2012 Head Gasket Replacement - Timing Chain Tensioner won't insert

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by Chase B, Apr 9, 2026 at 9:33 PM.

  1. Chase B

    Chase B Junior Member

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    2012, 249k miles, attempting to do a head gasket replacement on my own. Things have gone...mostly OK, but I am at the point where I am trying to re-insert the timing chain tensioner and it will not insert. When putting my fingers through the hole it feels like there is not enough room for the locked in place tensioner to insert, and I'm wondering if the plastic chain guide is blocking it, as I can certainly feel the chain guide with my finger when inserting into the hole. I'm more than a little worried the tensioner guide is not seated correctly. Has anyone had this issue, and if the chain guide isn't seated correctly is there any other option other than taking apart the timing chain cover and starting over from that point? I'm confident the chain guide was inserted into the hole at the bottom, but there were times when it would shift to the left (although I didn't think it did before I put the cover on).

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    #1 Chase B, Apr 9, 2026 at 9:33 PM
    Last edited by a moderator: Apr 10, 2026 at 1:41 PM
  2. CR94

    CR94 Senior Member

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    Is there a chance that's due only to tension on that side of the chain, which you could relieve by pushing on it or by rotating the crankshaft forward slightly?
     
  3. NutzAboutBolts

    NutzAboutBolts Senior Member

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    When the timing cover is mounted back up, the chain slipper hugs tight enough on the chain and you can insert the chain tensioner back in. The slipper doesn’t have any room to obstruct the chain tensioner being inserted once the timing cover is back in.

    if you still can’t fit the chain tensioner back in. Remove the timing cover and redo the rtv/fipg seal but this time, use mechanic wires to hold the slipper and chain in place against the top of the chain so it doesn’t slip to the left.
     
  4. Chase B

    Chase B Junior Member

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    Thanks to you both for your comments/suggestion; NAB I watched your video (and rewound, and rewound...) and saw the wire trick. I ended up taking the cover off and actually putting the tensioner in while the cover was off but just ever so slightly starting the bolts back on the studs, and this seemed to work OK as I was able to fully tighten the tensioner on the studs once the cover was back on.

    Although it took me way longer than even I estimated, I think she's all back together in one piece, and I've driven it about 25 miles without any engine codes, so I think she's good to go. Thanks!
     
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  5. cdherman

    cdherman Junior Member

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    Chase B -- are you sure you were not putting the timing chain tensioner backwards the first try? The holes are symetrical, but the plunger part of the tensioner goes towards the block. I had to use a mirror to figure this detail out - NAB video did not have it (or I missed it)......
     
  6. NutzAboutBolts

    NutzAboutBolts Senior Member

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    The timing chain tensioner only goes in one way or else it won’t insert properly.
     
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  7. ChapmanF

    ChapmanF Senior Member

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    The OP may have been about it not inserting properly.