Skipped Timing started Ticking... Tore down replaced Timing Chain ... Still Ticking ...Now What?

Last month driving into the sierra's I got an error code p0016. the car started ticking and the engine lost 70% of it's horsepower. I pulled over had it towed and began researching potential causes.

Possible Problems:

Dirty oil?
Bad VVTI Solenoid?
Skipped timing (the chain literally moved a tooth on the timing gear)?
Bad Intake cam shaft VVT Sproket?​

I got the courage up and pulled the valve cover off, the chain looked warn and it sure looked like the timing was off a sprocket or two.

I decided to replace the timing chain. Bought a kit off eBay and replaced the timing chain. I found the full repair manual online somewhere and it was a life saver. I'll upload the manual or a link to it. It is a process that is easier in theory than actual practice. It was an amazing experience to get into the engine.

Basically removed the everything off the top to get to the valve cover then removing the motor mount, then removed everything on the left side of the engine to get to the timing cover, water pump, pulleys, headlight and other things.

I finished the repair completed and put everything back together.

The problem is that the car continues to make a ticking noise after the repair.

I tore it down again and checked my work ... it looked right. I noticed the intake cam sprocket, the one that adjusts the timing (VVT), was moving back and forth 40-50 degrees? I looked at it and saw that it has oil bays that fill up with oil and adjust the timing based on oil pressure. The amount of oil is controlled by the Solenoid on the front of the motor near the timing cover and valve cover on the left side. I thought it would move until there was enough oil pressure to lock it into place.

To be safe I bench tested the VVTI solenoid. it opened and closed freely. (youtube video on how to test)



I called a Mechanic and he said those things (Intake camshaft sprocket VVT) are not supposed to move.
I bought another one off a used motor and installed it.

Put it back together... started it up and ticking still!!!

I have tried a few things and am looking for assistance from the community to diagnose this problem to get my beloved Prius back on the road! I do 500 miles a week and have a refreshed appreciation for the amazing milage of the Prius.

Any Ideas?

does the VVT intake cam shaft sprocket move when there is no oil pressure? Am I missing something with the timing chain repair instructions?
I there another problem with the valves that require me to take the head off and inspect? I'm looking for good assistance here!


Attached Timing Chain Repair Shop Manual for the 1NZE-FXE Prius Gen 2 motor.

(uploaded 1NZ-FXE- Mechanical and the forum said the file was too large. It's a PDF 18mb
I extracted the timing chain portion of the manual out and attached it as "Untitled Extracted Pages.pdf".

I will try and find the link to download all the manauls. It's a huge file ...everything!

 

It was low on oil. It was burning a quart a week.

 

Thank you DXTA, I added a youtube link to the posting to show the sound. there is a cyclical repetition to it.

Sound

 

Thank you for the insight. I'm amazed with all of the input and help. thank you.

based on your advise:

I'm trying to understand the condition of the intake camshaft sprocket/phaser to give an accurate answer:

the camshaft will not turn.
the intake camshaft sprocket/phaser turns 40-60 degrees in either direction by hand. ( It moves without compressed air. I'm moving it while it is mounted to the cam)
​

should I replace the camshaft since it (the sprocket/phaser) turns by hand while installed?

I will check those. thank you. I did not know about them until you said. I had to google it.

Here's link I found about the cone bearings for other users:
https://www.autozone.com/repairguides/Toyota-Prius-2002-06/Engine-Mechanical-Components/Camshaft-Bearings-Lifters/_/P-0996b43f80379c4d

Thank's again for the assistance Dxta

 

I pickup an engine that a recycler I know. He said was overheating and sold it to me for $50. (I bought it to have as an instructional device). I pulled the plugs from the engine and it was the NKG iridium with the weird 3 prong tips. I don't know if I can use any of it to fix my engine.

I pulled the sprocket/phaser off of it and it moved too.

 

I checked the oil control valve by pulling it out and putting 12v from a battery charger on it.

the valve opened and closed fast and smoothly every time power hit it.

​

I do not know how to check the oil filter on it. I have not seen it.
any advice on how to check the oil control valve's oil filter?

 

Thanks for the advice edthefox5. really appreciate. ultimately the engine is worn. it put in 277k and was a good engine.
I am really concerned with figuring this out.
is the filter inside VVT oil Vane Assembly? Advice above said the filter could be clogged... is the filter inside of it?
I can buy a new one and throw it in...

Also, I could have fried the solenoid when I applied 12v/2amp direct from the battery charger to test it... I don't know.

TRUE!
How much harder is it to just swap the engine?
I have that other engine from the recycler that was overheating. can I take the low-end from it? Should I just buy a running one for $300-$500?
Should I rebuild mine?
I have the car int eh garage and the operating room setup all around it now.

I am ready to dive in because I have to get this Prius back on the road. Ive spent so much time I could not bare to sell it as a mechanic's special on cl. I really want to get it driving again.

Never rebuilt or swapped and engine but I am up for it.

Is there an advantage over either option? which is most pragmatic given the fact that I would like to keep the car.

 

I saw this interesting video on how to replace a Variable valve timing oil filter

that filter seems to be below/before the solenoid. it could be that there is no oil getting to the solenoid.?

 

I pulled the oil filter and it was clean but there was a clump of sludge that came out near it. The oil cover gasket is nice and soft. and the camshaft bearing caps came off but I don't know how to tell. they stunk with a weird oil smell.