Prius (Gen 3) :: Fan Noise During Morning Startup


Aug 30, 2010

I am experiencing a fan noise that precedes the ICE during morning startup. It sounds like a model airplane with a cheap, buzzy propeller. It is not the cabin blower and it comes from the front of the car. It goes for about 10sec and then the ICE fires up, drowning out the fan noise, which I presume fades out. And then I don't hear it again when the ICE shuts off. I also don't hear it at a stop light or subsequent restarts. Seemingly, it only does it after it has sat overnight.

It wasn't always like this. Nothing has changed in my routine. Build date Sep 09. 10000km.

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1997 F150 4x4 210,000 4.6L Windsor 5 Speed. Engine totally rebuilt 15k ago (besides for timing chains and tensioners). No codes thrown.

This morning when i started my truck, it made a knocking sound (almost like metal slapping) that seemed to be coming from the bottom end of the engine. At first I thought it was a spun bearing, but then the sound went away after a minute or 2. I have Google'd the problem, and have found a few diagnoses such as: oil draining back from the filter (or something like that), or an exhaust manifold leak that stops when the metal warms up and expands, or even the starter motor not being aligned right and not disengaging properly...

This is the first time this truck has ever done this. I changed the oil and filter about 1000 miles ago with 10w-30 oil and I believe a WIX filter. Also, this is the first time using the WIX filter

The weather this morning was around 51*F, so not too cold (to me).

Also, a few weeks ago when I changed my oil, I noticed milky white stuff only on the bottom of the oil cap, and in the feed neck. The rest of my oil looked like perfect used oil. After I noticed the milky stuff, about 2-3 times a week I would clean the stuff out of the neck and off of the cap. Just recently, there hasn't been as much milky fluid. My coolant level has not changed since I marked it during the oil change. A few buddies have said it might be condensation, but it's never been like this before.

I guess my question is, is this something that could put my truck out of service if left untreated? I'm assuming it's not a spun bearing because the noise goes away, but is there a possibility coolant could be leaking into the case but stay the same level in the reservoir?

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2003 F150 5.4L 140k miles
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I read a sticky post concerning a service bulletin for engine knocking at start-up but what i heard seemed to be more than knocking and it was well above 40 degrees.

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