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2009 D4D Engine Clatter/rattle/noise after head replacement & EGR/intake clean.

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  • 2009 D4D Engine Clatter/rattle/noise after head replacement & EGR/intake clean.

    Hi all,

    Any advice would be helpful.

    2009 Prado 152,000Km D4D.

    I have a problem with a clatter/rattle/valve train noise/EGR noise???

    Approx 1000-1500km ago I replaced injectors, new fuel pipes etc. Replaced cam belt, tensioner, pulley. Replaced water pump. Full service, oil, filters etc, along with Bilstein suspension.

    Since then I had an overheat problem and blew a head gasket. Top end stripped down, new head (set up) purchased and replaced. New head gasket, bolts VRS kit etc.

    Whilst all apart I cleaned intake manifold, EGR valve, throttle body etc due clogged up with the dreaded black gunk.

    Engine reassembled, & on start the engine had a very loud clatter/rattle from what seems to be the top end.

    Unassembled again and valve clearances checked, cams reset, buckets checked for clearance and free movement.

    Engine reassembled again to no avail. C-Scan computer put onto car and fuel injector values checked ok.
    Cylinder isolation test carried out with the noise still apparent with each of the cylinders isolated, thus to me showing it is not pointing to an injector fault.
    Fuel pressure check done and all ok. All other C-Scan figures & tests ok. Also removed sump and checked oil pick up (all clean)

    Engine disassembled once again, and old cams from original head installed, clearances all checked within limits, assembled once again with the same loud engine clatter/rattle/noise present.

    Noise increases with RPM, & is still present at idle cold or hot engine (idle being 750-850 rpm)

    The engine is running perfect, no smoke, not missing, accelerates ok, no codes set, no engine light. Drives perfect, have driven approx 10-12km testing engine. As said runs with no problem except for the loud knocking noise.

    Due to the head been looked at & checked 3 times, cam replaced, clearances done etc, has anyone had a knocking noise after EGR, inlet manifold clean, or any other tips on this problem.

    Any advice will be much appreciated.

    Cheers.


  • #2
    So it only started rattling after she overheated?

    Comment


    • #3
      Yes only after overheat and head replaced, & inlet/EGR clean.

      Comment


      • #4
        did the pistons come out?
        have you had the sump off?
        did you check your oil pick up ?
        2008 Dune D4D manual GXL update - with lots of fruit !! + Roma Razorback Off Road Van

        Comment


        • #5
          Pistons didn't come out, tops looked ok, no excessive sideways piston movement. Nil metal when oil drained & sump removed to check oil pick up.

          Comment


          • #6
            As the noise changes with engine speed I would think it is a mechanical fault.As the issue has occurred since replacing the head that is the logical place to start looking.
            Was the "new" head a used head or a new head? Did you check piston to head clearances? When you say unassembled do you mean you lifted the complete head off or just the valve train?
            If you removed the head did you check for any contact witness marks, I have seen a engine where 1 valve was high and just "kissed" the piston and as the valve was fully seated each time they touched did not do major damage (only ran for a couple of mins due to the noise)

            Lee
            '18 VX, Billies with Dobinson springs, Summit bar with Narva Enhanced Optics to help my old eyes

            Comment


            • #7
              Lee, complete new head installed. Head removed once again and found number 3 piston slightly picked up on the cylinder. I'd say this is the noise.
              Looking at a options......reco motor from D4D engines or a rebuild....probably end up being the same cost.

              Comment

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