Broken Lift Bolt removal: TSB Method

phillycheese917 · 04-12-2007, 05:38 PM

Broken Lift bolt TSB
This guide is meant to help an individual through the TSB(TSB (#EG010-03) ). This is not meant as a substitution to the TSB just a helping guide. I will have pictures or a description of what to do. If you follow the TSB and this guide you will have no problem completing the TSB. To get started here are the tools you will need.

Tools:
Lift bolts
Car Jack
Jack Stands
Rags
Wrenches
Flash Light(optional)
Time

Before you start make sure that your rocker shaft has rotated. If you cannot see the bolt it has rotated or if it looks like mine does. It is offset in the hole.

************************************************** **********************
Step 1 is pretty much self-explanatory.
Step 2: This is where it may get a little confusing for people who do not know much about celicas. The first thing to do before step two is to remove the plastic from under the car on the passenger

imhotep · 04-12-2007, 08:39 PM

^^^ just use two wrench... stick the first wrench on the drive belt bolt then connect the other wrench to the other end of the first wrench so you can get a grip pull towards the front of the car....

**Smaay** · 04-12-2007, 10:07 PM

you dont have to take off the accessory belt....what you do need to do is unbolt the (2) 10mm nuts on the timing chain tensioner. pull it out and rotate it so you can see the detent to reset it. then use 2 screwdrivers to reset. one ot hold detent, other to push in the tensioner. once you got it reset, leave it pushed back, dont put it back in untill the end of the job.

BadTOYO · 04-13-2007, 12:17 PM

so smaay, are you saying that removing the belt tensioner and the belt itself isn't necessary at all? i thought removing that was needed to clear enough room to get to the timing chain tensioner itself...
R

**Boosted2.0** · 04-13-2007, 12:27 PM

The TSB was written to be done with the engine in the car - I gaurantee it

You just need to loosen the mounts and jack the engine up a tad to remove the tensioner.

When I do the TSB style I don't even do that. I have a REALY long skinny small flat head screw driver I use to keep the teeth on the lock tab on the tensioner pushed away and then I put the tensioner back in with a big screw driver. Once the piston is all the way in I just swing the hook over the pole on the tensioner and I'm good to go.

BadTOYO · 04-14-2007, 11:27 PM

failed again, that damn chain tensioner is a bitch to get to... i contacted jamasco motorsports in hollywood (the guys who built the GT4 converted 7th gen), i'm dropping off the car monday morning, i met up with them earlier today and they said they could do it... i'm done messing with this thing...
R

**Boosted2.0** · 04-15-2007, 02:07 PM

did you try popping the power steering pump loose? That can sometimes give you the room you need.

BadTOYO · 04-15-2007, 08:01 PM

Quote:

Originally Posted by Boosted2.0

did you try popping the power steering pump loose? That can sometimes give you the room you need.

well, no, i didn't, but i was able to remove the 2 timing chain tensioner 10mm nuts without much trouble. the problem was, trying to pull out the tensioner from the timing cover housing; there was not enough room to pull the tensioner back without hitting the belt tensioner assembly...
i know you said that you don't remove either one of the tensioners and instead, you use 2 screwdrivers to work some magic... i could not see how i could do that in there, the space between the chain and timing cover is so tight...
R

phillycheese917 · 04-16-2007, 03:40 PM

Quote:

Originally Posted by BadTOYO

well, no, i didn't, but i was able to remove the 2 timing chain tensioner 10mm nuts without much trouble. the problem was, trying to pull out the tensioner from the timing cover housing; there was not enough room to pull the tensioner back without hitting the belt tensioner assembly...
i know you said that you don't remove either one of the tensioners and instead, you use 2 screwdrivers to work some magic... i could not see how i could do that in there, the space between the chain and timing cover is so tight...
R

Just started back up on the car today and I had the same problem. Boosted said something about compressing the chain tensioner inside the car. But I looked and couldn't figure out how you could do that. I got the belt off but I can't get the damn bolt for the belt tensioner off. I frikin cut my fingure pretty bad today. I am going to work on it again tomarrow see what I can do.

**Smaay** · 04-16-2007, 06:15 PM

like i mentioned leave the belt tensioner alone...undo the 2 nuts for the chain tensioner, pull it back and then rotate it so you can see the ridges and detent. push the tensioner back in so you have more room. then put 1 nut back on to hold the tensioner in place...

then use one screwdriver to push in the detent, use the other to push the tensioner back in...then rotate the catch...now its reset....remove the nut on the back and push the tensioner back out....leave it alone!!!!!

now reset the cams and timing...when all that is assembled correctly...finally push the tensioner back in and secure it....

phillycheese917 · 04-17-2007, 05:09 AM

Quote:

Originally Posted by Smaay

like i mentioned leave the belt tensioner alone...undo the 2 nuts for the chain tensioner, pull it back and then rotate it so you can see the ridges and detent. push the tensioner back in so you have more room. then put 1 nut back on to hold the tensioner in place...

then use one screwdriver to push in the detent, use the other to push the tensioner back in...then rotate the catch...now its reset....remove the nut on the back and push the tensioner back out....leave it alone!!!!!

now reset the cams and timing...when all that is assembled correctly...finally push the tensioner back in and secure it....

I think I understand. I am going to try that when I get home from school. It is just hard to see the chain tensioner clearly because it is on the back of the engine, but I will see what happens.

phillycheese917 · 04-17-2007, 06:26 PM

I got the drive belt tensioner bolt off. I jaked up the engine and stuck a socket on there. Other than that it is almost impossible to get that thing off it is really tight on there. I took the chain tensioner out and compressed it then put it back in so that I could put the belt tensioner back on and unjake my car. I live in condos so I can't have the car on jackstands I have to take it down everyday when I am done. Well I have to work tomarrow. But thurday I am going to continue.

As a Weapon · 04-18-2007, 03:19 AM

Don't forget to take a lot of pictures.

phillycheese917 · 04-18-2007, 06:06 AM

Quote:

Originally Posted by As a Weapon

Don't forget to take a lot of pictures.

I will try. It is hard to take pics when I start working. Idon't want to stop to take a picture. LOL. Iwill take as many as I can.

As a Weapon · 04-19-2007, 01:28 AM

Do it for the team ha ha. A couple people have been trying to get a thread like this started.

phillycheese917 · 04-19-2007, 12:58 PM

Alright everyone I have reach the part where I have to use a punch and a hammer to knock the rocker shaft out the only thing is the rocker shaft doesn't seem to want to budge. I tried hitting it over and overrr but nothing. I wanted to see if anyone had suggestions for me I am just afraid of damaging something.

BadTOYO · 04-19-2007, 01:36 PM

well, i read someone's post which came up during a search, that sometimes, if the bolt breaks and a piece of it is still sticking out above the edge of the rocker shaft, when the shaft rotates, it scores the aluminum housing which surrounds it (read: the head!), and that makes it impossible to slide the shaft out of the head... this resulted in his particular case, in his car needing the head to be pulled off and some other work i can't recall anymore...

i was aware of this when i tried doing mine, so that was just another reason why i decided to let someone else do it...

btw, did i tell you that i got my car back tuesday afternoon? it's fixed and from what the mechanic told me, my rocker shaft slid right out without much trouble. he replaced it with the new one i bought, since i attempted to drill out the bolt unsuccessfully a while back... i'm back in full lift, $600 later mind you... this guy also mentioned that he was hoping my rocker shaft hadn't scored the housing, because he said he had seen some cases where the rocker shaft was jammed in the head...

i'll try to post some bad pics of the rocker shaft and old bolts later tonight...

R

phillycheese917 · 04-19-2007, 01:54 PM

If this is the case with my car I am going to shoot myself. LOL My dad will tell me to put it back together and sell it if this is the case. I hope not though.

Here is a pic of the broken lift bolt.

And here is the broken half in the head!! I already tried drilling it out but see how it is rotated.

BadTOYO · 04-19-2007, 02:34 PM

here are pics of my rocker shaft and bolts...
R

As a Weapon · 04-19-2007, 11:59 PM

Bump for a good thread. Keep it going. I know you can do it. Oh yeah, more pictures.

ZZT231Ryda · 04-20-2007, 05:10 AM

Quote:

Originally Posted by phillycheese917

If this is the case with my car I am going to shoot myself. LOL My dad will tell me to put it back together and sell it if this is the case. I hope not though.

Here is a pic of the broken lift bolt.

jpg[/IMG]

Wow!! That is the same exact thing that happen to my intake lift bolt, being broken like that

. My exhaust lift bolt is the same also when I was gonna replace them with the new ones. I was like f*** when I saw the bolt broken in half, so all I did was just replaced the exhaust bolt till I get a hold on a drill & a bolt extract to take it out... I still hit lift for one being broken though

, but I don't know if that's a good thing to do.

phillycheese917 · 04-20-2007, 05:23 AM

Quote:

Originally Posted by ZZT231Ryda

Wow!! That is the same exact thing that happen to my intake lift bolt, being broken like that

. My exhaust lift bolt is the same also when I was gonna replace them with the new ones. I was like f*** when I saw the bolt broken in half, so all I did was just replaced the exhaust bolt till I get a hold on a drill & a bolt extract to take it out... I still hit lift for one being broken though

, but I don't know if that's a good thing to do.

Have you done anything about it? Well when I am done wgetting mine out I am going to finish this thread. I have been taking pictures so it should be a pretty good guide to doing it yourself.

ZZT231Ryda · 04-20-2007, 05:40 AM

Quote:

Originally Posted by phillycheese917

Have you done anything about it? Well when I am done wgetting mine out I am going to finish this thread. I have been taking pictures so it should be a pretty good guide to doing it yourself.

Not yet, which really sucks

... Your DIY guide w/pics would really help out with people who have the same situation I do

.

verbal272 · 04-20-2007, 06:53 AM

why do you have to remove the drive tensioner belt?

[edit] nvm i'm a noob ha

BadTOYO · 04-20-2007, 07:37 AM

you don't, but it makes it easier to remove and work with the timing chain tensioner...
R

phillycheese917 · 04-20-2007, 03:46 PM

After tons of drillign and hammering I got the bolt out today before work!!!
YAYAYAYAYA.
Didnt damage anything either. I am so happy. Took lots of pics too. I will post when I am done with everything.

BadTOYO · 04-20-2007, 05:19 PM

good job!
R

**Smaay** · 04-20-2007, 05:44 PM

good job philly

phillycheese917 · 04-21-2007, 10:19 AM

I lined the rocker shaft up with a wrench now how do I push rocker shaft back in place?

phillycheese917 · 04-21-2007, 08:17 PM

Here is the picture of the room I was talking about Smaay.
I am afraid to use the side of the head to get leverage. Let me know what you think.

SilvrGTS · 04-21-2007, 08:24 PM

yea my lift bolts looked the same way yours did...we got the head off from the top, never had a problem getting to any of the bolts.

phillycheese917 · 04-21-2007, 08:38 PM

Quote:

Originally Posted by SilvrGTS

yea my lift bolts looked the same way yours did...we got the head off from the top, never had a problem getting to any of the bolts.

Did you have to do TSB or did you just extract your broken one?

SilvrGTS · 04-21-2007, 08:44 PM

i looked at the TSB once, just to figure out where everything was.

phillycheese917 · 04-25-2007, 05:34 PM

bump

As a Weapon · 04-26-2007, 12:17 AM

Is this thread dead all ready?

phillycheese917 · 04-26-2007, 05:45 PM

no I ran into a problem today. I had to order a part and the warehouses dont have them. So I will have to wait a minimum of a week for the part. God if I had the part I could fininsh in 30 minutes. LOL But Once I am done I am going to update.

As a Weapon · 04-26-2007, 11:31 PM

What part? You just need the lift bolts, o ring for the OCV, and the rubber gasket for the valve cover, right? Keep up the progress.

phillycheese917 · 04-27-2007, 05:09 AM

Quote:

Originally Posted by As a Weapon

What part? You just need the lift bolts, o ring for the OCV, and the rubber gasket for the valve cover, right? Keep up the progress.

I accidently bent the stud that holds on the chain tensioner when I tried to put the chain tensioner back in and compress it inside the engine instead of taking the belt tensioner off to get the chain tensioner off.

phillycheese917 · 05-02-2007, 03:03 PM

I finished today. I was so excited to feel the true lift again!!!

**2way** · 05-02-2007, 03:09 PM

May the force be with you.

**Smaay** · 05-02-2007, 06:38 PM

Quote:

Originally Posted by As a Weapon

What part? You just need the lift bolts, o ring for the OCV, and the rubber gasket for the valve cover, right? Keep up the progress.

only parts you need are the lift bolts. the valve cover gasket dosent need to be replaced if its still soft. if its hard and brittle then yes replace it...and you dont touch the OCV so no gasket needed there

TRD033 · 05-08-2007, 04:24 AM

What is the part number for the valve cover gasket? I'm not really sure.. but I had a gasket, ventilation one.

**Boosted2.0** · 05-08-2007, 11:35 PM

Quote:

Originally Posted by phillycheese917

I finished today. I was so excited to feel the true lift again!!!

congratz - glad you finally finished it.

As a Weapon · 05-08-2007, 11:38 PM

Fantastic!!! Good Job bro.

As a Weapon · 05-08-2007, 11:41 PM

Quote:

Originally Posted by Smaay

only parts you need are the lift bolts. the valve cover gasket dosent need to be replaced if its still soft. if its hard and brittle then yes replace it...and you dont touch the OCV so no gasket needed there

What about that little O ring on the bottom side of the valve cover? When I talked to Toyota they said I would have to replace all that stuff in an atempt to justify the $900+ bill for the lift bolt job.

phillycheese917 · 06-10-2007, 10:09 PM

After a few hours of working on this guide I am finally done. All we need is Larryd to sticky it.

phillycheese917 · 06-17-2007, 10:23 AM

So is anyone thinking about using this guide?

Kore971 · 06-24-2007, 08:37 PM

I am.., my rocker shaft was rotated slightly as well...

, so now i got to try this...

Higgo · 06-28-2007, 08:16 AM

Reckon me and my buddy (its his Car) will give this a go soon.

Been wanting to try the TSB after we discovered his intake bolt had sheered and the rocker shaft had rotated to the point that no broken piece of bolt // bolt hole was visible!

We been lookin for a guide like this for ages, so TY philly!