3DC#DS016895
2WD
JTMZF4DV#BD031671
4WD
JTMBF4DV#BD043071
2WD
JTMWF4DV#B5042326
4WD
JTMRF4DV#B5048712
2WD
2T3YF4DV#CW153020
4WD
2T3BF4DV#CW264373
2WD
5TDZA3EH#DS035562
2WD
4T3ZA3BB#DU070721
4WD
4T3BA3BB#DU039056
Warranty Information
OP CODE
DESCRIPTION
MODEL YEAR
TIME
2010 – 2011
2.6
2012
2.2
Highlander
2009 – 2013
2.6
RAV4
2009 – 2012
2.4
Sienna
2011 – 2013
2.8
Venza
2009 – 2013
2.7
MODEL
Camry
140021
R & R Camshaft Timing
Gear Assembly
© 2013 Toyota Motor Sales, USA
OFP
T1
T2
13050-0V010
13050-0V011
13050-0V030
13050-36010
13050-36011
06
40
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Brief Engine Knock/Rattle Noise at Cold Startup (1AR/2AR)
Warranty Information (Continued)
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 occurrence of the specified condition described in this
bulletin.
Parts Information
PART NUMBER
PART NAME
MODEL
1
Camry
Highlander
RAV4
(from April ’11)
Sienna
13050-0V010
13050-0V011
13050-0V030
13050-36010
13050-36011
1
1
13050-0V040
Gear Assembly, Camshaft Timing
13050-0V010
13050-36010
13050-36011
1
13050-0V011
11213-36020
ALL
1
1
Venza
RAV4
(from ’09 MY until
end of March ’11)
QTY
NEW
PREVIOUS
Gasket, Cylinder Head Cover
1
11159-0V010
11159-36010
11159-36011
11159-0V011
Gasket, Camshaft Bearing Cap
Oil Hole No. 1
2
90430-10024
90430-A0001
Gasket, Camshaft Bearing Cap
Oil Hole No. 2
1
11328-36020
11328-0V010
Gasket, Timing Chain Tensioner
1
Gasket, Timing Chain Cover, No. 2
1
Gasket (for Chain Tensioner)
1
11329-36010
13552-36010
13552-0V010
© 2013 Toyota Motor Sales, USA
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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
1
TSPKG1
TSLITEDLR01
SPECIAL SERVICE TOOLS (SST)
PART NUMBER
QTY
Torque Wrench Adapter*
09249-63010-01
1
REQUIRED MATERIALS
QTY
FIPG Sealant: Three Bond 1207B, or Equivalent
As Needed
NOTE
• Only ONE of the Techstream units listed above is required.
• Software version 8.30.023 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
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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 example of the engine
knock/rattle noise:
Engine Knock/Rattle Noise Example (1AR/2AR)
2. Remove the cylinder head cover.
Figure 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
gear, place paint marks on the chain and
both gears.
Figure 2.
1
2
1
Paint Marks
2
Timing Marks
© 2013 Toyota Motor Sales, USA
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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. Align the holes of the stopper plate and
tensioner, and insert a pin into the stopper
plate hole to lock the tensioner.
Figure 3.
1
2
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
.
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Brief Engine Knock/Rattle Noise at Cold Startup (1AR/2AR)
Repair Procedure (Continued)
5. Remove the intake side VVT 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
1
© 2013 Toyota Motor Sales, USA
Service Hole Plug
T-SB-0041-13
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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 7.
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.
Figure 8.
© 2013 Toyota Motor Sales, USA
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Brief Engine Knock/Rattle Noise at Cold Startup (1AR/2AR)
Repair Procedure (Continued)
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.
NOTICE
The VVT gear bolts may interfere with the
housing during removal. After the VVT
gear slides out from the camshaft, carefully
rotate the VVT gear to the position shown in
Figure 9 to avoid interference and remove
it in the arrow direction shown.
Figure 9.
© 2013 Toyota Motor Sales, USA
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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.
1
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.
3
4
2
4
3
1
Advanced (Unlocked) Position
2
Retarded (Locked) Position
3
Knock Pin Hole
4
Alignment Mark
C. Remove the tie from the timing chain.
© 2013 Toyota Motor Sales, USA
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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.
Figure 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 seal the oil
hole with adhesive tape or equivalent
as shown in Figure 12 to prevent air
from leaking.
Figure 12.
2
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
3
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
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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.
1
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.
1
Compressed Air
• 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.
© 2013 Toyota Motor Sales, USA
T-SB-0041-13
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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
1
8. For Camry ONLY:
Install the No. 2 timing chain cover with the
2 bolts.
Service Hole Plug
Figure 15.
.
Figure 16.
.
Torque: 10 N*m (102 kgf*cm, 7 ft*lbf)
9. Install the chain to the VVT gear.
NOTICE
1
Align the marks that were placed on the gears
and chain.
2
1
Paint Marks
2
Timing Marks
© 2013 Toyota Motor Sales, USA
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Brief Engine Knock/Rattle Noise at Cold Startup (1AR/2AR)
Repair Procedure (Continued)
10. Install the timing chain guide with the bolt.
Figure 17.
.
Figure 18.
.
Torque: 21 N*m (214 kgf*cm, 15 ft*lbf)
11. Install the chain tensioner.
A. Install a new gasket and the chain tensioner
to the service hole.
1
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.
2
Torque: 10 N*m (102 kgf*cm, 7 ft*lbf)
1
Stopper Plate
2
Timing 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
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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 1207B, or equivalent
1
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.
1
• Install the cylinder head cover within
3 minutes and tighten the bolts within
15 minutes after applying FIPG sealant.
4
3
2
A
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
A
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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.
A
10
11
9
4, 12
13
14
2, 20
1, 19
3, 21
8
15
B
16
7
6
A
Pin A
B
Pin B
5, 18
17
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