Toyota - Corolla :: Loud Rattle At 1950 Rpm From Drive Belt Area


Oct 21, 2014

I have a 2002 Corolla with a 1.8Liter 1zzfe engine.

I can hear a loud "rattle" at 1950 rpm from the drive belt area whether I'm driving down the street or if I rev it up while parked in neutral. It's not a tapping sound, more like a sheet metal rattle but I can't locate an loose sheet metal.

I thought it might have been the drivebelt tensioner. The plastic bushing on the small bolt cracked to pieces and I simply replaced it with a stack of washers. That's the bolt at the top of the piston that screws into the valve cover. I replaced the tension but still hear that rattle. I tried to locate it with a stethoscope but no luck.

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Here's the short video : [URL] ....

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One pulley does seem like it is not perfectly round and I can see some very slight run out from side to side. Nothing really obvious though - that might be normal?

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To date I have had wires/brackets either replaced and/or tightened, and also foam applied in numerous places. Still, the rattle persists.

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Here's a brief video: [URL] .....

The conditions when the noise appears are as follows:

Start car, turn AC on, place into drive/reverse. Rattle is present initially, then goes away after driving a bit.

The noise seems to be worse after the car has been sitting overnight.

If car is started and placed in drive/reverse without turning on the AC, then the noise is not present.

If the car is started and the AC turned on and the car is in park/neutral, then the noise is not present.

The tensioner pulley seems to be moving quite a bit in the video. Is this normal?

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Now several weeks later, last night when I got out of the car with the engine running I heard a pretty loud noise that sounded like one valve very out of adjustment. This morning when I started the car the noise was no longer there but when I checked the oil it was a quart low. I have put about 1800 miles on the car since I bought it and the oil was changed at the dealer right before I bought it. I thought it being low on oil might be causing the noise. I took the car to the dealer and explained everything, the put a quart of oil in it and said to bring it back in about 1000 miles to check it out.

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