Oh boy, Rod knock already?

[Baddog]

I just had a 93 Ej22t rebuilt using OEM bearings and all were in spec. I went to show a buddy of mine the car and got home and heard a loud knocking noise. It DOES NOT increase with revs however. It actually goes away with revs.

150 miles on the motor and not pushed past 3500rpm's yet. I know there are 2-3 bad HLA's on the side the noise is coming from.

Here is a video

https://sl-i.net/FORUM/images/imported/2013/01/th_20130104_221443-1.jpg (http://i830.photobucket.com/albums/zz223/Baddog909/20130104_221443.mp4)

Update: Just went outside to do a little bit of testing. I confirmed again it goes away when the motor is revved. The valve tick noise is still there at all revs (of course).

I pulled each plug wire off one at a time. The knock sound went away when I did this. Regardless of which cylinder I pulled the plug wire from.

[Dead91silvia]

I cant play it, but I'm betting it spun a rod bearing. My ej25d in my BD did that a couple year ago. Had a knock at idle but went away at higher RPM...

[dropdfocus]

It does resemble rod knock.

[anothernord]

I don't know, that doesn't have enough of a "clacking" noise to be rod knock. It's more of a dull thudding noise.

If you know some of the HLA's are bad, take em out and bleed them.

[decke48]

I pulled each plug wire off one at a time. The knock sound went away when I did this. Regardless of which cylinder I pulled the plug wire from.
Like Anothernord said its more of a dull thud noise. ive here this kind of noise when spark plug wire are grounding out.

[Baddog]

I thought it wasn't rod knock either. I drained the oil pan and than removed it from the motor. Tons of swirl and small metal pieces in the pan.

Damn. What happened

[anothernord]

Bad day! Time to tear it down.

[lord flashheart]

when u put it together, did u:
use bearing guard or prelube?
did you crank the motor with out spark plugs to get oil pressure or 'prime' it?
did u use a good bearing? (ACL, Clevite, Cosworth)
did u use a good oil, heavier oil?
did u replace the old oil cooler? (if you dont the debris from the old motor can nuke a motor very fast)
did u clean EVERYthing that comes in contact with oil?

those are the major things that can cause a bearing failure after a rebuild.

[Baddog]

when u put it together, did u:
use bearing guard or prelube?
did you crank the motor with out spark plugs to get oil pressure or 'prime' it?
did u use a good bearing? (ACL, Clevite, Cosworth)
did u use a good oil, heavier oil?
did u replace the old oil cooler? (if you dont the debris from the old motor can nuke a motor very fast)
did u clean EVERYthing that comes in contact with oil?

those are the major things that can cause a bearing failure after a rebuild.

Yes prelubed.
Yes i built oil pressure before i started the motor fully
I used acl mains and oem rods
Rotella t6 oil
No oil cooler
Everything was hot tanked. Heads were rebuilt.

I suspect oil pump failure

[lord flashheart]

did you rebuild your pump? debris likes to get packed into the nooks and crannys of the pump. also, your oil galleys should be brushed, and flushed

[Baddog]

That's one thing I didn't do. Was rebuild the pump.

How much would it cost to have the block galleys brushed and flushed? Hot tanking wouldn't clean it out enough?

[Baddog]

So gents. Here is what I found today. Keep in mind I installed a BRAND new fuel filter when this motor was put in.

This is in all of the heads. Hard as a rock. Have to use a screw driver to break it off.
https://sl-i.net/FORUM/images/imported/2013/01/20130109_123343-1.jpg

And traces of it in the fuel filter. Pull it out. Same color and hard texture.
https://sl-i.net/FORUM/images/imported/2013/01/20130109_175732-1.jpg

Sugar in the gas tank? Whatever it is. I believe it is the reason the old heads locked up on the intake side.

[dropdfocus]

Yikes!!! Did it end up ruining the engine or would having it re-hot tanked make it usable again? So sad to see.

[Baddog]

Bearings are shot. Crank will need to have machine work done. Block halves and heads hot tanked. And doing a full fuel system clean up. As well as replacing the fuel pump and fuel tank.

[lord flashheart]

damn dude that sure looks like sugar in the gas tank to me..
they got just that perfect mixture that can really fuck shit up.
too much sugar and it will stay in the bottom of the tank.
not enough sugar and it wont get the desired effect (plug the lines)
these assholes managed to get just enough that it doesnt plug the line but the
sugar gets into the bore, scars the cylinders, causes debris, wipes out bearings..
shitty man.. shitty.

[Baddog]

damn dude that sure looks like sugar in the gas tank to me..
they got just that perfect mixture that can really fudge shit up.
too much sugar and it will stay in the bottom of the tank.
not enough sugar and it wont get the desired effect (plug the lines)
these assholes managed to get just enough that it doesnt plug the line but the
sugar gets into the bore, scars the cylinders, causes debris, wipes out bearings..
shitty man.. shitty.

Thankfully the bores seem okay. Machine shop will be able to let me know more.

Honestly never even thought to look.

[lord flashheart]

Yeah i wouldnt bore it. I highly doubt its outta round. I would do crank and bearings. Possibly rings.
Also i want to reccomend the joe gibbs brake in oil 15-50.

[Baddog]

Any suggestions on getting this substance out of the hard lines? Acetone? Carb cleaner?

[lord flashheart]

Man ive never had to clean it. Ive heard a combination of heat or isopropyln alcohol (rubbing alcohol). If it was me i would get some chunks and see what it responds to.

[harrymaneuvers]

Did I miss something??

Who on earth would put sugar in your gas tank???? Are you feuding with anybody??

Doesnt your car have a fuel door release lever down on the floor?


Either way, this is one of the most jacked up things I have seen... ever.