3L making a knocking noise over 2100rpm

[spongerx]

My 3L started making a knocking noise over 2100 rpm while driving today. There's no loss of power, excess smoke or warning lights on the dash and it's not overheating. It sounds like metal hitting metal towards the back of the engine making the noise.

The engine has under 40,000km on it, is non-computer controlled and is in a 2003 Hilux which is dealer serviced at 5000km intervals. I've never seen the temp gauge go over half way under any conditions.

Anyone have any idea what this noise could be?

[NHV6]

bit hard to tell but it could be a big end bearing. they usually only knock in a narrow rev band and will do it mostly when there is no load or very light load. should be able to hear it loudest if you hold it at the same revs in neutral, or maintain a constant speed in a low gear, but it will quieten down somewhat when you hit the gas or back off. or it could be any number of other problems. seems strange in a new engine, maybe a warranty issue???

[spongerx]

Thanks for the input NHV6. I didnt try revving it too far past 2100 rpm cos the noise got worse the higher the revs went. It was making the sound under load and no load and also when i brought the revs gently up to 2100 rpm when downshifting. The noise sounds like it's coming from near the top of the engine towards the back and sounds like a metal object hitting thinnish metal.

Spoke to 2 mechanics about it yesterday. The dealership one wants to pull the engine to pieces and rebuild, warranty expired last October so that'd be at my expense.... The other mech thinks it could be a valve adjuster hitting the tappet pan cover so he's having a look under there today. Spoke to the dealership mech again this morning and he agrees it could be somthing as simple as a valve adjuster but then added it's more likely to be a valve guide which would mean takin the head off.

Hopefully it's nothing too major and dont need a rebuild on an engine that's still relatively new. Should know the full story on it this afternoon.

[spongerx]

Got the bad news this afternoon that the engine definitely needs to be pulled down and rebuilt. Seems at the last service the wrong oil was put in. Either a synthetic that was too light or oil for a petrol hilux engine. The mech that was lookin at said the oil was like water.

It's only ever been dealer serviced too so they better pick up the bill on this repair.

[phippsy]

Good luck with the dealer. If they are any good hopefully they'll help out with some of the cost of the repair. I had to fight with the company my warranty was with when the engine needed rebuilding. Eventually when I was able to prove that the problem had started prior to my ownershiop, they came good.

[Ruffy]

It's a tough situation to be in. The dealer has no responsibility to pay someone else's bill unless they have agreed to do so prior to the work taking place. Also if you give it to them and there is no negligence proven then you have to pay them to fix it.. Catch 22.
Good luck. Wrong oil is a tough thing to prove. It means you need to send a sample away to have it analysed by a chemist. Trucking companies do this all the time, ask around diesel mechanics and they'll point you in the right direction of where to get this done.
Cheers Dan

[Chucky]

It's a tough situation to be in. The dealer has no responsibility to pay someone else's bill unless they have agreed to do so prior to the work taking place. Also if you give it to them and there is no negligence proven then you have to pay them to fix it.. Catch 22.
Good luck. Wrong oil is a tough thing to prove. It means you need to send a sample away to have it analysed by a chemist. Trucking companies do this all the time, ask around diesel mechanics and they'll point you in the right direction of where to get this done.
Cheers Dan

It's called an oil spectrual (SP) analisis. it will tell you what sort of metal you have in the oil (Expect white metal from bearing as a starter) it will tell you how much carbon, ash, sulphate and any other type of crap in the oil. And it will tell yu the viscosity of the oil as well.
Make sure you get an oil sample and send it off asap.

[Sic Lux]

Yeah do the oil sample straight up to make sure you have firm ground to start on dealerships

[spongerx]

Yeh the 1st thing my mechanic did was take a sample of the oil when he saw its condition. Unfortunately to get it tested we have to ship it off to another island cos there's no places on my island that are qualified to do that sort of testing. In the meantime we're trying to arrange for a representative from the local Toyota dealership here to come see the oil still in the engine before it's taken apart any further and see if they'll admit liability since they're the ones that serviced it 3000km ago and did a full vehicle inspection on it for insurance purposes at the same time.

The engine's going to take over a week to rebuild due to everyone being super busy here right now which raises another problem, thanks to world cup cricket goin on over here in the Caribbean at this time theres no rental cars available on my island

[spongerx]

Turns out a bolt on the #4 cylinder connecting rod had come loose which was causing the noise. Seems like a very odd occurrence. The dealership agreed to pick up the costs even tho the vehicle was out of warranty so that was great news. They never mentioned anything about the oil seeming to be too thin and said everything else was fine.

They now tell me I should change my clutch. They'll pick up the labour costs for this since the engine is out and they can access everything easily but I'll have to pick up the cost of the clutch parts which works out to about 650 Aud. I've only ever smelt the clutch burnin twice in the time I've had it and never noticed any slipping onroad. The previous owner never even had it in 4wd.

How long do 3L engined Hilux clutches normally last? Are they just having me on with having to change the clutch on my truck at 39,000km?

[Luxo]

$650 for a clutch kit, holy crap!

I think they are trying to get back some of the dollars they will be losing

[seaeagle]

i had the same noise untill last weekend...lol i now have a bearing size hole in the sump......rang around the wreckers and $1500 is too much for me....

[Sic Lux]

Price around and that way you can either run one of the better aftermarket ones availalbe or get them to knock some of the mark up off the one they will be supplying 39 thou it should have only just worn in 200k to 300 k they should get around unless you drive round with the clutch half in which is highly unlikely