Knocking and rattling sound, no codes shown on techstream

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by Baje, Jun 14, 2019.

  1. Baje

    Baje Junior Member

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    Hi all, I have a problem that I thought was solved about a month ago. It all started when I was parked outside one of my clients house which is at the bottom of a hill. When I moved off I heard the loudest knock and engine shake coming from the car engine and it continued all the way home, no CEL illumination. Parked car at home and connected techstream still to see if I could see if anything was wrong.

    Fast forward, took it to mechanic, fair acknowledgement here, we have no hybrid savy mechanics here besides the dealer. Did all sorts of checks, I left the vehicle with him, came back and all sorts of codes where there, inclusive of codes relating to misfires, cleared the codes and the only one that stayed was on No 3.

    I assume this was from him pulling the plugs to see what was happening. No 3 ignition coil had completely failed, side note EGR valve, cooler throttle body and everything else in there was cleaned of carbon was blocked up.

    Ok so back to no 3 ignition coil, while we were checking to make sure it was indeed the coil, I remember him saying he's going to adjust the magnet in the EGR valve, instead of tightening it completely he slightly backed it off. Car wouldn't start but this was because it was out of gas also, bought gas filled her up, recharged battery part ways with hybrid reconditioning pack.

    Car started then cut out, moved the ignition coil and the code followed the ignition coil. So bought new ignition coil, car started and no noise or knock and ran better than ever before.

    Fast forward one month and same thing again, noise started with coming over another steep hill and no codes. Checked EGR valve because I thought that might actually be the issue, why? Reason is after car left mechanic the next day I cleaned the engine down and I was checking the magnet in the valve, just being curious. Put it back on and car was knocking and shaking, I took it back off turned the spring around and it stopped all the shaking and knocking. So I thought it was that once again. Took the magnet off and realised that the magnet had spung all the way up and not locked off and the spring was actually stuck inside the magnet, this didn't happen last time the spring stays on the valve itself.

    Ok so went to the ignition coils, pulled them while car was in maintenance mode no 1 2 and 4 shows a pending code once pulled on my OBD2 was just quicker than techstream at the time, the thing about number 3 it shows a definite fault code and not pending. I changed the coils around still the same, clear the codes and all codes go and stay away. No change in engine noise.

    Could there be something wrong cylinder 3 that it shows definite fault and not pending like the others or is it my EGR valve starting to fail. I don't want to be spending aimless amounts of money when the parts are limited and so expensive here. No used parts in my part of the world, which is Barbados btw.
     
    #1 Baje, Jun 14, 2019
    Last edited by a moderator: Jun 16, 2019
  2. bisco

    bisco cookie crumbler

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    how many miles on her?
     
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  3. Baje

    Baje Junior Member

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    About 82000 miles on it, which is 132000km
     
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  4. bisco

    bisco cookie crumbler

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    that is pretty low mileage, any idea why so much has gone wrong?
     
  5. Baje

    Baje Junior Member

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    That's what I'm trying to find out now since I've seen so many on here with high mileage, the only issue is the constant shaking and partial knocking. No coolant leakage nothing, oil doesn't seem to be burning. Just this issue. Could the EGR valve be causing the issue without the CEL being illuminated?
     
  6. bisco

    bisco cookie crumbler

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    yes, if it is not clean, along with the intake manifold. i've never heard a spring loaded magnet mentioned before.

    have you cleaned the throttle body?

    see the @NutzAboutBolts you tube videos
     
  7. Baje

    Baje Junior Member

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    It was cleaned, previously. On the EGR valve if you open the black part the sensor connects to inside there, there's a magnet and a spring under that. Which locks down on the plunger that goes in and out that opens and closes the EGR valve, that's the spring I meant. I can try cleaning the throttle body and intake manifold once again.
     
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  8. bisco

    bisco cookie crumbler

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    i suppose the egr could be bad, but i don't recall reading that before. none of this makes sense on a car with 82,000 miles. (except the egr circuit) have you owned it since new?
     
  9. Baje

    Baje Junior Member

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    No I'm the second owner of the car, is there anyway to check the circuit? I think I will spend the weekend trying to make sure everything is cleaned again and then post an update.
     
  10. bisco

    bisco cookie crumbler

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    have you watched the videos?
     
  11. Baje

    Baje Junior Member

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    Yes probably more times than I need to
    As I've mentioned before the knocking and all that stopped about a month ago after cleaning and a change of one ignition coil. Just don't understand why it came back

    As I've mentioned before the knocking and all that stopped about a month ago after cleaning and a change of one ignition coil. Just don't understand why it came back
     
    #11 Baje, Jun 14, 2019
    Last edited by a moderator: Jun 16, 2019
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  12. Raytheeagle

    Raytheeagle Senior Member

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    You got an oil catch can installed?
     
  13. Baje

    Baje Junior Member

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    No oil catch can installed, seriously considering it after this second clean over the weekend
     
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  14. Raytheeagle

    Raytheeagle Senior Member

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    I’d add it sooner rather than later ;).

    Good luck and keep us posted (y).
     
  15. wheezyglider

    wheezyglider Member

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    The only way I could imagine the EGR causing these symptoms is if the valve's pintle was sticking slightly open. One way to maybe eliminate that possibility would be to unplug the electrical connector to the EGR valve. (The CEL will come on and throw an EGR DTC.) That won't unstick the valve, but higher RPM should run smoothly even if idle is rough. Otherwise it's not the valve.
     
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  16. Baje

    Baje Junior Member

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    Cleaned everything today again, no change after cleaning but I did change out one of my ignition coils and the knocking went away but the car seems not to be firing evenly, sounds like the engine is missing, best I can explain. Strong exhaust scent present also. This is the spring inside the EGR valve I was mentioning, for some reason it gets stuck inside the magnet and I'm sure the magnet is supposed to spin around it, also the magnet isn't locking down onto the shaft like it used to.
     

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    #16 Baje, Jun 15, 2019
    Last edited: Jun 15, 2019
  17. Raytheeagle

    Raytheeagle Senior Member

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    Did you spin the magnet all the way in prior to putting the black housing back on?

    I’ve not had any problems locking that back down in the about 10 times I’ve had that apart;).

    At least you’ve eliminated one variable from the equation though(y).
     
  18. Baje

    Baje Junior Member

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    Yes I did spin it on completely. Checked the same magnet again, guess what, it's completely unspun. I have question, the times you have taken that magnet off did the spring stay up inside the magnet because mine was lodged inside the magnet once again.
     
  19. Raytheeagle

    Raytheeagle Senior Member

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    Sometimes it is and sometimes it isn’t. As long as the components are there and the black cap is secured, there shouldn’t be an issue;).

    As long as the plunger for the valve is free to move, that’s what I am mainly concerned with :).

    Good luck and keep us posted (y).
     
  20. Baje

    Baje Junior Member

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    Ok more info, decided to pull plugs even though I knew they were changed a month ago. Numbers 1 & 4 burnt oil smell with slight oil on firing tip only. I forgot to mention one more thing to this large equation. After the car was hot and I turned the engine off, there was a a very slight constant hissing sound coming from around number 1 area. Honestly didn't hear it this morning, I heard it 2 days ago. Forgot to mention it.
     

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