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Engine Rattle/Knock

687 Views 25 Replies 8 Participants Last post by  JohnD
Okay, this is driving me nuts, ive been twice to 2 different dealerships and i have been in contact with ford but they say they cant do anything unless the dealership finds something, but the dealerships either deem this sound a "normal operation sound" or they "cant replicate the the noise" but i hear it...every....single...day to and from work. Below is the link to a video of the first 5 ish minutes of my startup every morning where its at its loudest but it can also be heard even when the engine is hot but only when under a load like going up a hill. I recorded the noise by securing a camera under the bonnet, and i know it will amplify the sound being under the bonnet but it is still loud and easily heard even when driving behind the wheel, plus i have already tried recording from inside the car but the mic doesnt pick it up very well, its a surprise the dealerships say they cannot hear it.

Its had a service a few weeks back so its not old oil.
70 Plate ST Edition
roughly 18.6kmiles

https://www.dropbox.com/.../e4kz3m.../20230424_054253.MOV...

1:26 1:33 1:55 2:18 2:23 2:38 2:48 3:00 3:12 3:28 3:57 4:24 are the times its heard the loudest if you dont wish to sit through the whole recording

I still have waranty on this so i would like to get it fixed under warranty before i do any modifcations
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Defo doesn't sound right hopefully you can get it sorted what mods you looking at getting I have airtech intercooler induction kit miltek exhaust system stage 2 remap sounds nice
It's hard to tell from clip but almost sounds like it's dropped a cylinder.

A common "rattle" is the high pressure fuel pump which makes it sound like a diesel when cold. But doesn't really sound like that.
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Not that it helps, since I haven't resolved the issue, but here's my experience with what is likely the same issue on my 2018 MK8 ST with around 26k KM.

I've been dealing with the same noise in my car for about a year now. Initially, I only noticed it during the first minute of driving, but it gradually increased to about five minutes. After that, it completely goes away, and it only happens again if I let the car sit for around 24 hours. The sound becomes more prominent when you apply any kind of load to the engine, such as when exiting an underground garage. It's also really difficult to hear the rattle/knock unless there's a nearby wall for the sound to reflect of.

I haven't taken it to the dealer because they would need to leave the car idle for a day and then apply some kind of load in order to hear it.

Apart from you, only two other people have described a similar issue. @eliteA92 mentioned it at Injector noise when car is cold and IDecX on the other Fiesta ST forum in a thread titled "Cold start rattle" (not sure if I'm allowed to post to there). I remember listening to the recordings the latter posted, and it was a similar sound. However, he has since removed them from his Dropbox. In both instances, people mentioned the loud direct injector gasoline, or the high pressure fuel pump.
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Defo doesn't sound right hopefully you can get it sorted what mods you looking at getting I have airtech intercooler induction kit miltek exhaust system stage 2 remap sounds nice
Scorpion cat and scorpion cat back exhaust or miltek dual exit cat back with RS style diffuser, Stage 1(LairdPerformance, ColinsPerformance, Mountune Or revo, still havent decided), with their choice of induction kit, skirts, front splitters, lip spoiler, maybe change the alloys but the stock ST edition ones are pretty nice alone and some Smoked rear lights(just wating for stock)

And yeah, it doesnt sound right at all, its been to 2 different dealerships and they cant fault the car which i find BS, with the warmer weather approaching its going to be even harder to diagnose as its harder to hear when warm
It's hard to tell from clip but almost sounds like it's dropped a cylinder.

A common "rattle" is the high pressure fuel pump which makes it sound like a diesel when cold. But doesn't really sound like that.
Dropped a cylinder? I dont understand fully. And yeah, does not sount right at all, its even worse in person. im really surprised both dealerships are either ignoring this sound or are deaf
Dropped a cylinder? I dont understand fully. And yeah, does not sount right at all, its even worse in person. im really surprised both dealerships are either ignoring this sound or are deaf

Sorry "drop a cylinder" is when one cylinder isn't firing.

So something like a failing spark plug, injector, coil pack etc.


I don't think dealers give enough time to intermittent faults.
Sorry "drop a cylinder" is when one cylinder isn't firing.

So something like a failing spark plug, injector, coil pack etc.


I don't think dealers give enough time to intermittent faults.
Ah okay, i get you now, and yeah i agree, i even asked TCH(they fit mountune stuff) if they have access to a dyno which could help diagnose the noise but no luck. I darent put any more money into it than i already have untill its sorted but the dealers are being a **** pain in the arse, im going up with my dad tomorrow for him to hopefully upgrade his car. ill ask again and be a bit more direct
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I wonder what would happen if the cylinder de-activation was stuck on all the time. Surely it would run rough and lack power, but I am assuming total outage of one cylinder. If the spark was there but poor lets say, it would still fire but badly.
Could it even be a manifold leak perhaps?

Just a few questions though....
Does the engine run normally with full power aside from the noise?
Does selecting sport mode alter things in any way?
Did the noise begin before it was serviced a few weeks ago?
Does it make any difference with the air-con switched off?
PS.... I got mine from TCH in Peterborough and really have found they are good to deal with.
I wonder what would happen if the cylinder de-activation was stuck on all the time. Surely it would run rough and lack power, but I am assuming total outage of one cylinder. If the spark was there but poor lets say, it would still fire but badly.
Could it even be a manifold leak perhaps?

Just a few questions though....
Does the engine run normally with full power aside from the noise?
Does selecting sport mode alter things in any way?
Did the noise begin before it was serviced a few weeks ago?
Does it make any difference with the air-con switched off?
Hmm.... I never thought of the cylinder deactivation, might mention that to the dealership tomorrow.
Engine runs and has power, just sounds rough
No difference in all modes
Noise before and after the service
Air con is mostly off, but no change with it on either
Just to be clear, the noise began after you got the car.... it has not always been there?

If possible, if it were me, and the dealer insits it is normal operational noise, ask them if you could test-drive another one to see if it is the same. A big ask I know, but at least that way, you will know for sure.
The noise started around 5 months after owning the car. I've had it for nearly 9 months now and has gotten worse over the past 2 months. Both dealerships I went to didn't have any st's available to drive that that moment.
I must admit, it does sound pretty bad on your recording from under the bonnet.
I have no idea what mine would sound like, given the same recording being made though.

In any case, if it has got worse, you must keep on at the dealer and not be fobbed off.
At least now they have a record of your reporting of the fault, so if anything happens, you can say that to them.
Yeah, the last dealership I went to said the fault/noise/knock .ect has been forwarded to ford. But dunno how true that is but I'll keep on at them.I got a lot planned for this car and I want to keep it but it's driving me nuts and edging me closer to selling it

Yeah with the camera being under the bonnet it does amplify the noise quite a bit, I did try recording from inside the car but the camera and my phone's mic didn't do a very good job picking it up.
Just to be clear, the noise began after you got the car.... it has not always been there?

If possible, if it were me, and the dealer insits it is normal operational noise, ask them if you could test-drive another one to see if it is the same. A big ask I know, but at least that way, you will know for sure.
They didn't have a st available to test at the time.
Sorry "drop a cylinder" is when one cylinder isn't firing.

So something like a failing spark plug, injector, coil pack etc.


I don't think dealers give enough time to intermittent faults.
You don't Think it could be piston slap could you? I hope to god it's not
They didn't have a st available to test at the time.
You don't Think it could be piston slap could you? I hope to god it's not
If it is at least you'd get a replacement engine for free.

I'd like to think it's extremely unlikely, slap is normal reserved for badly rebuilt engines.
Just to be clear, the noise began after you got the car.... it has not always been there?
Yeah, i had the car for about 5 months when it started, its been getting worse over the past 2 months but been going on for nearly 4 months now
that sounds bad. mine for sure doesnt sound like this at all.
another thing you can do is to find another one st mk8 (your friend or something like that, i know its not easy) to proof them that is not normal to sound like that.
fiesta st's are to the end of production and i dont think they will ever have eny test drive

if its piston slap you will see oil consumption, a great amount

EDIT: it could be a timing chain problem as well, or the tensioner of the timing chain.
Sounds like good old fashioned piston slap. My wife's Performance edition does it. Starts about 15 secs following a cold start and goes as the engine warms. I actually started a post about it some while back.
Piston slap has been around since the invention of the internal combustion engine. I've had cars which have suffered from it. Engines with forged pistons often suffer due to increased piston clearance when cold. I remember the handbook for the Mk1 Sierra mentions it in the Cosworth section "piston noise when cold which is normal and may be ignored"
As long as the noise goes as the engine warms it should be ok Some engines do it, some don't, just keep the load on the engine low until warmed. Got a feeling this 1.5 can be prone to it. I don't know but the 1 ltr is probably fine!

JohnD
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