2003 - 2008 Toyota Matrix Corolla 1ZZ-FE Timing Chain Tensioner DIY using the Toyota FSM Technique

This video shows the Toyota FSM technique for replacing the Timing Chain Tensioner (and O-ring) on late 1ZZ-FE engines ('03 - '08 Corolla and Matrix). This technique is the most conservative and "fool-proof" method for this repair and requires removing the Valve Cover, which is shown in the video. Check the Pinned Comment or below for more info:

Timestamps, Part numbers, Torque values:
00:27 Timing Chain Tensioner location and oil leak pattern
01:27 Explanation about the variety of methods for this repair
04:19 Why the Tensioner must be extended properly
05:03 Why some mechanics charge for a Valve Cover job with this repair
05:41 Differences in this video versus some other videos (FSM technique)

09:03 Begin Removal of the Valve Cover, make a bolt template
10:37 Disconnect the electrical connectors for the ignitors
11:48 Remove two fasteners for the electrical harness (10mm)
12:18 Remove four bolts for the ignitors (10mm)
12:39 Remove the ignitors
13:35 Disconnect the breather hose
14:04 Disconnect the hose to the PCV valve
14:44 Locations of the Valve Cover fasteners (ten 10mm, one 12mm)
16:06 Slip the harness off of the three brackets for easier access
17:22 Remove the Valve Cover fasteners
22:17 Tie up the electrical harness for easier access
22:47 Remove the Valve Cover

25:12 Turn the crankshaft clockwise to TDC/Compression (19mm)
27:25 Detailed view of turning clockwise to TDC/Compression
29:02 Detailed view of timing marks
32:04 Demonstration: making another two crank turns to show how the
camshaft timing marks align every other crank rotation

34:03 Clean up the old gasket maker/RTV at two spots on the head

36:31 Remove the Timing Chain Tensioner (two 10mm nuts)
39:26 Don't turn the engine with the Chain Tensioner out

40:02 Chain Tensioner on the bench (Toyota 13540-0D010) and O-ring
(Toyota 90301-22013 or JIS P22.4)
42:12 Remove the old O-ring (if just replacing the O-ring)
42:46 Experiment: I treat the new O-ring with Dow Molykote 55 O-ring
grease
43:25 Install new O-ring to the Chain Tensioner (use a sleeve if possible)
44:54 Retract the Chain Tensioner piston onto the little hook for install

46:36 What's inside the Chain Tensioner?

50:19 Install the Chain Tensioner (80 inch-lbs)

53:29 Review of Toyota FSM procedure for extending the Chain Tensioner piston/plunger
58:38 Slide of the FSM procedure

58:41 Boroscope view of Chain Tensioner
1:00:07 Using the FSM procedure to extend the Chain Tensioner
piston/plunger
1:03:41 After extending the Tensioner piston/plunger, verify tension and
timing with two clockwise turns
1:07:35 Slide of the FSM Timing Marks note
1:07:47 Note about using a screwdriver to release the piston/plunger

1:08:10 Remove the old Valve Cover gasket (Toyota 11213-0D040, or Fel-Pro
VS 50542 R)
1:09:18 Install the new Valve Cover gasket

1:11:00 Clean the Valve Cover gasket mating surface
1:11:20 Apply FIPG/gasket-maker/RTV onto two places on the head (I use
Permatex Ultra Black RTV)
1:13:30 Install the fasteners for the Valve Cover (Perimeter bolts/nuts: 96
inch-lbs; Center bolts: 80 inch-lbs)
1:17:04 Reconnect the electrical harness to the brackets
1:17:50 Re-install the ignitors and bolts (80 inch-lbs)
1:18:13 Re-install the electrical harness fasteners (80 inch-lbs)
1:18:40 Reconnect the electrical for the ignitors
1:19:06 Reconnect the two breather hoses

1:20:14 Allow the RTV to cure then start the engine
1:20:54 Clean up the oil leak (if applicable)

This is the experimental JIS P22.4 75 Durometer FKM O-ring I used in the
video:
https://www.oringsandmore.com/fkm-o-r...
minimum-3-pcs/

This is the experimental O-ring grease (Molykote 55):
https://www.amazon.com/Corning-Molyko...
Lubricant/dp/B01HEC1W3A/ref=sr_1_6

I hope this video was helpful for you.
Thank you for watching, and good
luck with your repair! 👍