Engine Knocking or Ticking?!? This Could Be Your "FIX" Ford/Mazda/Bmw/Honda/Toyota

hey guys in the fast lane here does your vehicle make a knocking noise you just can’t figure out where it’s coming from it doesn’t sound like it’s coming from the bottom of a block or the head but you still can’t find out where it is well here’s where your problem is most likely now I’m gonna go in the vehicle and start the engine and you’ll hear the knocking noise I was just describing just going to wait for that cooling fan to slow down so this knocking noise is actually coming from the runner flaps inside the intake manifold now it really sounds like you’ve got a bent rod or use fun a bearing but I can promise you that’s not what’s happening so I’m sure you’re hearing the chatter right now as soon as I pull this vacuum line it’s gonna go away see how quiet it is now now this is either a runner flat problem where they’re chattering in between and a runner clap it’s like a butterfly the throttle opens two closes that’s what’s inside here each one has a little butterfly in there and there’s a solenoid down here that runs off this vacuum line and sometimes those go bad but the chattering nine times out of ten is your runner flaps are getting loose so it was quiet I just took it for a run around the block and it started off nice and quick and then all sudden halfway through the run I could feel it starting to pull back again and sure enough the noise came right back so you can hear it chatter and again those flaps are going back and forth and they’re restricting airflow remove the entire intake manifold and delete the runner flaps and I’m going to show you how to do that we have two Phillips for the throttle body cover I’m just gonna take those out now that the throttle body covers off you’re just gonna take either a flat head screwdriver or a 5/16 socket I’m gonna be 5/16 and just loosen up the circle clamp and you’re gonna grab it and you’re gonna pull it well this one’s really suction on there good and if you can’t get it off quite yeah just pull on the top to break the seal unfortunately in order to remove the throttle cable you have to actually take the throttle body off so you got four 5/16 bolts just remove those and now once you to remove those you’ll be able to spin the throttle body around and it should come right off so just take your throttle body like this turn it forward until this little knob piece pops out of the actual throttle cable just take a pair of needle nose pliers and we’re gonna push in on these little tabs right here so we can push the throttle cable back in there we go let’s pull it all the way through and set that aside for the EGR pipe we’re gonna just use a 12 and a 10 millimeter now yours is more than likely just gonna be a 10 millimeter I had to put a 12 in here because I didn’t have a 10 at the time when I was reassembled it also what’s nice to have is sometimes you can’t get to that bolt and I use this swivel extension it actually has a cutout rivet so when you lock in it’s straight then you pull out just a hair and has a swivel action they’re made by an Pro I haven’t seen a manta advance auto anymore but when they were there they are really nice so as you can see it’s doing that nice swim election so we’re just gonna take these two bolts off and pull the EGR pipe out now that the EGR pipes out just kind of leave it right there I almost forgot to mention you got one more vacuum hose right here on the front I’m just gonna take that off so next we’re gonna unclip the main harness right here the main wiring harness that clips together let me zoom in I left it out so that you guys could see the location of it so here it is right here and you can see right here it’s just a little clip so we’re gonna take like a flat head or push on the back side of it and pull up now I got a Phillips I might be able to get away with this without using anything else but you got a push in and up there we go and just want to take it off that bracket because that’s attached to the intake manifold now that that’s off just

right here you can probably barely see it but I showed earlier in the video it’s the vacuum hose that goes to the intake manifold it controls the runner flaps or the swirl flaps just take that off there’s one bolt right here on the back side for the rudder solenoid it’s just it looks like it may be a 5/16 and I undo that we have a few more things we’re just gonna hook this vacuum line right here to kind of pull it through and set that aside there’s another vacuum line right on the inside of the intake manifold it’s right here straight down that runs off of the fuel pressure regulator so we’re gonna pull that hose off and man let me tell you something that was on there so that would probably be the first thing I would put back on just because it’s really tight okay so that’s done now we got to go into the back side again and it’s gonna be hard with the camera kind of in my way but we got a little grommet right here attaching the wiring harness to the intake push that aside and on the back you actually have the if I can remember I think it’s the the swirl flap controller in the back here barely see it but it’s got a plug and you’re gonna take the plug out maybe I’ll give you a better visual just so you can see what you’re really taking apart here’s the swivel flap control right here we’re just gonna unplug this one right here in the back there’s a vacuum line in the back of it too so take that off now we have one more crazy bolt it’s a 5/16 and this is why I make a lot of these videos there’s a lot of people out there that do know how to take this stuff apart in their real handy and that’s awesome but sometimes there’s so sneaky little bolts that you’re just wondering why that part won’t come off and you think to yourself I’ve had all the bolts out what’s going on here and this is why so right here it’s connected to the EGR pipe right in the back it’s a sneaky little guy and you’re just gonna take that out it holds the EGR pipe to the intake manifold and it’s kind of covered the wires usually run over here so you really can’t see it so make sure you take that one out okay so last step is removing the intake manifold bolts now you could probably see one in the camera in this video right here when I take this off I’m gonna let you know how many bolts there are I really don’t know off the top of my head the bolt size for the intake manifold are 10 millimeter so believe it or not it was only 5 bolts 5 10 millimeter bolts the hardest one to really get to is the one in the very very back I’m gonna show you the whole layout where all the bolts go when I pull it off so you’ll be able to get a better idea pretty much they got them all off just make sure everything’s out of the way all right I’m gonna remove this bracket because it is kind of hitting right there and then the things should come right out the brackets removed get this last bolt right here you don’t got to worry about the bolt size they’re all the same length and just set the bracket kind of in the same position that it was if you can’t remember which way it went and that’s it so here’s the bolt pattern this is the back side you got one here one here here here and here so two four five bolts and these are the flaps I was talking about these flaps right here are the swirl flaps and here’s the swirl flap control now what’s happening is they’re going there chattering like that you know and you’re having a problem so I’m gonna eliminate all four of these just get rid of them my turbo GSR I eliminated them and it ran a lot better we’re gonna take a t25 torx head and we’re going to take off the swirl valve controller and there’s one two three screws you just remove those you’re just gonna pull straight out Nancy here kinda yeah just pull out and as you can see there’s a little square for the actual rod that goes all the way through the swirl flaps so we’re gonna set this aside and if you know you can’t really get the swirl flaps out through the rod but here’s what they do they open and close and when they’re chattering like this that’s what you’re hearing inside the intake and if one of these breaks

off inside the intake manifold that’s it it’s over you’re pretty much in big trouble it’ll get down in the piston smash up into the valve and your whole entire engine will blow up I’ve actually seen a video of a guy that was supposed to change this out because they were chattering and he had a BMW he had the metal ones and one of them broke off and blew his entire engine up so that could be a hefty so I would eliminate them it’s ridiculous that they even put these things in here I mean as if the intake manifold can’t provide enough airflow itself now the goal is to grab on to this long square rod right here and somehow break it off or pull it out if you run into a problem you can actually bust off the swirl flaps inside there now once we take these swirl flaps off we can’t just slap it back on though we have to patch up each hole that leads to the other cylinder I’m gonna get a hammer and kind of smack it out a quick tip would be not to hit it right here I barely tapped it and it started coming out and it shattered the part where it bolts to the actual head so I’m gonna have to jb weld that up really good and let’s hope it holds I sure hope so because I don’t wanna have to replace this but this is probably one of the cheapest pieces of junk manifold I mean it’s just so brittle they just throw them in a mold and use real cheap plastic so you can imagine if I barely tap that and this swirl flap is made of the same plastic do you imagine that just a little piece like that guy in your engine I just took out the rod as you can see I just put it on there and kind of tapped it here’s the small flaps now these should come right out and if they don’t believe there’s a whole piece right here locking them in this whole plate right here so off the top of my head I’m just gonna kind of put this in here see if I can’t pop himself yeah let’s see I mean they just could you imagine if that broke off inside your intake man it’d be good night and definitely make sure you clean this out really well because you don’t want any of this getting inside there so that one there’s still some pieces in there this piece right here on the outside it looks like it wants to separate I know we’ll see I’m just gonna break them off oh there we go see how this piece just broke right off look at this it’s just pathetic but that’s all gonna have to go in there and I’m probably gonna JB well to all this shut real clean it up it’s pretty sad though if they built it like this they really built it to fall apart so here’s the swivel flat mechanism and I guess I mean these things look at that I just snapped it in half by pulling it so let’s see here since I got a cracked off main bolt right here that holds the intake to the actual head I’m gonna go to autozone or advanced and I’m gonna get some high temp epoxy there’s this epoxy that holds up to 3500 psi it bonds plastic to plastic and it does plastic to metal also for these plastic parts right here I’m just putting them in the ultrasonic cleaner a little jewelry cleaner and let them you know kind of clean up all the bad junk starting to come off you can see some of the stuff bubble on the top she’s gonna put all the little parts in here that I’m gonna be putting back but some just dunk some brake parts cleaner we’re gonna spray the inside of these cylinders so that it’ll be really clean for the epoxy I’m not gonna spray crazy I’m gonna fill it up a little bit and then get my wire brush and scrub out as much as I can because these cylinders get dunked up really really bad I have all my pieces cleaned up with a wire brush really clean the inside here is really clean just right in here the all the way back I didn’t really get too much but right where the pieces are gonna sit in there they’re really cleaned up so what I’m going to be using is a product called versa chem it’s a plastic welder dries in 15 minutes has 3500 psi it bonds to ABS acrylic ceramic

china fiberglass glass most metals most reinforced plastics PVC stainless steel Steel’s styrene vinyl and wood pretty much it comes with a little mixer right here and I’ll open it up and we’re gonna use this to set and fill the holes so you just hold on to the little packaging kind of set that down and you break off the two tabs and you squeeze it and I believe I thought it came with a little mixer I guess you just use the little flap they give you right here or actually I take it back in the middle I guess there’s a little mixer prong you take off but whatever I guess when you squeeze it pops out so pretty much if it dries in 15 minutes I gotta get organized so over here I got them all laid out on the last one this little piece broke off at the top I’m not gonna put that back in just because it’s such a small piece if that does fall in there it’ll Bend a valve so I really don’t even want to install these back but the only way to keep that gasket in there is to have this because it’s a two-piece thing so I’m gonna permanently put these pieces in there as just to hold the gasket in but they also make a nice incline right here if you look right here you can see how it the air would hit that and it wouldn’t be smooth flowing so just a poor design I just squirted it in there I’m just gonna mix it up real good I’m gonna take the first one here and just kind of paste it on the outside hopefully stuff don’t write crazy on my fingers and then I’m going to piece it on top and I’m gonna do this to all of them so I’m just gonna show you this one right here so you can get an idea and then the rest is gonna be off-camera but try to keep it away from the front because that’s where it mounts so now that that’s in there just kind of line it up this stuff’s drying already and push down really good now you’re gonna want to get it all out of the crevice right here so make sure you do that alright so after a lot of scrubbing with the wire brush after I applied the epoxy scrub the inside to smooth it out you know get as many birds as I could out I’ll probably work on just a little bit more you don’t want anything in the intake and then I’ll probably hose it off and then blow-dry it to clean it up so pretty much here’s what it looks like as you can see down in there it’s all smooth it looks a little rustic because the epoxy as I was rubbing it in kind of you know got on it I wouldn’t take any sandpaper and sand it because if you get sand in the intake manifold and you can’t get every last drop of it out you’re in big trouble because it’ll get inside your cylinder and scratch up your cylinder walls and then it’ll ruin your piston rings and you’ll start getting oil blow-by and you’ll be burning oil optic sauce I don’t suggest using any kind of abrasive now this wire brush yes one of them could come off but the chances of that is ran likely and I’m gonna clean it out very thorough so pretty much this is what I’m looking at you can see in here I epoxy every hole on the other side because the rod went through there and let me tell you this stuff is rock-hard okay it’s all over my fingers and when you peel it off it feels like it’s gonna take your skin with it but I don’t suggest doing it barehanded I kind of didn’t have a choice once I started it this stuff started drying within like 10 minutes they say 15 but man this stuff dries so quick that’s why I couldn’t really catch it all on video because I would have went through two tubes for the swirl valve vacuum little mechanism here I’m not gonna put this piece back in because this is what went in there I sealed it up so I’m going to take it completely off and just lift up and pop it out of it it’s gonna think that it’s moving in and out which I don’t care it can do whatever it wants up and down it’s not going to control the flaps any more so I’m just gonna mount it the way that it was supposed to be mounted just like that it’s already sealed up so I don’t got to worry about it and I’m gonna put the three screws back in and then that’s pretty much it for that job the other end of this intake manifold was already sealed up to begin with so there was no need to do any other modification the only reason why I’ve bothered to put this back at all it’s just so that I don’t get any check engine lights so I can plug the clip in other than that I wouldn’t put it back on hopefully I don’t get any check engine lights hopefully it doesn’t pick up on any kind of air flow up in this area we’ll see I’ll ride it around for a little bit and I’ll comment in the

about Me section as for this broken piece right here the shame that happened but nothing I’m gonna do about it I’m going to put it back together with this 3200 psi poxy well the same stuff I use for the flaps so I’m gonna check this piece out and make sure I get it in the right way okay it looks like that I’m gonna put this in there like that alright so mix up some of this epoxy alright and there’s that now I’m gonna put a little more on the outside right here stuff is really messy guys and I’m just letting you know alright and once this stuff dries man is it tough just taking some blue Permatex our TV and I’m just gonna line it up on the bottom of this gasket reconfigured in there so I’m just gonna lay this in there I’m gonna do this to all of them and as you can see right here it’s kind of wanting to go in so what I’m going to do is put a little bit of the plastic weld right in here alright guys day two as you can see right here I added some of the plastic weld where it cracked so try not to do that like I did it was kind of hard though to get that rod out without tapping the actual body to pull it out I mean even if you wedged something in there and pulled you you’re pressing on it so just be careful another thing I would say tip wise cuz this is my first time eliminating on this particular plastic intake I’ve done it on the GSRs the acura integra I’ve removed the butterflies but you don’t have to actually take out an assembly it’s just a centerpiece that you can remove as for these little couplings that go back in after your move the runners or the butterflies I would be careful taking them out mine are really stuck in there so they snapped in the middle right here if you can get them a whole piece it’ll save you a lot of trouble like I got this one hole and it was just one nice you know put the plastic well around it and slide it in and then fill the holes up so that would be a tip I would give you like you said it’s been it’s the next day hasn’t quite been 24 hours but I hit it with a blow dryer to speed up the process I just put this on today actually on either side it was already you know welded from the inside out but I put extra in it I hit it with a blow dryer and it’s already rock-hard they say 200 degrees this stuff can take up to but I think it takes higher than that I had the blow dryer blowing at about 350 degrees like right on it and it didn’t do nothing to it maybe for long long periods of time but you’re not gonna have to worry about it intake manifold doesn’t really reach 200 degrees I mean maybe on a hot hot day but I think this stuff will do it was the highest rated stuff I could find so that’s pretty much all I could do as for your little ports here just make sure they’re all sealed up and you don’t have any kind of you know leaks and holes because you don’t want to transfer you know air from this cylinder to the other cylinder so other than that it’s time to put it in so get yourself like a stepstool or something with these trucks a little higher up kind of hard to get to so first thing we’re gonna do is just make sure everything’s cleared out of the way like that and it looks good the only tricky part is getting the EGR pipe out of the way it’s real pain in the blunt though it is super tight a little at a time and it’s usually the back wires right here that play into giving you a hard

time another day have bruised the top of my knuckle and whoo just bumped it and you know how that feels and bruising the bone all right so we got that in there and we’re going to get one started so we’re gonna take our bolt and I’m just gonna get one in the intake manifold just to get it lined up the next thing I would put in is the fuel pressure regulator hose the vacuum line I would just put that in on the intake just so you don’t forget other than that we’re gonna put in the EGR pipe now I’ll do this we got to put our gasket back on so we got our gasket I’m just gonna slide it over and I’m actually gonna put it into the intake manifold there we go and then just kind of line it up and we got there’s supposed to be two ten millimeters and put those back in hook up all your vacuum lines just plug them all back in and then that’s pretty much it just plug in your your little vacuum swivel the runner flat controller and then you got your vacuum right here and you’re gonna plug that back in just the vacuum lines and it’s pretty much self-explanatory just plug in your sensors your intake manifold throttle body back on to put the cable back on you got to put it on first your throttle cable you got to put it on the throttle body first and then put the throttle body on don’t put the throttle body in and then try to get it on there cuz it won’t work and before you do that make sure you slide it through the end Hey so I’m just gonna tidy this up another thing you don’t forget to put your bracket back on like that with the two tap three ten millimeters back in there and that’s pretty much it but this this deletion of the runner flaps or the swirl flaps there’s all kinds of names for them or butterflies this applies to pretty much all vehicles out there BMWs like I said earlier have a really really bad problem with this and they don’t take it back to the manufacturer and there is no coverage and I’ve heard of dozens of BMW well went up so we got pretty much everything hooked up you know all the bolts in the intake manifold all the vacuum hoses just got to plug in the clips you really can’t put them wrong because they only go to one clip don’t forget this vacuum hose it goes under and then plugs it on this side you get your two vacuums in the back and you got your solenoid your runner solenoid on the side with the two vacuum lines so you’re hooking everything up the same way you took it apart the only thing we did is change the guts inside the intake manifold for this I’ll show you how to put the throttle body on you got to leave it loose you’re going to slide it through the intake manifold and you’re gonna put it on here first just kind of push down did you see that just push down on it and that’s it see it you couldn’t get it on the other way it’s gonna be flat so got that another thing to keep in mind is the idle adjustment screw right here it’s a 5/16 bolt so we might have to adjust that because I was hearing when the flaps get stuck open so that’s what they are right now they’re not even there so it’s wide open it chokes it doesn’t I guess maybe doesn’t have enough fuel at idle so we might have to adjust this to get the idle right so all we do is just put it back up when you put our four 10 millimeter actually 5/16 bolts in everything’s hooked up and we’re ready to start it so this is the first start I haven’t even started it off camera so let’s see what we got now that sounds like a really nice running motor no more clanking and ticking give it a little Rev we don’t even have to adjust the idle screw I think nothing’s really reven way faster than ever did so there you guys go inside with the

gauges you can see my RPMs are really nice they’re the exact same as they were at idle so I didn’t have to adjust anything you can see the engine’s heating up a little bit obviously it’s gonna go to the middle but just shows that I drove it around for a little bit I actually drove it around the block a couple times other than that no check engine lights the thing really goes a lot faster up in RPMs I noticed when I was in fifth gear before it would just kind of be sluggish I like you you want to barely be able to press the pedal and feel like you’re accelerating somewhat and I never did with the flaps in but now that I push it I feel as I’m letting off it’s still pulling a little bit so I can I actually don’t have to push the pedal down as far hope you guys enjoyed this video go ahead and comment like and subscribe all don’t forget to check out my facebook page website and Android app all that can be found on my youtube channel in the about Me section I’m in the fast lane and I’ll see you guys next time