I need some advise on a problem I'm having with my TW Magna.

The history of the problem started about 3 months ago. A rattle began somewhere in the engine bay. It is especially noticeable when the engine is cold and can often be heard when the engine is at low revs and under a little bit of load. I kinda ignored it for a month or so as it was not too bad, but it's been gradually getting more common and can now be heard when the engine is cold or warm. My thoughts were at first it was an exhaust shield or an engine mount. The car is still under new car warranty, so I've just taken it to the dealer so they could sort it, and here is where the drama has begun.
It's now been back TWICE to the dealer and the problem is still not resolved. The first time I took it in, they reckoned the problem was due to a dirty throttle body which is technically a maintenance item. So, they cleaned it without advising me first then told me I owed them $140 for the privilege. Luckily my complaining paid off as they dropped that charge. Anyway, whilst happy I now have a nice clean throttle body, the bloody rattle is still there! SO.... it was booked in again for another day.

ROUND 2... this time I insisted I a tech reproduce the rattle in my presence which was an easy thing to do. So, with confidence they knew what I was referring to this time, I left it with them for another day. I get a phone call later to advise that the problem is due to a worn timing belt and tensioner and as these are also considered maintenance items, they want $750 to replace them.

So, the car has done 74500kms, regularly serviced and well maintained. It seems WAY too early to have the timing belt done now and I have real trust issues with the dealers diagnosis considering they tried to pull one over me the first time. I just wouldn't be surprised if I spend the money to do the job only to discover that it's not the timing belt either.

Obviously, I just want the problem sorted and as far as I'm concerned the maintenance of the car is not a least bit in question. I've full service history and it's always been at a dealer. Considering the car is still under new car warranty why should I be out of pocket for this?

Anyone had a similar issue or have any advice?

I've actually got the exact same issue lol

Though, mine is rarely (if ever) noticeable when warm.

Usually happens when cold, right around 1150-1250rpm.

Will eagerly await possible answers in this thread.

Noisy lifters?

Sounds bottom end???

Familywagon had the same issue, I chased it for ages until someone changed his main alt belt and power steer belts. Although these looked fine the noise was gone.

His AWD was worse.

Mal - just had mine changed recently, including alternator pulley.

Noise is still there....

Kind of a metallic rumble, sounds like its coming from the bottom of the car (which reminds me, check exhaust heat shields).

Sounds like my car. Some mornings it will start up like a tractor, but if I switch it off and back on the noise is gone.

I also get the gruff sort of rattle noise when accelerating from low revs, sounds crap. Don't know what it is.

It's a common problem for the exhaust heat shields to rattle when they are cold. As they heat up, expansion of the metal takes up the slack. The facts it happening all the time could be that the shield bolts are coming loose.

Definently doubt its the timing belt or tensioner at 74K. For starters, the belt is not going to rattle like a chain. Belt change at 100K is normal and tensioner will last at least till the second belt change 180-200K.

Does the rattle increase it's frequency with RPM speed?

My experience is that yes it is the exhaust but not the heat shield.

Simply it is a small piece of metal inside the Y piece that links the pipes from each bank into the single pipe that goes to the back of the car. The metal involved is not needed as is left over from the weld / join process of the Y.

I have had this in my own TF and then TJ. It is not an issue and is normal for this many km. In my case the piece of metal involved broke off and thus stoped rattling at about 110,000 Km

The easiest way to diagnose this is to put the car on a hoist with the engine running and use a piece of timber as a stethoscope on the Y piece, you should be able to hear it flapping at idle over the timber.

The worst that can happen is the small scrap of metal may lodge inside the cat converter and reduce exhaust efficiency at full throttle.

I had that noise, the bit had broken off and had made its way down to the cat and was rattling. Replaced the cat, the metal was found/removed, exhaust rattle gone.

Not the source of my low rpm acceleration rattle.

Well, based on the replies to my post I'm taking that all are disagreeing with the timing belt tensioner diagnosis.

I thought of an inept description to the noise. It sounds a bit like a diesel engine. In answer to whoever asked if the noise is still there at higher revs, no the noise is not audible any higher than about 1500rpm.

Tell me, has anyone actually witnessed a timing belt snap on a magna pre 100,000k's?

I had that noise (in addition to the diesel rattle at idle), the exhaust place found that piece in my cat :rant: New cat (old one broken anyway), still have my idle rattle though :(

And instead of removing that splitter plate you should ideally weld it back in. You do not need to cut the pipel if you know where to drill you can acually drill into the pipe and re weld the plate in.

From what my brother tells me Mitsubishi only did this for a few years or so then stopped putting them in more likely to do with the rattle and that it really didn't do much anyway as when it is removed it hardly has a bend in it to even deflect much.

Also drilling it might not work as the plate moves a good deal as my brother showed me there was allot of play back and forth and left to right so if it's not sitting exactly were it was the chances are you would miss it and still rattle but might be a first job before going to the exhaust shop if you have to pay.

They continued the plate right up to the TW, they on the early models only spot welded them on one side, on the later models they were welded on both sides which stopped them vibrating and coming away

I have successfully drilled and welded them on many occasions, the one in my car currently has been drilled and welded with no issues, just need to know where to drill :)

Had mine fixed today it was the diverter/deflector plate making the rattle here are the pics of it.

http://img.photobucket.com/albums/v201/AussieHolden/DSC00003.jpg

http://img.photobucket.com/albums/v201/AussieHolden/DSC00004.jpg

http://img.photobucket.com/albums/v201/AussieHolden/DSC00005.jpg

These plates are only tac welded with small tacs only 2 one on top and one on bottom they come off from the heat and start to rattle just get them to take it out as there not needed anyway.

how much do you guys think it will cost for a exhaut shop to do this for me... as i dont have a welder.. nor a angle grinder.. co i cant cut it or i cant weld it..

or will they tell me to get a new Y piece (if that possible) as i have that same rattle (as i found out today... grr)

Bugger mine sounds like that as well

My TJ had that rattling sound from the tensioner from 50,000 kms, so it is definitely possible. I took it to Mitsi to get it checked, one dealer said it was the tensioner, another denied there was an issue - I left it for ages before getting it fixed but you should be able to something about it as it is under warranty. If the car has been regularly serviced and you have proof you can try for a goodwill repair. I tried for it but they denied it because I didn't have enough of a service history. Cam tensioners should not fail at these kms, they last atleast as long as the belt.

sounds very similar to my car, I've had a rattle for nearly a year tho, started a while after my timing belt was replaced.
A couple of weeks ago asked my mech to have a quick look at it and he thinks theres a chance is could be my water pump, but he needs to have a proper look.

Mat.

how much do you guys think it will cost for a exhaut shop to do this for me... as i dont have a welder.. nor a angle grinder.. co i cant cut it or i cant weld it..

or will they tell me to get a new Y piece (if that possible) as i have that same rattle (as i found out today... grr)

Bump Bump

I had something like this too, specifically after having timing belt replaced. Turned out the guy that replaced the belt adb't re-tensioned the front pulley correctly and it had worked its way loose, resulting in the pulley starting to rub against the side cover. Luckily found the source of the problem and fixed it at home before hazardous damage was done. Could be worth pulling the inside wheel arch cover off from behind the front r/h wheel and checking that you don't have a loose pulley like I did...

Ive got the same trouble. Anyone who starts their engine cold and rattles hard usually its the lifters rattling since there is not enough lubrication to assist them since with time they wear out and not hold enough oil in them.

I definately think ive got an exhaust problem some rattle. As i turn from left to right the sound comes and goes at that same rpm level between 1600-2000rpm. I guess the engine has a high amount of vibration from the block at that given rpm value. Therefore makes this sound. Thanks for your tip s311_bvm

Thanks guys for the info. I've got the same problem with a loud vibration at about 1700-1800 rpm. Only occurs when the engine is cold and definitely coming from underneath the engine bay. This might have solved my problem.

I had the same sort of problem with my TE, when cold at about 1100-1500 rpm i would get a bad rattle, turns out the bearing in the A/C compressor was worn but would only rattle at that rpm.Taking the belt off and running the engine comfirmed this.