This problem was supposed to have been fixed under TSB# 0087-09 which replaces the cam gear assembly. Since this engine has Variable Timing on both the intake and exhaust cams I am not sure which one was replaced. The noise went away until just after the 60000 mile warranty went out but now it has returned. Apparently the fix is not permanent.

I haven't contacted Toyota about it but I am sure they will only fix if I pay for repairs. This appears to be a fairly common problem with these cars and Toyota does not appear to know how to fix it. It sounds like a timing chain rattle and occurs for about 2 seconds after a cold start. I doubt if it is causing any permanent damage but I am not sure. It does not occur on every cold start but occurs more often than not.

I have owned Toyotas before and bought this one because I thought they were reliable but I am rethinking this now because of this issue and other recalls associated with various Toyota models. It seems that Toyota is no better than the American manufacturers that sell crappy cars and refuse to stand behind them. It seems that I read a lot of complaints about Variable Valve timing actuators in general and this appears to be another instance.

Since first day I picked up my 2010 Corolla first time starting the engine it had a bad engine rattle and knock. I went inside to report it to sales manager he said I will send out the assistant service manager. When he came out he said to bring it to the service center on your first oil change. I told the service adviser what I wanted to check, he did not write complaint on work order but verbally told the tech after completion, said no problem found.

I continued to bring it in the next 3 oil changes, car had 14.000 miles at this point. I insisted on writing all complaints on work order this time. I was there from 9 am to 4 pm. I was prepared this time, I did some research on this problem and of course they said no problem found. At this point I ask to bring out the tech who checked it. It duplicated on the first start up, he said it was the cam gears, I knew this. They had car three days. When I picked it up, had same problem and the car was a complete mess. I complained to the service manager and he had it detailed.

I later went to another dealership. The dealer who I bought it from was Auto Nation in Weston, FL, first fix, same dealer. Trying to get it solved I bought it to Lipton Toyota, they said no problem found. Well at this point I was angry and it went into arbitration. Corporate office, called was public relations manager, ask if I would give another opportunity and that they would have a field engineer and a master tech look at it. They duplicated the problem and said it was the cam gears. They had car for another 3 days. When I picked it up again it was a mess, I called public relations manager.

Problem besides them not caring about the car is that it still has the same problem after a field engineer and another master tech works on it. I am in arbitration again. Again they want a engineer and a master tech to work on the same problem. I read a lot of cases out there with same problem, dealers and Toyota are ignoring the problem, they all are saying no problem found but they know there is a design problem and not doing nothing about it.

I'm surprised they don't have a recall or a bulletin on this. This problem been going on as far back as 2006. If a field engineer and master techs can't fix it why do they keep getting away with selling defective cars with a bad engine design or cam gear design. This needs to be heard, who ever has this engine rattle on start up with their Toyota. It's not only Corollas. Stand up and fight. Do not let dealers or Toyota get away with this problem. Good luck to all out there, I hope this will help a lot of unsatisfied consumers that are being rip off and neglected. God speed.

Update from Jun 12, 2014: After two repairs i still have rattle knock on start up 2010 corolla.I was at a arbitration meeting today 6/11/2014 try to duplicate the problem it would not act up with arbitrator or field engineer today.I only have 21.812 miles on my car it is garage kept not abused. of coarse when i maid it home had to leave it happen i am going to take a video to duplicate the problem they do not want to do any thing about this problem.this has been a on going problem for years not only with my year model but other years make and models thousands of consumers are getting the run around because the are saying no problem found or replacing cam gears and still having the problem Toyota and dealerships are well aware of this problem but not addressing it properly .So they keep getting away with this poor engine design and the consumer is stuck with it because Toyota will do nothing about it.Is there any way to expos this get enough complaints or have this investigated so Toyota can be held accountable.I would be glad to go to bat for all consumers that are have this problem.like i said its not only 2010 corollas its 2006 and up also with toyota matrix Camry.Need help resolving this please complaints.com email me or call me or leave your number on my email so i can call you.This is a serious problem need to be addressed.Thank you for your site and your cooperation.Hope to here from you soon.