Liam Posted May 17, 2018 Share Posted May 17, 2018 Hello, My 2007 2.3L Fusion has a rattling noise coming from the engine area when over 2000RPM. It is most pronounced under acceleration. It goes away when cruising. I can get it to happen when stationary in park by revving the engine hard up and down through the RPM range but it is not as loud as when I am accelerating. I attached an audio file of me driving it. So far the following items have been replaced but the noise is still there. Timing chain, serpantine belt tensioner, wrist pin, cam shaft counterbalancer. The noise started recently at 103 K miles. Any ideas? Thanks, Liam Fusion engine rattling noise.mp3 0 Quote Link to comment Share on other sites More sharing options...
bbf2530 Posted May 17, 2018 Share Posted May 17, 2018 (edited) 1 hour ago, Liam said: Hello, My 2007 2.3L Fusion has a rattling noise coming from the engine area when over 2000RPM. It is most pronounced under acceleration. It goes away when cruising. I can get it to happen when stationary in park by revving the engine hard up and down through the RPM range but it is not as loud as when I am accelerating. I attached an audio file of me driving it. So far the following items have been replaced but the noise is still there. Timing chain, serpantine belt tensioner, wrist pin, cam shaft counterbalancer. The noise started recently at 103 K miles. Any ideas? Thanks, Liam Fusion engine rattling noise.mp3 Hi Liam. Were the catalytic converters, their heat shields and other engine compartment and underbody shielding components ruled out as sources of the noise? Edited May 17, 2018 by bbf2530 0 Quote Link to comment Share on other sites More sharing options...
Liam Posted May 17, 2018 Author Share Posted May 17, 2018 Yes - heat shields are ok. The noise seems to be coming from the right side of the engine. 0 Quote Link to comment Share on other sites More sharing options...
FusionDiffusion Posted May 17, 2018 Share Posted May 17, 2018 Is this a manual? Sounds like it. At the beginning there is a noise that sounds like it's the result of weight transfer, possibly suspension. Have you ruled out suspension components by turning the wheel all the way both directions while stationary, and bouncing each corner of the car up and down? That could be a separate issue. If you manually raise the revs of the engine in neutral, does it make the noise? Try to raise them slowly like you would be normally accelerating. I'd hold the revs and then get under the hood with a mechanic's stethoscope to pinpoint it. Is the engine running fine or is it misfiring? 0 Quote Link to comment Share on other sites More sharing options...
Liam Posted May 17, 2018 Author Share Posted May 17, 2018 It is an automatic transmission. The creaking noise at the beginning is a suspension/strut noise and is unrelated. "Have you ruled out suspension components by turning the wheel all the way both directions while stationary, and bouncing each corner of the car up and down?" Yes "If you manually raise the revs of the engine in neutral, does it make the noise?" Yes but the noise only occurs as RPM increases. If I hold the RPM steady or reduce RPM there is no noise. Engine runs perfectly otherwise. I'm sure many people could happily ignore the noise. I believe that my mechanic (or former mechanic now ;)) used a stethoscope but could not pinpoint it. 0 Quote Link to comment Share on other sites More sharing options...
FusionDiffusion Posted May 18, 2018 Share Posted May 18, 2018 Take out the front oxygen sensor and look in the hole to see if the catalyst bed is damaged or not. It should look like a grid of tiny squares. If there are pieces then you need to replace the catalytic converter. 0 Quote Link to comment Share on other sites More sharing options...
bbf2530 Posted May 18, 2018 Share Posted May 18, 2018 19 hours ago, Liam said: Yes - heat shields are ok. The noise seems to be coming from the right side of the engine. 8 hours ago, FusionDiffusion said: Take out the front oxygen sensor and look in the hole to see if the catalyst bed is damaged or not. It should look like a grid of tiny squares. If there are pieces then you need to replace the catalytic converter. Hi Liam. As FusionDiffusion just asked and I mentioned above, were the actual catalytic converters (not just the shields) also ruled out as a cause? 0 Quote Link to comment Share on other sites More sharing options...
Liam Posted May 18, 2018 Author Share Posted May 18, 2018 Thanks for the suggestions guys. I don't think it is catalytic converter. I just listened to it again with my head over the engine and somebody revving the engine. I think the sound is from under the valve cover. I understand that this engine has variable valve timing. Could that be a factor since the noise is only there when the engine is increasing in RPM, particularly under load? 0 Quote Link to comment Share on other sites More sharing options...
con_fusion Posted May 18, 2018 Share Posted May 18, 2018 How about the engine mount on the passenger side? If the rubber has collapsed or torn it could leave the metal bracket against the metal of the engine mount perhaps? Take a look at yours and compare to a picture of a new one. 0 Quote Link to comment Share on other sites More sharing options...
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