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Engine Noise (rattling) at driving speeds - 2004 3.3L

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3.1K views 9 replies 5 participants last post by  kimcoughlin101  
#1 ·
2004 Nissan Xterra XE 3.3L V6 AT 4WD

Good day! This problem has become worse over the last few months and I haven't been able to pinpoint exactly where it's coming from.

Situation: No codes thrown; No Engine light, but this issue typically occurs after the engine is warm and applying more throttle (assuming it's not a throttle issue).

The rattle gets worse and a very large drop in power is experienced as it sounds like something broke off and is rattling around inside somewhere, but subsides, or lessens in intensity after throttling back.

While parked, nothing... I can throttle the RPMs very high for a long iterations (within reason) and can not seem to replicate the noise.

The sound seems close to the top of the engine, on the driver's side, or possibly close to the firewall. The intensity comes and goes, but the issue is audible and power reducing, and obviously not correct.

Things I have done to this Xterra:
  • New Timing Belt
  • New water pump
  • New plugs / wires
  • Distributor Cap
  • Knock Sensor
  • Camshaft position sensor
  • Idle Air Control Valve
  • Radiator Replacement
  • A/C Compressor & Component Kit
  • A/C Condenser
  • Starter
  • Master Cylinder (mechanic performed)

Hypothesis: I have also replaced the valve cover gaskets along with other associated gaskets involved in the replacement of. I do not believe anything foreign was introduced into the engine because of the precautions taken by placing paper towels into the valve cavities and alike. All were removed carefully, parts like the platinum were cleaned and vacuumed prior to installation of parts.

I think I might have read somewhere that it could be a bearing somewhere that is loose, I am just not sure where that would be coming from or what part that has a bearing that I could replace. Any assistance would be greatly appreciated.
 
#2 ·
The only time that EGR activates should be after being warmed up. If yours has an EGR valve, do you know if you check or cleaned it while you were doing all that other work?
 
#3 ·
I do not recall attempting to clear the EGR when performing any of the maintenance, so I assume that would be a great place to revisit. What exactly should I be looking for or would it be just an easy replacement to see if that's the problem?

Appreciate the inputs, because honestly I never even thought of the EGR.

Pointers? Again, thanks again and look forward to sharing what I find.
 
#4 ·
I have a 2004 SE 3.3 and had a similar problem minus the drop in power. I located my issue in the drivers side fender where the intake baffle lives. I had some areas of rust and it was in the fender loose rattling around. It got worse with speed, but rattled the most about mid RPM range. Not sure if that is what you’re experiencing, but I thought I would share just in case.
 
#5 ·
Kozybe,

Appreciate the heads up regarding the intake baffle. I did check the undercarriage exterior next to the body thinking it was something like a heat shield on the catalytic converter rattling at certain RPMs, or something like that, but I can't replicate it.

However, it is definitely something internal. I'm pretty confident this is the case because I can feel it subside if I totally let off of the throttle when it gets bad and it goes away, so walking the dog, it seems to be either engine, fuel system or exhaust system related.

Again I do appreciate the input Kozybe, thanks.
 
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