Nasty sounding noise from engine (With video!)

[Screwloose]

Help!

I have a '94 5-speed Sport with roughly 130,000 miles. She was running beautiful until the other day when it started making a rattling noise that got progressively worse until it stalled. When I popped the hood, there was smoke rolling off the exhaust manifolds and coming back out of the intake. According to the temperature gauge, it did not overheat. Once it cools off, it will fire back up with no problem at all, and will run for about 10 minutes before making the noise again.

So far, I have:

Cleaned the MAF.
Changed the fuel pump assembly. (Sender wasn't reading right, needed to be changed anyway)
Swapped the fuel pump relay.
Checked the cats to make sure they weren't clogged.

I pulled codes:
111, 335, and 556.

Here's a link to the video of the noise:
Http://youtu.be/pB2FiKK2pBo

Any ideas?

 

[natenkiki2004]

In the video, the rattle doesn't sound muffled. My guess would be something in the belt, either an idler or one of the pulleys' bearings. Feel the pulleys one at a time after running the engine and see if one is super hot. That might be the culprit. You can also check them by removing the belt and turning them one at a time.

If that's not it then it could be something internal (though not too deep since it's not a muffled sound). Maybe a valve/rocker/pushrod.

 

[Screwloose]

Ah, forgot to mention, I also replaced the tensioner. Spun all the pulleys while I had the belt off and didn't feel any issue with the others.

If it were something in the valvetrain, would that be enough to cause the engine to get hot and choke out?

 

[2stroke]

I suppose I don't even have to ask, but I will anyway. Did you check and make sure its full of oil, and that the oil pressure is normal?


Code 111 is all clear

335
(O)
EGR feedback signal is/was out of range - EVR or DPFE

556
Fuel Pump Relay Primary Circuit Failure
C/O


For me, code 335 was a faulty DPFE sensor. As for 556, the next step is to follow the wires to the fuel pump. Before that, un-plug/re-plug the fuel inertia cutoff switch. Its a stupid design, and I've fixed more problems doing that than you would believe.

As for the noise, Its always tough to tell from a video. Two things come to mind. One is lugging. If you have a faulty EGR system, plus the possibility of the engine not getting the fuel it needs, what you could be hearing is pre-detonation. The other thing that comes to mind is a failing timing chain. If your engine is lugging, it would cause the internal temps to sky rocket. That would be an explanation for smoking exhaust manifolds. The other thing it sounds like is an out of adjustment valve. I'm not sure if its any of those three, but thats what comes to mind when I hear that.

 

[2stroke]

One thing I just thought of is replace all the spark plugs. See if one of the old ones is wet, or in bad shape.

 

[gmbroy]

I think 2stroke is on the right path except there is no way to adjust this valve system .if it is in the valve system it could be a rocker , pushrod , lifter , might even be a lobe wore on the cam . a loose bolt that holds down the rocker assy. would make it tick all the time . these rocker arms have tiny oil holes & if you dont keep the 5w-30 to them they will wear out !! hope this helps some

 

[Screwloose]

Did some wrenching today.

Pulled the spark plugs. Previous owner installed E3 plugs with cheap wires, plugs look like crap, with cylinder 4 worse than the others.

Pulled both sets of rocker arms. I didn't see the indents that they usually get worn into them and the rest of the valvetrain looked fine.

Found the upper intake manifold gasket cracked, but I doubt that would cause such a severe problem...

I'm debating whether or not I should check the timing chain next...

 

[vq5speed]

The sound in your video sounds external to me. I watched every time your throttled it made the noise. That noise to me doesn't sound like rocker arm tapping.

 

[gmbroy]

Darn I hate that you pulled the rockers for nothing as it looks . Is there any chance of a cracked flex plate acting like this ??? The noise I could understand but the other symptoms just dont fit . I am now curious as heck about this . I need to do some research on this !! :roll:it just doesnt sound like a flex plate to me . sounds like a gas rattle in the valvetrane . I will keep working on this & try to do what I can .

 

[murkinstock]

Those are the weirdest plugs I have ever seen. Good luck though!

 

[Screwloose]

The flex plate came to mind, but to me, it doesn't make sense that it would only make noise when hot. You would think a broken flex plate would constantly make noise?

And those are E3 plugs. Previous owner must've installed them. Personally, I think they are garbage, and have a set of motorcraft plugs to replace them with.

 

[natenkiki2004]

Like vq5speed and I said, it sounds external. However, I wonder if it might be a valve seat or something like that? Do you have a compression tester?

 

[gmbroy]

Take a close look at the two rockers for the #6 cyl. The oil holes looks bigger than the one for # 5 cyl. , also the end that pushes down on the valve is different than the ones for # 5 . The ones for #5 look all flat while the ones for #6 have a small notch . Did the two rockers move as much as the other ones???? If the hole is wore deeper you loose valve travel which could give you that rattle . I have listened & it sounds somewhat like a flex plate BUT with all the other symptoms I dont think it is . Just take a really close look I if possible measure the depth of the hole for the push rods on #6 . it might turn out to be nothing , but I am starting to smoke up the place here !!! LOL Hope this helps you some . if not just keep us informed

 

[SSI]

the heat shroud on the exhaust log...both bolts tight? .....fan blade not stiking shroud? ...gummed up lifter , not rebounding fast enough to keep pressure up on pushrod? water pump have any play in the shaft? PCV grommet good on valve cover...pcv not gummed up ? old oil pump not getting enough oil up there fast enough or oil pickup tube screen clogged? Exhaust donut worn, missing , loose bolt?


I got no idea from the video , just throwing stuff out there to consider , though you probably already checked these. I had a front license tag vibrate and make noise until I shoved a piece of foam behind it once .

Video makes me think the exhaust manifold shroud is loose .

Sorry , all I can think of right now.

 

[Jimi_73]

My 92 Eddie just started doing the same thing. The getting warm part as well, but it runs semi ok just a bit sluggish. Then I shut it off and it doesn't want to start. Cools down and its fine. Only difference with mine is the noise is a bit louder and I smell gas.

 

[smegun]

sounds like the fuel rail has remnant ....? fuel regulator kaput? in some ways yours sounds better at full rev than mine he ha vacuum cleaner comming back down return fuel rail ???? clink clink clink though its got good excelleration though partial vacuum leak with partial clogged injectors possibly bad fuel pressure regulator

but im just gessn ....let us know how you did

typical valve click i used chevron complete fuel system flush ...beter than seafoam better than berrymans .put about 8 gallons on it take small trips cleans injectors

i had some tick but got rid of it by using the flush and drilling holes in my cat ....
patients with the chevron after a few days of small trips better better better .. exhoust has to go some where if cat is packed with resins is it possible that too much exhoust pressure on the exhaust valve ??? i fixed the typical tick yours sounds different late detonation of waste fuel

 

[FR-425]

I made the mistake of putting those plugs in mine!

What you are hearing is some SERIOUS spark knock.

Just replace the plugs and reset the computer.

I thought it was gonna bust a ring it was pinging so bad,,,, worse than yours!

Those plugs just have way to much surface area, and as soon as they get the slightest bit of carbon on them they act like a glow plug. Hot enough to pre-ignite.

The DPFE is the other contributor to this kind of excessive spark knock.

Just get some proper plugs and a DPFE and you'll be all set.