FORUM CLASSIFIEDS DIFFLOCK.com Links & Networks
Forum Homepage
Log in
Profile
Search
Private Messages
Forum Members
Register
Classified Ads
Search Ads
Place New Ad
My ads
Place your classified
ads here for FREE
NB: Adverts placed in the general
forum areas will be deleted
Difflock Homepage
Online Shop
Contact Us
FAQ
Calendar
Garage
Facebook
Twitter
Youtube
Advertise With Us - Reach your target market by advertising on the Difflock.com forum.
Click here or call 0845 125 9407


Mysterious tappeting noise from my engine

 
 
Post new topic   Reply to topic    Difflock Forum Index -> Suzuki
View previous topic :: View next topic  
Author Message
Little Toe
Guest








PostPosted: Thu Dec 27, 2007 8:47 pm    Post subject: Mysterious tappeting noise from my engine Reply with quote

As some of you may have read on my other post - http://forum.difflock.com/viewtopic.php?t=18898
I've been searching for a mysterious tappetting noise coming from the 1300cc engine in Little Toe.

Culprits were
1. a rocker arm
2. a stick/bent valve
3. fuel pump,
4. distributor
5. cracked exhaust manifold
6. a little end bearing on a con-rod.

So having checked the valve train and tappets, replaced the fuel pump, examined the distributor I moved onto No.5.

Took the exhaust manifold off and low and behold - a hair line fracture in the casting...

Cleaned off the baked on mud...


Close up of the crack...


Cleaned up the area with a rotary abrasive wheel on an angle grinder...


Then chased the crack with a slitting disc in the angle grinder...


Then drilled a hole at each end of the crack to stop it propagating...


Then welded it all up with the MIG welder (0.8mm Mild Steel on CO2 gas)...


Then refitted it all back on the engine, turned the ignition key and up she fires - AND STILL THE BL_ _ DING TAPPETTING NOISE IS THERE ! Twisted Evil

At this point I was about to call it a day and then while checking the distributor cap, I felt a puff of hot gases on my hand.

A quick feel around the base of the distributor and I could feel what felt like a circular hole in the cylinder head, just below the fuel pump and facing the bulkhead. Placing my finger over the hole the tappetting noise stops ! Laughing Laughing

With bated breath I inserted my camera phone down the back of the engine and took about 5 pics before I got what I wanted Laughing ...

This was the picture I got...


And this is were it is in relationship to the rear of the cylinder head...


It looks like its a corroded head plug core - but only exhaust gases is coming out it, no water or oil.

Questions
1. How do I repair this?
2. Do I have to take the cylinder head off?
3. Whats the part number ?
4. and where can I get one from?

Cheers
Shaun
Back to top
silver zuk
Off-Road Guru


Joined: 10 Oct 2007
Odometer: 1800
Location: surrey



PostPosted: Thu Dec 27, 2007 8:57 pm    Post subject: Reply with quote

hi Shaun what the hell is that plug for my engine makes that noise i will have a look tomorrow and see if i have the same problem
Back to top
View user's profile Send private message
patroldriver1
Just got MTs


Joined: 09 Dec 2006
Odometer: 343
Location: blackpool



PostPosted: Thu Dec 27, 2007 8:59 pm    Post subject: Reply with quote

can you tap it n put a bolt in it ???or bung it up ???
__________________________________
what do they put in flys to make them stick???
www.nw4x4response.co.uk
Back to top
View user's profile Send private message
Little Toe
Guest








PostPosted: Thu Dec 27, 2007 9:30 pm    Post subject: Reply with quote

Not sure if I can plug it with a bolt, as I'm not sure what it might block off.
Here's a close up ...


As it's got exhaust hot gases and is under considerable gas pressure, I'm not sure if using a would work either Confused
Cheers
Shaun
Back to top
patroldriver1
Just got MTs


Joined: 09 Dec 2006
Odometer: 343
Location: blackpool



PostPosted: Thu Dec 27, 2007 9:40 pm    Post subject: Reply with quote

hmmmm dose the metal look weldable ???
__________________________________
what do they put in flys to make them stick???
www.nw4x4response.co.uk
Back to top
View user's profile Send private message
Little Toe
Guest








PostPosted: Thu Dec 27, 2007 10:13 pm    Post subject: Reply with quote

not sure - it might be steel or it might be a copper base alloy.

Anyone got a loose head that they can have a look at and confirm where the hole goes to?
Back to top
Nathaniel
Difflock Royalty


Joined: 13 May 2003
Odometer: 17901
Location: North, North Yorkshire


1979 Suzuki LJ

PostPosted: Thu Dec 27, 2007 10:17 pm    Post subject: Reply with quote

I have a removed engine up at the farm, will try and look tomorrow night.
__________________________________
Nat

If You Open Your Mind Too Much Your Brain Will Fall Out
Back to top
View user's profile Send private message Visit poster's website MSN Messenger eBay Name
(pete)
Mud Obsessed


Joined: 19 Nov 2006
Odometer: 5806
Location: aldershot



PostPosted: Thu Dec 27, 2007 10:24 pm    Post subject: Reply with quote

i will pop to the shed and have a look for ya back in five Laughing Wink
__________________________________
X-RATED 4x4 systems
Back to top
View user's profile Send private message Send e-mail AIM Address
Little Toe
Guest








PostPosted: Thu Dec 27, 2007 10:25 pm    Post subject: Reply with quote

Thanks
Back to top
(pete)
Mud Obsessed


Joined: 19 Nov 2006
Odometer: 5806
Location: aldershot



PostPosted: Thu Dec 27, 2007 10:32 pm    Post subject: Reply with quote

rite just been out and had a look and that hole on the head i have in the shed is threaded mate I'm sure i have the right one

i looks like a mount hole for the dizzy

ill just drop you a pm with my number mate give me a quick call of send me yours and i will call you

__________________________________
X-RATED 4x4 systems
Back to top
View user's profile Send private message Send e-mail AIM Address
Little Toe
Guest








PostPosted: Thu Dec 27, 2007 11:11 pm    Post subject: Reply with quote

Cheer Pete.
He's a pic showing how there's a passage running from the No.4 exhaust manifold, then turns at right angles and then mates up with the cast tube that runs across the rear of the cylinder head.
Back to top
(pete)
Mud Obsessed


Joined: 19 Nov 2006
Odometer: 5806
Location: aldershot



PostPosted: Thu Dec 27, 2007 11:15 pm    Post subject: Reply with quote

here ya go you can see where the wire goes
__________________________________
X-RATED 4x4 systems
Back to top
View user's profile Send private message Send e-mail AIM Address
(pete)
Mud Obsessed


Joined: 19 Nov 2006
Odometer: 5806
Location: aldershot



PostPosted: Thu Dec 27, 2007 11:45 pm    Post subject: Reply with quote

i don't think it is to be honest Shaun come up with a good one on the phone could well be a heat exchange for the intake heating built in to the intake manifold itself but its a strange one that much is obvious
__________________________________
X-RATED 4x4 systems
Back to top
View user's profile Send private message Send e-mail AIM Address
4x4rick
Off-Road Guru


Joined: 06 Dec 2007
Odometer: 1900
Location: J25 M25



PostPosted: Thu Dec 27, 2007 11:46 pm    Post subject: Reply with quote

hi , if its hard to get to and u don't want to remove the head how about some liquid metal to bung it up? would take the heat and pressure....Ricky
Back to top
View user's profile Send private message
Little Toe
Guest








PostPosted: Fri Dec 28, 2007 12:09 am    Post subject: Reply with quote

Just been chatting to Pete ( Bonerattler) and Pete (xxamtex) and studing the Haynes book of lies - and blow me down with a feather, Haynes manual was actually useful Shocked
Mind you that's only because it was written for the US market, and not the English market.

Anyway, I digress, if you turn to page 6.6, diagram 7.1b ...

what you mean you don't have a Haynes manual Rolling Eyes

okay here's the page....


and if you look at the cylinder head to the left of the picture, you can see a dotted tube running under the cylinder head and into the inlet manifold.
Thats for the EGR (Exhaust Gas Recirculation System) and is only applicable on US spec zukes, not on UK spec zukes.

So all I have to do is weld up the EGR take-off hole on the exhaust manifold...



and NO MORE TAPPETTING NOISE Laughing

I'll weld it up tomorrow and post the good news (hopefully Confused )
Cheers
Shaun

ps, a big thanks to both Pete's for helping me out on this.
Back to top
(pete)
Mud Obsessed


Joined: 19 Nov 2006
Odometer: 5806
Location: aldershot



PostPosted: Fri Dec 28, 2007 12:26 am    Post subject: Reply with quote

grayspeed i was wrong i stand corrected on that one

Shaun i guess you are a happy bunny now nice job bud get it welded up and should be sorted Very Happy Cool

__________________________________
X-RATED 4x4 systems
Back to top
View user's profile Send private message Send e-mail AIM Address
xamtex
Difflock Royalty


Joined: 02 Dec 2003
Odometer: 11903
Location: nuneaton



PostPosted: Fri Dec 28, 2007 1:15 am    Post subject: Reply with quote


just spotted first pic.....kitchen sink?????your missus still talking to you????

__________________________________
gods zoo is mighty....BUT..his fence is too low.?
Back to top
View user's profile Send private message MSN Messenger eBay Name
Little Toe
Guest








PostPosted: Fri Dec 28, 2007 1:24 am    Post subject: Reply with quote

She stopped talking to me years ago Pete Laughing Doing things like that on a regular basis keeps her quiet Laughing Wink
Back to top
Nathaniel
Difflock Royalty


Joined: 13 May 2003
Odometer: 17901
Location: North, North Yorkshire


1979 Suzuki LJ

PostPosted: Fri Dec 28, 2007 10:54 am    Post subject: Reply with quote

Well thats wierd!

Well spotted, get it bunged up quick!

__________________________________
Nat

If You Open Your Mind Too Much Your Brain Will Fall Out
Back to top
View user's profile Send private message Visit poster's website MSN Messenger eBay Name
Little Toe
Guest








PostPosted: Fri Dec 28, 2007 2:36 pm    Post subject: Reply with quote

I took a quick video so that you folks can hear what this mysterious tapetting noise actual sounds like. You can see be putting my finger over the hole and lifting it off again and hear the difference it makes...

http://www.youtube.com/watch?v=FLKSBJhhR_Y

I then took the exhaust manifold off - yet again ( I can now get it off in under 5 mins now Laughing )

and then welded up the EGR hole on the manifold...


then dressed it with the trusted angle grinder and a file...


Then chucked it all back on and hey presto - the mysterious tappetting noise has now gone - Razz Razz Razz

Cheers,
Shaun
Back to top
oshimon
Mooch Master


Joined: 24 Oct 2003
Odometer: 6786
Location: Jerusalem. Israel



PostPosted: Fri Dec 28, 2007 4:58 pm    Post subject: Reply with quote

Excellent thread!

And the most amazing thing about it?

Quote:
I then took the exhaust manifold off - yet again ( I can now get it off in under 5 mins now )


Shocked

The bolts on mine scare the heebie-jeebies out of me, I'd rather let the thing sound like a tractor than have a go at them!

Simon 'is starting to fear parts of the zook' Owen.

__________________________________
There are some days when even my lucky underpants can't help.....

For Ian's sake, desperately trying to keep up at the back.
Back to top
View user's profile Send private message Visit poster's website
Little Toe
Guest








PostPosted: Sat Dec 29, 2007 12:20 pm    Post subject: Reply with quote

Hi grayspeed - you don't need to plug both ends as on UK spec zukes only the exhaust end of the EGR tube is open, the other end is left un-machined, and only gets drilled through to the inlet manifold for US spec zukes. So all I've had to do is weld up the exhaust side.
Cheers
Shaun
Back to top
srcars
Winch Assistant


Joined: 03 Sep 2006
Odometer: 72
Location: Dorset


1990 Suzuki Samurai

PostPosted: Mon Dec 31, 2007 12:14 pm    Post subject: Reply with quote

Thanks Little Toe

I could never find the cause of the noise. Manifold off welded up and refitted this morning and no more annoying bl**** tapping.

Your a star Very Happy

Happy New Year Every Body Wink
Back to top
View user's profile Send private message Send e-mail Visit poster's website
Philpy
Just got MTs


Joined: 24 Nov 2007
Odometer: 349
Location: Cornwall


1985 Suzuki SJ

PostPosted: Sun Mar 14, 2021 9:54 am    Post subject: Reply with quote

Well, I’ve recently fitted a 1.6 to my sj and thought I’d bought an engine with a problem. I’ve been chasing this noise for weeks, and sure enough found this hole and covered with my finger and the noise disappears!
Thanks Little Toe
Back to top
View user's profile Send private message
Philpy
Just got MTs


Joined: 24 Nov 2007
Odometer: 349
Location: Cornwall


1985 Suzuki SJ

PostPosted: Tue Mar 16, 2021 9:21 pm    Post subject: Reply with quote

Not that many read this forum anymore, but as an update I’ve welded up the hole as per above and sounds so much better. Well chuffed.
Back to top
View user's profile Send private message
Display posts from previous:   
Post new topic   Reply to topic    Difflock Forum Index -> Suzuki All times are GMT - 12 Hours
Page 1 of 1

 
Jump to:  
You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot vote in polls in this forum
You cannot post calendar events in this forum
Specialist Tools

Service Kits

Evo Oils

Oil Safe

Adrian Flux 2019

Join our mailing list for upcoming events, special offers, discount coupons and expert advice on the latest 4x4 products!

* indicates required





    
Powered by phpBB © phpBB Group