Broken VVT phaser

2006 V6 Tacoma. I was getting a few codes related to the camshaft position sensor (P0022, P0348) and the first time I checked it the sensor tip (that goes inside) was broken off. I replaced but was still getting P0345, also related to the camshaft position sensor. The second time around I decided to lift the valve cover on that side and discovered the propeller-like VVT phaser (is that what you call it?) that goes on the outside of the VVT sprocket had 2 out of 3 wings or prongs or whatever you call them, also broken off. I am guessing something may got in (through the oil filler?) which interfered with the VVT/camshaft like a wrench thrown in gears and made a mess.




My questions are:

1. Do I need to find the broken pieces of can I assume that they are in the bottom of the oil pan?
2. Can I replace just the phaser (broken part of the VVT sprocket) or do I need to replace the whole sprocket ($$$? If yes, can it be done without removing the sprocket drum, which would necessitate removing the timing chain)?

 

I wouldn't think you would have to remove the cam, I think you can use the procedures below to replace it minus removing the cam.

I would be concerned where the pieces went however, you could pull the lower oil pan and see if they ended up there.

 

You can pull the sub pan and see if there's pieces, inspect the pickup tube screen as well, the upper oil pan can't be removed without pulling the front diff if equipped and steering rack needs to be at least loose if not fully removed makes the job much easier.

But for you just the 10 or so 10mm head m6 bolts and the FIPG seal to check the lower pan.

Very very odd to have those exciters break off, first time seeing that, have you had your timing adjusted, tuned, or heads worked on before? I know the earlier 1GR's had some head gasket and fuel delivery due to heat issues and they reworked the heads. Wondering if something was left loose or came loose to get caught in the timing chains and jam to break that.

Last thought I see a fair amount of varnish, have you checked your VVT-i screen filters in the heads? Wondering if they clogged enough to reduce flow to the point the VVT-i cogs were slamming causing the breakage.

You should be about to change it without pulling the whole cam without issue but I would confirm with the Factory Service Manual and make sure everything is aligned first like when doing anything with engine timing.

 

Those wings are used for the sensor to know where the cam is. Chances are if the engines still running its just at the bottom of the pan now. Unless you’ve got shavings in the oil or other issues I’d just pull the cover and replace both cam actuators and put a nEw main chain in.


I’ve seen this once and we saved the engine. But it was caused by another shop mangling a timing cover reseal.

 

I can't find to buy just the "propeller" (broken piece), only a whole VVT sprocket drum. Any ideas?

 

I removed the timing cover and reinstalled it maybe 5 years ago when I did my head gaskets. I took EVERYTHING out. But this just know started showing so I don't know if that's what caused it.

 

It is part of the VVT Sprocket Assembly, not serviced separately.
Is it possible someone accidentally left a funnel stuck in the filler and started the engine?

 

I wouldn't exclude that possibility.

Will I be able to replace it without taking the timing chain off (lots of work)?

 

I sneak them out on the 5.7. So possible it can be done on the 4.0. But unsure.


Key is to mark everything with paint market and you’ll have to remove the whole cam to get the phaser out. And properly torque the new one. But if the chain drops your in for a cover removal

 

I just can't see how the whole sprocket comes off without the timing chain removal

 

Have to get slack in the chain by locking the tensioner in. I don’t remember on the 4.0 but on the 5.7 this is doable

I think there’s an timing chain tensioner access hole on the cover

 

Y'all think a junkyard might have the phaser only to avoid buying a whole VVT sprocket?

 

A pick n pull might but you gotta make sure you get the correct one, I belieive there was 2 different reluctors depending on year model.
I'm not sure about using used timing components but you can give it a go.

 

Same for the 4.0. It is not easy though.

 

Wow... Looks like a Doo-Hickey from a KLR

 

what job are you doing on the 5.7 that you are pulling them and not the timing cover? Cam tower reseals?

 

Indeed

 

EPILOGUE: I found most of it right under the drivers side VVT drum, between it and the oil filter connection. It was stuck there and miraculously not interfering on any moving parts. There is another smaller piece unaccounted for. I thoroughly examined the TC area as well as cam cases. I also removed the bottom oil pan but it wasn't there.

 

Were you ever able to swap the sprocket/reluctor assembly without a full timing job? I have the exact same issue. As a matter of fact, in my online exploration, this is not quite as "rare" as one might think, and I've encountered a handful of similar stories on the blown apart reluctor/sensor plate with the 1GR-FE motor.
Here's their stories...

CAMSHAFT CONTROLLER LOST 1 O'CLOCK & 5 O'CLOCK ARMS

LARGER PORTION OF THIS RELUCTOR BROKE OFF FOR SOME REASON

BANK 1 CAM SENSOR PICKUP ON THE PHASER HAD BROKEN

BANK 1 CAMSHAFT TIMING GEARS SENSOR TAB BROKE

THE RELUCTOR WHEEL WAS DAMAGED!

PHYSICALLY BROKEN CAMSHAFT POSITION SENSOR​

The only error code my truck is posting is the P0340 (camshaft positioning sensor BANK 1 circuit). When I lifted the valve cover, it all made sense. It was the same half that broke off on my reluctor as yours. It was harmlessly sitting right below in the cam case. Mine is way less chewed up than yours...it clearly broke off, hit the still intact half of the reluctor and bent it out a little, bumped and scratched the surface of the sprocket assembly a tiny bit, tore off some of the casing on the camshaft positioning sensor, and then landed right below. Zero other damage done. My best guess is that heat, centrifugal force and compromised metal gave way to the wheel breaking off at it's narrowest/weakest points. (shrug) Anyway, I'm being super hopeful that I can do an in-place swap of the sprocket assembly (Toyota P/N 130500P010). Here's a 3:44 video of my situation...

https://www.youtube.com/embed/icxPJNQv3zY

Insights appreciated!

 

Update: Had to pull timing cover to fix this. Got the replacement Camshaft Timing Sprocket Assembly shipped to Hawaii for $231 from OEM Part Source. Took my time and did it right.



Most time-consuming and tedious aspect of this job for me was cleaning all the parts. I used Easy-Off Ultra oven cleaner to clean the timing cover exterior as well as the valve covers (don't use on the insides or mating surfaces, as this stuff essentially etches into aluminum)...cleaned it to new!



Brass-brush drill attachment, steel brushes, mineral spirits and lots a elbow grease for all the filthy parts. Repainted lots of pulleys, valve covers, and any parts needing a fresh coat of protection. Chain was perfect with just a millimeter of travel in the chain tensioner, so didn't need to replace it. Timing was also flawless and easy to put back at TDC after re-installing chain. Replaced all seals, o-rings, water pump, thermostat, PS seals, valve cover gaskets, tube seals, etc. I also swapped out the cam timing gears with these mods from Kel.. for some extra responsiveness & improved MPG


(I couldn't speak to any improvements from these gears, as when I got this truck, it was in limp mode, so I had no baseline).

Used Permatex Right Stuff 90 minutes Black (oil-friendly) for timing cover mating services along with Permatex Right Stuff 90 Minutes Gray (coolant-friendly) around the 2 coolant inlets.



This was one of the more involved automotive efforts I've taken on, and super stoked it worked out (glory to God!) Once everything was torqued back to spec and fluids replenished, the truck started right up with no error codes...purred like a kitten and drives like a champ! It's got great pick up and go and I imagine that Kel's cam gears have also contributed to that! Thanks TacomaWorld for all the FSM's, resources, tut's, etc! Also found this vid super helpful for the job. Woohoo!