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 Figure 9.
position prior to installation.

NOTICE

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.

1 | Advanced (Unlocked) Position
Retarded (Locked) Position
Knock Pin Hole

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Alignment Mark

C. Remove the tie from the timing chain.

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Brief Engine Knock/Rattle Noise at Cold Startup

Repair Procedure (Continued)

D. Insert the tool from the service hole and install Figure 10.
the bolt of the intake VVT gear.

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 Figure 11.
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.

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 | Make a Hole in Adhesive Tape

(2) Make a hole in the adhesive tape covering the oil hole as shown in Figure 11.

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Brief Engine Knock/Rattle Noise at Cold Startup

Repair Procedure (Continued)

(3) Apply approximately 200 kPa Figure 12.
(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).

CAUTION
Cover the oil passages with a piece of

cloth when applying pressure to keep
oil from splashing.

NOTICE

adhesive tape.

* 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.

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Brief Engine Knock/Rattle Noise at Cold Startup

Repair Procedure (Continued)

7. Install the service hole plug with a new gasket. Figure 13.
Torque: 30 N*m (306 kgf*cm, 22 ft*lbf)

[ + | service Hole Plug

8. Install the chain to the VVT gear. Figure 14.

NOTICE

Align the marks that were placed on the gears
and chain.

1 Paint Marks

2 | Timing Marks

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Brief Engine Knock/Rattle Noise at Cold Startup

Repair Procedure (Continued)

9. Install the timing chain guide with the bolt. Figure 15.
Torque: 21 N*m (214 kgf*cm, 15 ft*Ibf)

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*Ibf)

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*Ibf)

Stopper Plate

Ry

Timing Tensioner

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Brief Engine Knock/Rattle Noise at Cold Startup

Page 12 of 14

Repair Procedure (Continued)
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 Figure 17

caps.

C. Install a new gasket to the cylinder head cover.

NOTICE
Remove any oil from the contact surface.

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Brief Engine Knock/Rattle Noise at Cold Startup

Page 13 of 14

Repair Procedure (Continued)

D. Apply FIPG sealant as shown in Figure 18. 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.)

NOTICE

* Remove any oil from the contact
surface.

* Install the cylinder head cover within
3 minutes and tighten the bolts within
15 minutes after applying FIPG sealant.

FIPG Sealant

Timing Chain Cover

Camshaft Housing

3.0 to 6.0 mm

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Application Width “A”

© 2013 Toyota Motor Sales, USA