2001 Windstar engine rattle

I started to work the normal engine tuneup on my Ex's 2001 Windstar that has an annoying rattle, (yeah I'm a nice guy). It sounds like a bearing rattle or external mechanical rattle, but based on my experience on "engine sounds", it does not seem to be valve or internal, more to the water pump bearing?...belt tensioner kinda?...although the belt seems to run pretty firm with no tension wobble. It may happen when in neutral and not immediatly after starting in the morning, just about after the RPM settles down to about 750RPM and basically stays when the AC is running, all this is at Neutral, when the tugboat is running it's not noticeable at all. Initially I though it to be the AC compressor, but since it rattles also when the AC is not on, that throws me off. The sound is not that deafening, but she says it's embarrassing when she gets to work, everyone knows she "arrived".

So, instead of initially pouring unthinkable amounts of money into this fabulous Windstar engine trying to square this out, I posting the issue here and take a look at a few responses first, that may make some sense.

So, let's hear it!

I started to work the normal engine tuneup on my Ex's 2001 Windstar that has an annoying rattle, (yeah I'm a nice guy). It sounds like a bearing rattle or external mechanical rattle, but based on my experience on "engine sounds", it does not seem to be valve or internal, more to the water pump bearing?...belt tensioner kinda?...although the belt seems to run pretty firm with no tension wobble. It may happen when in neutral and not immediatly after starting in the morning, just about after the RPM settles down to about 750RPM and basically stays when the AC is running, all this is at Neutral, when the tugboat is running it's not noticeable at all. Initially I though it to be the AC compressor, but since it rattles also when the AC is not on, that throws me off. The sound is not that deafening, but she says it's embarrassing when she gets to work, everyone knows she "arrived".

So, instead of initially pouring unthinkable amounts of money into this fabulous Windstar engine trying to square this out, I posting the issue here and take a look at a few responses first, that may make some sense.

So, let's hear it!

if you take belt off and start it see if it's in 1 of the pulleys this way you can tell don't leave it running to long it will get hot but you can see if it's not one of the pulleys or engine or exsaust system?

if you take belt off and start it see if it's in 1 of the pulleys this way you can tell don't leave it running to long it will get hot but you can see if it's not one of the pulleys or engine or exsaust system?
Good thought. I'll try that today and post back.

Thanks

When you remove the belt you can also try to spin by hand the pulleys, if any seems noisy or "brushy" replace it, I had a similar noise and ended up replacing the belt tensioner and idler pulleys. That solved my problem.

Oscar.

When you remove the belt you can also try to spin by hand the pulleys, if any seems noisy or "brushy" replace it, I had a similar noise and ended up replacing the belt tensioner and idler pulleys. That solved my problem.

Oscar.

Makes sense. I decided to move this into the weekend as the MV is in use so I'll post results on Saturday. I hope it's just a pulley issue and nothing more serious. By the way, this vehicle is designed so it cannot be worked on by weekend mechanics! There is basically no space around the block to access the spark plugs facing the firewall and the belt side of things is in the same predicament.

Yeah I know what you mean, actually you might find some problems when removing the tensioner pulley, take your time and lean it towards the front, it will come out without the need to remove anything else form the van.

Another suggestion is to work from underneath and with the wheels all the way to the right.

Good luck!

Oscar.

I've also found it easier to access serpentine tensioner from the the bottom. You can remove passenger tire and I believe an access panel in fender well to give you a better view. The napa tensioner I put on is nice, it has a metal tab that catches and holds it in position when changing belt.

Another thought with the rattle, some have had problems with the baffle coming loose in the upper intake manifold.

I've also found it easier to access serpentine tensioner from the the bottom. You can remove passenger tire and I believe an access panel in fender well to give you a better view. The napa tensioner I put on is nice, it has a metal tab that catches and holds it in position when changing belt.

Another thought with the rattle, some have had problems with the baffle coming loose in the upper intake manifold.

Hmm, how do I access the baffle in the upper intake? Is that inside the intake? Sorry, an intake baffle is something new to me....Man, these Windstars....

I am betting on the baffle underneath the intake vibrating when the engine is at idle. Your a nice guy helping your Ex, hope she knows what she is losing out on. LOL


Good Luck

I am betting on the baffle underneath the intake vibrating when the engine is at idle. Your a nice guy helping your Ex, hope she knows what she is losing out on. LOL


Good Luck

Among other things...a good weekend mechanic! But really I just hate to see a good car go to one of those no-diagnostic-at-all-lets-replace-parts-and-bill-the-customer kind of thing. She tossed $400+ out to one of these fancy shops to troubleshoot and they could not find what it was.

Hey, by the way. are you the guy who replaced his rims with "sporty" ones and now has a Windstar GT? Did it really make that much of a difference in handling? This van moves just like a tugboat.

The inatke baffle would make a diesel engine like sound. You can try pushing down on upper cover of the plastic intake manifold. If the noise goes away you've found your problem.

The only way to access it is removing the upper cover of the manifold and replace it or some users have glued it with RTV sealant.

Oscar.

The inatke baffle would make a diesel engine like sound. You can try pushing down on upper cover of the plastic intake manifold. If the noise goes away you've found your problem.

The only way to access it is removing the upper cover of the manifold and replace it or some users have glued it with RTV sealant.

Oscar.

Thanks Oscar.

I did re-tighten the intake manifold screws to spec as I did a full inspection before looking at the belt side, a few were somewhat loose but nothing major. So, the baffle is inside the plastic manifold. I'll take it apart this weekend also. This should be easier to work out that replacing the belt.