Toyota Technical Service Bulletin T-SB-0094-09
Date: March 19, 2009
Subject: 2GR-FE Engine Ticking Noise and / or MIL ON P0014, P0015, P0024, P0025, P0017, or P0018
Service Information
Category: Engine/Hybrid System
Section: Engine Mechanical
Market: USA
Toyota Supports ASE Certification ®
Applicability
| YEAR(S) | MODEL(S) | ADDITIONAL INFORMATION |
|---|---|---|
| 2005-2009 | Avalon | |
| 2007-2009 | Camry | VDS(s): BK46K |
| 2008-2009 | Highlander | |
| 2006-2009 | RAV4 | Engine(s): 2GR VDS(s): BK31V, BK32V, BK33V, BK34V, BK35V, ZK31V, ZK32V, ZK33V, ZK34V, ZK35V |
| 2007-2009 | Sienna |
Introduction
Some 2005 – 2009 model year vehicles with 2GR-FE engines may exhibit a ticking/clicking type noise from the cylinder head cover area which may be accompanied by a MIL “ON” and one or more VVT-i related Diagnostic Trouble Codes (DTCs). Please use the following repair procedure to address customer concerns.
Warranty Information
| MODEL | OP CODE | DESCRIPTION | DRIVE-TRAIN | TIME | OFP | T1 | T2 |
|---|---|---|---|---|---|---|---|
| Avalon | 2WD | 16 | |||||
| Camry | 2WD | 14.3 | |||||
| Highlander | EG8053 | R & R Exhaust VVT-I Gear, Camshaft, Camshaft Housing | AWD | 17.1 | |||
| RAV4 | 2WD | 15.4 | |||||
| Sienna | AWD | 16 | |||||
| 2WD | 14.1 | 13080-31030 13080-0P020 |
91 | 99 | |||
| AWD | 14.3 | ||||||
| - | Combo A | Add R & R Intake VVT-I Gear | - | .2 | |||
| - | Combo B | Add R & R Exhaust VVT-I Gear, Camshaft & Camshaft Housing (Opposite Bank) | - | 1.2 | |||
| - | Combo C | Add R & R Exhaust & Intake VVT-I Gear, Camshaft, & Camshaft Housing (Opposite Bank) | - | 1.4 |
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.
Parts Information
| PREVIOUS PART NUMBER | CURRENT PART NUMBER | PART NAME | QUANTITY | ||
|---|---|---|---|---|---|
| BANK 1 REPAIR ONLY | BANK 2 REPAIR ONLY | BOTH BANKS REPAIR | |||
| 11103-3102# 11103-0P014 |
11103-0P021 | Housing Sub-assembly, Camshaft, RH | 1 | 0 | 1 |
| 13502-31040 13502-0P020 |
13502-0P021 | Camshaft Sub-assembly No.2 | 1 | 0 | 1 |
| 11104-3102# 11104-0P010 |
11104-0P011 | Housing Sub-assembly, Camshaft, LH | 0 | 1 | 1 |
| 13054-31030 13054-0P020 |
13054-0P021 | Camshaft Sub-assembly No.4 | 0 | 1 | 1 |
| 13080-31030 13080-0P020 |
13080-0P040 | Gear Assembly, Camshaft Timing, Exhaust, LH | 1 | 1 | 2 |
| 13050-0P### 13050-31### |
13050-0P070 | Gear Assembly, Camshaft Timing | 1* | 1* | 2* |
| 17176-0P020 | Same | Gasket, Air Surge Tank to Intake Manifold | 3 | 3 | 3 |
| 17177-0P020 | Same | Gasket, Intake Manifold to Head, No.1 | 1 | 1 | 1 |
| 17178-0P020 | Same | Gasket, Intake Manifold to Head, No.2 | 1 | 1 | 1 |
| 11159-0P010 | Same | Gasket, Camshaft Bearing Cap Oil Hole | 4 | 4 | 4 |
| 90430-A0001 | Same | O-ring (standard part) | 2 | 2 | 2 |
| 90430-12031 | Same | Gasket, Oil Pan Drain Plug | 1 | 1 | 1 |
| 15147-0P020 | Same | Gasket, Oil Strainer | 1 | 1 | 1 |
| 12151-0P010 | Same | Gasket, Oil Pan | 2 | 2 | 2 |
| 96721-19010 | Same | O-ring, for Oil Level Gauge Guide, No. 2 | 1 | 1 | 1 |
| 90301-12018 | Same | O-ring, for Oil Level Gauge Guide | 1 | 1 | 1 |
| 15193-0P010 | Same | Gasket Oil Pump | 1 | 1 | 1 |
| 11213-0P010 | Same | Gasket, Cylinder Head Cover | 1 | 1 | 1 |
| 11214-0P040 | Same | Gasket, Cylinder Head Cover No. 2 | 1 | 1 | 1 |
| 90430-16016 | Same | Gasket, Oil Pipe No. 2 | 2 | 2 | 2 |
| 90430-16012 | 90430-16017 | Gasket, Oil Pipe No. 1 | 4 | 4 | 4 |
| 90311-A0005 | Same | Seal, Oil, for Timing Gear Case | 1 | 1 | 1 |
| 11328-0P010 | Same | Gasket, Timing Gear Cover | 1 | 1 | 1 |
| 96761-24021 | Same | O-ring (standard part), Coolant Pipe | 1 | 1 | 1 |
| 90301-79006 | Same | O-ring (for Oil Filter Cap) | 1 | 1 | 1 |
| 96723-35028 | Same | O-ring (for Oil Filter Cap Drain Plug) | 1 | 1 | 1 |
| 16325-31010 | Same | Gasket, Water Inlet Housing No. 2 | 1 | 1 | 1 |
| 90080-43036 | Same | Gasket, Exhaust Pipe | 1 | 1 | 1 |
| 04152-31090 | 04152-YZZA1 | Element Kit, Oil Filter | 1 | 1 | 1 |
| 16271-0P010 | Same | Gasket, Water Pump | 1 | 1 | 1 |
* Part may not be needed based on inspection.
Required Tools & Equipment
| REQUIRED MATERIAL | PART NUMBER | QTY |
|---|---|---|
| Three Bond 1324 or Equivalent | - | As Needed |
| FIPG Sealant or Equivalent | 08826-00080 | As Needed |
| Toyota Genuine Seal Packing Black, Three Bond 1207B, or Equivalent | - | As Needed |
| Toyota Genuine Seal Packing Black, Three Bond 1282B, or Equivalent | - | As Needed |
| Toyota Genuine Adhesive 1344, Three Bond 1344, or Equivalent | - | As Needed |
| ILSAC GF-4 Multi-grade SAE 5W-30 | 00279-1QT5W-01 | 6.0 U.S. qts. (5.7 liters) |
| Super Long Life Coolant (SLLC) | 00272-SLLC2 | 9.5 U.S. qts. (9.0 liters) |
| Oil Filter Wrench* | 09228-06500-02 | 1 |
| Companion Flange Holding Tool* | 09330-00021 | 1 |
| Universal Puller Set "C" | 09950-50013-01 | 1 |
| Gasket Seal Cutter* | 09032-00100 | 1 |
* Essential SST.
NOTE: Additional SSTs may be ordered by calling 1-800-933-8335.
Required Equipment:
| REQUIRED EQUIPMENT | SUPPLIER | PART NUMBER | QTY |
|---|---|---|---|
| R134-a Refrigerant Recovery/Recycling Machine | ADE | Robinair ROB34200* (or equivalent) | 1 |
NOTE: Additional refrigerant service equipment may be ordered by calling Toyota Approved Dealer Equipment (ADE) at 1-800-368-6787.
Inspection Procedure
- Start the engine and listen for any ticking/clicking type noises coming from the VVT-i gear area of the engine.
- Remove the cylinder head cover and inspect the Exhaust VVT-i Gear Assembly on the affected cylinder bank.
NOTE: This condition may or may not be accompanied by one or more of the following DTCs stored in the Engine Control Module (ECM) (SAE term: Powertrain Control Module/PCM).
- A. P0014: Camshaft Position “B” – Timing Advanced or System Performance (Bank 1)
- B. P0015: Camshaft Position “B” Timing Over Retarded (Bank 1)
- C. P0017: Crankshaft Position Camshaft Position Correlation (Bank 1 Sensor B)
- D. P0018: Crankshaft Position Camshaft Position Correlation (Bank 2 Sensor A)
- E. P0024: Camshaft Position “B” – Timing Over-Advanced or System Performance (Bank 2)
- F. P0025: Camshaft Position “B” – Timing Over-Retarded (Bank 2)
NOTE: If no concerns are found with the VVT-i gear actuator bolts, the actuator center section alignment or actuator body this TSB does NOT apply. Refer to Repair Manual procedures for further diagnosis.
Repair Procedure
- If any concerns are noted with the exhaust VVT-i gear bolts or actuator follow the four steps below:
- Replace the camshaft housing sub-assembly, exhaust camshaft, and exhaust VVT-i gear assembly on the affected bank.
- Inspect the intake VVT-i gear assembly and bolts on the affected bank. Replace the intake VVT-i gear assembly if necessary.
- Inspect the opposite bank exhaust VVT-i gear actuator and bolts. If any concerns are noted replace the opposite bank camshaft housing sub-assembly, exhaust camshaft, and exhaust VVT-i gear assembly.
- Inspect the opposite bank intake gear actuator assembly and bolts. Replace the intake VVT-i gear assembly if necessary.
- Start engine and test drive to verify the repair.
For complete disassembly procedures refer to the Technical Information System (TIS), applicable model and model year Repair Manual:
- 2005 model year Avalon Repair Manual, Engine/Hybrid System,“Engine Mechanical: Camshaft (LH Bank) 2GR-FE : Replacement"
- 2005 model year Avalon Repair Manual, Engine/Hybrid System,“Engine Mechanical: Camshaft Camshaft (RH Bank) 2GR-FE : Replacement”
- 2007/2008/2009 model year Avalon Repair Manual, Engine/Hybrid System,“2GR-FE Engine Mechanical: Engine Unit: Disassembly”
- 2007/2008/2009 model year Camry Repair Manual, Engine/Hybrid System, “2GR-FE Engine Mechanical: Engine Unit: Disassembly”
- 2008/2009 model year Highlander Repair Manual, Engine/Hybrid System, “2GR-FE Engine Mechanical: Engine Unit: Disassembly”
- 2006/2007/2008/2009 model year RAV4 Repair Manual, Engine/Hybrid System, “2GR-FE Engine Mechanical: Engine Unit: Disassembly”
- 2007/2008/2009 model year Sienna Repair Manual, Engine/Hybrid System, “2GR-FE Engine Mechanical: Engine Unit: Disassembly”
For complete reassembly procedures refer to the TIS, if applicable etc.
- 2007/2008/2009 model year Avalon Repair Manual, Engine/Hybrid System, “2GR-FE Engine Mechanical: Engine Unit: Reassembly"
- 2007/2008/2009 model year Camry Repair Manual, Engine/Hybrid System, “2GR-FE Engine Mechanical: Engine Unit: Reassembly”
- 2008/2009 model year Highlander Repair Manual, Engine/Hybrid System, “2GR-FE Engine Mechanical: Engine Unit: Reassembly”
- 2006/2007/2008/2009 model year RAV4 Repair Manual, Engine/Hybrid System, “2GR-FE Engine Mechanical: Engine Unit: Reassembly”
- 2007/2008/2009 model year Sienna Repair Manual, Engine/Hybrid System, “2GR-FE Engine Mechanical: Engine Unit: Reassembly”
