Canada - Engine - Brief Rattle/Knock On Cold Start Up

Bulletin
3148R

Issue Date
March 27, 2009

Market
Canada

Title:
BRIEF ENGINE KNOCK/RATTLE NOISE AT COLD STARTUP

Component
ENGINE MECHANICAL

Models
'09 - '10 Corolla; Matrix

TSB REVISION NOTICE
- August 6, 2010: Applicability has been updated to include 2010 model year Corolla and Matrix vehicles.
- Production Change Information with VIN breaks has been added.
- Parts Information has been updated (Camshaft Timing Gear Assembly).

Any previous printed versions of this service bulletin should be discarded.

INTRODUCTION:
Immediately following a cold soak startup, some 2009 - 2010 model year Corolla and Matrix vehicles may exhibit a brief knock/rattle noise from the engine compartment for approximately one second. Follow the repair procedure below to address customer concerns.







APPLICABILITY:

PRODUCTION CHANGE INFORMATION:







This TSB applies to ALL 2009 - 2010 Japan-built Corolla vehicles and to North American vehicles produced BEFORE the Production Change Effective VINs shown.







WARRANTY INFORMATION:







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.







REQUIRED MATERIAL:

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

1. If a knock/rattle noise is present, replace the camshaft timing gear assembly.

HINT
This repair is simplified by performing the following:
- DO NOT remove the engine - complete repair in the vehicle.
- Set No. 1 cylinder to TDC/compression.
- DO NOT remove the timing cover or camshaft housing sub-assembly.
- Loosen and remove all camshaft bearing caps. Remove the No. 1 camshaft bearing cap and No. 2 timing chain vibration damper as an assembly - DO NOT separate.
- Remove the intake camshaft with the camshaft gear intact and tie the timing chain to keep tension on the crankshaft timing gear, avoiding separation.
- Ensure the new camshaft gear is unlocked (advanced position) prior to installation and lock the gear (fully retarded position) AFTER tightening to proper torque.

Refer to the Repair Manual within E-TAS / TIS library:
- Division: Toyota
- Model: Corolla/ Matrix
- Year: 2009/ 2010
- Service Category: Engine/Hybrid System
- Section: Engine Mechanical
- Keyword: 2ZR-FE Engine Mechanical: Timing Gear: Removal
- Keyword: 2ZR-FE Engine Mechanical: Timing Gear: Installation

- Division: Toyota
- Model: Corolla/ Matrix
- Year: 2009/ 2010
- Service Category: Engine/Hybrid System
- Section: Engine Mechanical
- Keyword: 2ZR-FE Engine Mechanical: Engine Unit: Disassembly
- Keyword: 2ZR-FE Engine Mechanical: Engine Unit: Reassembly

2. 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.