CAM chain tensioner install problem

Tiny
PATOS
  • MEMBER
  • 2004 TOYOTA MATRIX
  • 1.8L
  • 4 CYL
  • 2WD
  • AUTOMATIC
  • 134,000 MILES
Trying to install cam chain tensioner but when I insert it into place the hook keeps disengaging on the tensioner causing the plunger to extend out and prevents the tensioner from being pushed in any further to seat it. I've reset the tensioner and hook 7 times, because the manual says reset the tensioner and hook if it releases too soon, but I don't think try 8, 9, 10, 11+ will be any different unless something changes. Cylinder 1 is TDC, all timing marks were lined up on the money, two yellow chain links on the cam sprockets are on their marks, the one yellow link at the bottom is spot on the timing mark of the crankshaft sprocket, key-way on crank is at 12 o'clock. Plastic cam chain guides went on without a problem, new timing cover oil seal, Toyota foip red gasket maker on the timing cover, tightened bolts and torqued to specs. Next step is to install cam chain tensioner and where I run into the snag. Seems like I'm getting resistance too soon when inserting the tensioner, and that would be coming from the plastic cam chain guide on the left side. Do I need to take up a little slack on the left cam chain guide by pulling it closer to the slipper guide on the right, thus allowing the cam chain tensioner more clearance to slide in before it contacts the plastic chain guide? Is there another technique used to create some slack to be able to insert the tensioner deeper, such as rotating/rocking the crankshaft 1-2 degrees clock or counter clockwise? The manual states do not rotate the engine with the tensioner out but I wondered if it's acceptable to rotate ever so slightly if one encounters this issue? I will open the timing gear cover back up if no one can offer a tip or solution but I wanted to get others advice first. Thanks
Saturday, May 25th, 2019 AT 2:16 PM

6 Replies

Tiny
SCGRANTURISMO
  • MECHANIC
  • 4,897 POSTS
Hello,

I'm not sure if this is the same information you have or not but I have included what I've got on installing the timing chain tensioners in the diagrams down below. Please go through this guide and get back to us with what you find out.

Thanks,
Alex
2CarPros
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Saturday, May 25th, 2019 AT 5:20 PM
Tiny
PATOS
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Hi Alex, thanks for the reply. Yes, that is exactly what I have. No matter how many times I reset the tensioner it always releases before I get it seated even half way into position. From videos I've watched it should slide in about 90% of the way pretty easy and the last 10% needs a good firm push to seat the o-ring and tensioner the final bit.
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Saturday, May 25th, 2019 AT 7:27 PM
Tiny
SCGRANTURISMO
  • MECHANIC
  • 4,897 POSTS
Hello again,

Okay, I have never done this on a PT Cruiser before, before, but there has to be some way to give yourself some slack in the chain without moving your timing marks. Maybe you could stick a paperclip or something small in the lock to hold it in place and keep from coming open prematurely. It would have to easily removed once the tensioner was in place, though. Please keep us informed, we want to hear how you finally get it.

Thanks,
Alex
2CarPros
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Saturday, May 25th, 2019 AT 7:52 PM
Tiny
PATOS
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  • 6 POSTS
I'm not sure how I could get something wedged in there to keep it from releasing too soon. I have to be missing something because the manual gives clear directions and should not need any gadget tricks. I think I will go ahead and pull the cover off again tomorrow and recheck all my timing marks. I will make a dry run and install the timing cover with a few bolts snugged down then try inserting the cam chain tensioner and make sure it seats completely before I reapply fip gasket sealer and torque down all the timing cover bolts. I'll let you know what I find. Thanks for the help. Btw, it's a Toyota matrix 1.8L 1zzfe engine.
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Saturday, May 25th, 2019 AT 8:40 PM
Tiny
PATOS
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  • 6 POSTS
Hey Alex. I pulled the timing cover. All timing marks were set correct except the crankshaft had a mark above the key-way which the manual did not mention, it only says may sure the key-way is in the up position, which I took as 12 o'clock. The key-way was just a tick off with the mark above so I rotated the shaft 358-359 degrees and lined the key-way with the mark above, reset all other timing marks, did a dry run assemble and installed the cam chain tensioner, slid right in no problem. Thanks for the help.
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Tuesday, May 28th, 2019 AT 5:03 PM
Tiny
STEVE W.
  • MECHANIC
  • 12,940 POSTS
I've fought with those tensioners a few times when they want to release. If you look the hook on them isn't very large so it falls with very little movement. I take a pair of nippers and bend the tip of the hook just a bit to make it lock a little better. Just a tip if you need to do one again.
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Friday, May 31st, 2019 AT 9:25 PM

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