Engine - Brief Rattle/Knock On Cold Start Up

T-SB-0087-09

Rev1

March 13, 2009

Brief Engine Knock/Rattle Noise at Cold Startup

Service Category
Engine/Hybrid System

Section
Engine Mechanical

Market
USA





Applicability

TSB REVISION NOTICE

^ September 22, 2009 Rev1:

^ 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 this condition.

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

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





Required Tools & Equipment

Repair Procedure

Confirm the customer complaint. See video for an example of the engine knock/rattle noise: Engine Knock/Rattle Noise Example

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 the 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 Technical Information System (TIS) applicable model and model year Repair Manual:

2. Confirm the repair.