Engine - Brief Knock/Rattle On Cold Start Up

T-SB-0087-09

March 13, 2009

Brief Engine Knock/Rattle Noise at Cold Startup

Service Category
Engine/Hybrid System

Section
Engine Mechanical

Market
USA





Applicability

Introduction

Immediately following a cold soak startup some 2009 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.





Parts Information





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 correction of a problem based upon a customer's specific complaint.





Required Tools & Equipment

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 Technical Information System (TIS) 2009 model year Corolla or Matrix Repair Manual:

^ 2009 Corolla / Matrix:
Engine/Hybrid System - Engine Mechanical - "2ZR-FE Engine Mechanical: Timing Gear: Removal"

^ 2009 Corolla / Matrix:
Engine/Hybrid System - Engine Mechanical - "2ZR-FE Engine Mechanical: Timing Gear: Installation"

^ 2009 Corolla / Matrix:
Engine/Hybrid System - Engine Mechanical - "2ZR-FE Engine Mechanical: Engine Unit: Disassembly"

^ 2009 Corolla / Matrix:
Engine/Hybrid System - Engine Mechanical - "2ZR-FE Engine Mechanical: Engine Unit: Reassembly"

2. Confirm the repair.