Engine noise

[Skid-136]

Just got my car back on the road tonight after it being confided to the garage for the last month and a half or so due to oil cooler pipe failure!! Now fitted with Forge kit so don't need to worry about that happening again

After topping up the oil and getting it all back together I took it for a good run and there now seems to be a whirring noise coming from the engine,starts at about 2600rpm and then goes away after 3200rpm. Now I know I haven't driven the car for a few weeks but I'm pretty sure it wasn't their before it broke down. Any ideas what it could be??

Just to add the oil leak was noticed before it got to bad and was not run low on oil.

[Rick_RS4]

make a video maybe? could be dry belt tensioner pulley, not sure without hearing it

[CellDamage]

I had my Forge cooler fitted just before Christmas and also noticed this, like you say, pretty sure it wasn't there before the cooler was fitted.

Mine is relatively faint so not sure a video would really pick it up over the engine sound.

Is yours quite a low pitch sound?

Anyone else with the kit fitted noticed this?

My first thought was it may be one of the lines vibrating against something (wishful thinking perhaps). It was The Phirm who fitted mine and whilst I was there they did point out an area where one of the lines was slightly resting against something on the front end, as a result they wrapped a couple of heavy duty cable ties round it to prevent chafing damage to the line.

Haven't really had time to investigate further.

[Rick_RS4]

strange, maybe something on the coolers are vibrating? or an old clip or something from the old cooler that has been removed maybe

[Skid-136]

Yes it is a low pitch sound and as you say I don't think you would be able to pick it up on a video.

I've sat the car at the same rpm whilst being parked and I can't seem to hear it which makes it even more confusing,you would think if it was something vibrating it would do it wether the car was moving or not.

Glad I'm not the only one with this problem though.

[Surrey Sam]

I can't quite remember the ins and outs of the Forge setup but I think the cooler is re-located higher up, if so there will be more strain to the oil pump. Perhaps that's the new noise?

[CellDamage]

Yep, it's mounted higher.



I doubt the extra distance would create that much more pumping work, not to the extent that it would cause the pump to make this noise, at least I hope not anyway.

Please can others with the Forge cooler fitted add to this thread?

[adsgreen]

Very much doubt it would make a difference - the pressure of the pump should be pretty high and it's got to get it into the engine head anyway.

[Youngben]

Evening all,

You are right in saying there is a noise since fitting the oil cooler. I have had the noise since mine has been fitted also but due to my car having been away for a month i lost sense of normal noises but was starting to think that it may be a AUX belt idler failing. Im glad that this thread has popped up as this has reassured me that it is the cooler. I mentioned the noise when my car was given back to me but as said i was not sure enough it was the cooler due to the time to develop the kit.

The Forge Development Manager has been made aware of the noise and i am waiting for him to get in touch with me and i have sent him a link to this thread also so it will be seen. I would say that my car will be taken back in and the problem resolved and any modifications would be made available to people who have purchased the kit to solve the noise for you guys also.

I have been doing a lot of digging the last 24 hours since seeing this thread and this seems to be a very common problem when fitting oil coolers and the noise is by no means mechanical and is in fact Resonance due to where or how the cooler has been mounted and the Resonance is being passed through the body of the car. This may be just a simple fix because the cooler is affixed to the rear of the front crash bar without the use of a cushion between 2 metallic surfaces. The above in regards to the design is all speculation though so don't take it as fact.

Here is a similar noise on a RX8 for the same reason but sounds much more amplified than what mine does but it give you an idea of what to look out for...

http://www.youtube.com/watch?v=HO2u3i_FqLY

All i can say in the mean time is please bare with us and be assured you are in the best hands in regards to customer service and there is no doubt in my mind that this will be turned around with minimal fuss by the Forge team. I will update this thread as and when i have news.

[CellDamage]

Nice one Ben, good to know Forge have been made aware of this.

Although it's early to say, I think your comments with regards to a resonance/vibration are on the right track. The fact that it doesn't seem to occur throughout the rev range and when the engine is not loaded supports this also.

The video of the Mazda does indeed sound similar to the noise on mine too, although as you say, much more amplified.

Hopefully hear from you soon.

[Skid-136]

Yes cheers Ben much appreciated

[hughes457]

Hi I have recently had the oil cooler fitted And too have noticed the noise ...forge have recently sent me some new bolts but are longer than the originals
My mechanic has narrowed the fault down to the plastic surround where the pipes pass through
My point is has anyone managed to sort this noise out as my mechanic is not happy with pulling my car apart again after fitting this unit before I ring forge again

[CellDamage]

The longer bolts should fix the noise issue or at least reduce it enough so it's not as noticeable, they seemed to on mine anyway.

[MikeFish]

Which bolts is it? When I had mine fitted the mechanic said some of the bolts were missing so he used some other ones he had with a load of washers. Pretty sure I get the noise though.