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Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
This posting relates to an ongoing piston-slap issue on a Mazda-3 Katano (1,600cc petrol), which we bought new from {deleted - no naming/shaiming please} at the end of October 2006. While I am sure there are many satisfied Mazda-3 owners, I?m looking for specific feed-back from any owners who have (or have had) similar problems/noise with their Mazda-3.

Within a week of delivery, the car developed a loud, metallic knock when started from cold, which I thought was akin to big or small-end knock. I requested that the car be changed or my money refunded. However, the garage Technicians tested and persistently denied any problem, stating that the noise was 'normal' for a Mazda-3. I am aware that the 1,600cc engine used across the range can rattle, but the hammer on our car is entirely different and is a distinct knock, especially when pulling away cold (i.e. engine loaded).

After much protesting and at my insistence, a Mazda UK specialist was sent to assess the noise while at the garage's premises. The specialist diagnosed the problem immediately as that of piston-slap, saying that he had heard that noise before on the Mazda-3, advising that a new short-engine would be fitted at Mazda?s own cost.

Some weeks later, the new short-engine was fitted by the garage, just a week before we were due to drive from the UK to the Czech Republic (CZ). I should explain that although native British and still UK residents, we semi-retired to CZ and are renovating a dilapidated farm-house on an intermittent basis.

Shortly after arriving in CZ, the power-steering hoses severed and all power-steering was suddenly lost. We survived, but it could well have been a different story had the failure occurred while at speed on the autobahns, or had the escaping fluid ignited.

Subsequent investigations by the Czech Mazda dealer found that the garage's Technicians had routed both hoses entirely the wrong way, to the extent that they had actually been made to contact the pump drive-pulley. Additionally, it was discovered that the bolts which secure the power-steering pump to the engine had been left loose and that one bolt was actually missing! When the hoses failed, the pump-casing also fractured, causing the pump to detach completely, where it came to rest against the bulk-head. I can support all of the above with digital photos, taken by the Czech dealer's Senior Engineer, all of which were sent to the Technical & Customer Services Manager, Mazda Motors UK Ltd.

That abysmally dangerous repair issue aside (for which we have never even received an apology from the garage), we found to our dismay that the new engine also developed the same cold-start hammer not long after arriving in CZ. That noise has become progressively worse, and we have been battling with Mazda and the garage ever since.

Digital recordings of the noise (.wav files) are available to anyone who wishes to analyse or compare, and are certified virus-free (PC-Cillin.) I know that accurate assessment of any recorded sound is difficult at the best of times. However, the hammering noise is very prominent and even our ?mechanically unaware? colleagues have told us that something is detrimentally wrong with this, Mazda's second engine.

Repeated complaints and requests for a replacement car or our money back (since I first reported the problem), have been refused by both the garage and Mazda UK. During my exchanges with Mazda UK, I mailed the Technical & Customer Services Manager, Mazda Motors UK Ltd, asking him directly if ours was the only car to have suffered piston-slap. He conceded, in writing, that a 'small number of other instances have occurred in the UK '. We were then offered a £1,000 compensation, which we refused on the premise that a new car should have been issued immediately (besides, our costs and losses already exceed that amount).

When I insisted that the new engine is also faulty, Mazda UK advised that we take the car to our local (Czech) Mazda dealer for assessment. When we did, however, we were told (surprise, surprise) that they ran the engine for two hours and that the noise was normal for a Mazda-3. I maintain that running the engine (unloaded) for any length of time is in no way an appropriate test for piston-slap, especially when the noise only occurs from a cold start. For example, at circa minus 7C, the engine sounds as if it is running without oil, which it is not.

Trading Standards (deleted) advise that, should the car fail, it is covered under warranty, but that if I believe there is a manufactured issue ( i.e. piston-slap), then legal action and employment of a Technical Expert is the only recourse, which is why I?m looking for any similar experiences.

Our first (and last) experience of Mazda UK, is that it seems content simply to replace items as and when they fail (viz; the first engine, an as yet unexplained rear shock-absorber failure, the power-steering pump, and now the second engine) under the umbrella of their warranty. Customer satisfaction or peace of mind appear not to enter their equation. Above all, piston-slap should NOT occur at all, let alone in a new engine. That the same noise now emanates from this, Mazda?s second engine, equates to a 100% failure rate in my book.

I am in the process of employing an Expert Witness, with a view to litigation. Consequently, any and all supportive case-histories or comments would be welcomed.


{Some editing done to comply with this site's policy on no naming & shaming. Edited words are in italics - DD}

Edited by Dynamic Dave on 16/01/2008 at 12:40

Piston-Slap Issue, Katano 1,600cc Petrol. - SlidingPillar
No specifics, but piston slap implies too generous a bore/piston clearance, but the compression being still adequate owing to the piston rings expanding correctly. Never met it on a new engine, but have encountered it on older engines which otherwise worked fine so were left alone.

No idea if the Mazda pistons are made by them, but independent piston manufacturers usually give figures for the bore/piston clearance and ring gaps. Recommendations do differ a little bit and it may be in your interest to investigate this aspect, but rather pointless if the head is not lifted.

Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
Many thanks for the advice and my apologies for not being able to reply before today.
Piston-Slap Issue, Katano 1,600cc Petrol. - Saltrampen
I too have suffered piston slap on a 2 yr old 02 Civic. Although strangely was not too noticeable at cold. The explanation I was given was that modern engines have high conmpression ratios and short cylinder head sizes compared to older engines. This means that the tolerances during manufacture are much less than they used to be.
I have also driven an Astra and a couple of other almost brand new petrol cars which sound slightly "knocky" for the first 30 seconds after starting, perhaps for the reasons above.

Anyway Honda allowed me (with their mechanics) to compare my car with several similar on the forecourt, we all agreed my noise was worse and the short engine was changed.
Interestingly on the new civic the oil lubrication to the cylinders was redesigned for quiter running. So maybe oil flow to cylinders when cold maybe a factor?
Mazda ought to allow you to compare your car with similar used cars of the same age to see if the noise is similar or worse. With my new short engine, the noise returned, but not as bad as before, but irritating nonetheless.

If the noise sounds like a diesel for the first minute, but then quietens and gives no problems I expect most dealers will not change the engine again. You really need to compare it with similar models with the same engine and see whether the repaired car is vastly different.

However the level of workmanship you rec'd when having the engine repaired is not acceptable. If you haven't already get another garage to check everythingelse is where it should be.
Piston-Slap Issue, Katano 1,600cc Petrol. - oilrag
Wasn`t there a similar sort of problem recently with Toyota petrol engines in the Avensis?
Piston-Slap Issue, Katano 1,600cc Petrol. - Saltrampen
02 - 04 1.8 petrol engines in Toyotas can suffer from excessive oil consumption.
Not 100% sure - if this was something to do with bores wearing too fast or piston ring problems.
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
Mmmm, don't know, but will check. Thanks for that.
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
Thanks for that and sorry I couldn't reply before today. Yes, I already had the car checked thoroughly following the first 'repair'. However, when I asked the second dealer/inspector if they would confirm that the engine was now safe, they refused, stating that as they had not opened the engine, they had no idea how well the original repairs had been done!

The second dealer has, just this week, given the car its first service. It still knocks like a diesel when started. Interestingly, though, he advised that the Digital Service Record for my car does not contain any record of original engine change/repair!

Coincidentally, the first dealer has just this week offered a side-by-side test on my return to the UK. I've agreed, but only only on the premise that it's done after I've had the car analysed by a UK-approved Expert Witness. I'm waiting for the dealer to accept.

Many thanks for taking the time to respond.
Piston-Slap Issue, Katano 1,600cc Petrol. - Screwloose

It can't be helping the power output either. If the engine is excessively noisy, it will cause the knock-sensor signal to retard the timing, as the ECU will think that it's pinking.

In fact; as the knock sensor should ignore all normal engine noise; if it's picking-up the piston slap at all, then that alone would indicate that this engine isn't "normal."
Piston-Slap Issue, Katano 1,600cc Petrol. - Lud
I am bothered by this thread. A friend (a lady) is thinking of buying a Mazda 2 or 3 secondhand from a dealership near where she lives in Richmond, and I went there with her the other day on a preliminary wander. I have said that as far as I know Mazdas are well made cars that ought to be reliable (she wants one because she thinks they have cute looks) although spares may cost a bit when needed. The dealership seemed OK from the two salesmen on duty but it was a Sunday and I don't feel I can tell without getting at least a glimpse of the service end of the operation.

They said they might be getting a 323 in that would be well within her budget. Any opinions?
Piston-Slap Issue, Katano 1,600cc Petrol. - Galad
>They said they might be getting a 323 in that would be well within her budget. Any opinions?>

I've had a 323 T Diesel from new (2002) and all that's been replaced in 80k miles, apart from the usual oil and fuel filters, are 2 side light bulbs. The car has been used as a family taxi and has been faultless mechancially. As for the Mazda 3, I too am concerned about the posts here - quite disturbing in fact.
Piston-Slap Issue, Katano 1,600cc Petrol. - daiking
This is an unfortunate tale having read it earlier on a mazda 3 owners site, especially the incompetence of the dealer in question.

Yes, mazda's current 1.6 does clatter on start up but it soon settles - mine does anyway but otherwise has been without problem for 18mths/19k miles and not used enough oil to bother topping up yet.

I would be interested to hear of any similar tales but assume (hope!) this is not a common occurence.
Piston-Slap Issue, Katano 1,600cc Petrol. - Dude - {P}

My daughter has owned a Mazda 3 1.6 from new, which has now done 35k and quite frankly the engine at tick over is almost inaudible and does not burn any oil between oil changes.

In fact the car has been a paragon of reliability, but then she drives in a sympathetic manner and ran the car in strictly according to H.J`s guidelines (FAQ`s).

I would wholeheartedly recommend a new Mazda 3 or any other model, - they don`t feature so highly in the J.D. Power survey without good reason.!!!!
Piston-Slap Issue, Katano 1,600cc Petrol. - moonraker244
I have now idea about piston slap but owned a Mazda 3 and a Mazda 323 before that. Again the Mazda 3 was almost inaudible at idle and reasonably quiet on the motorway. Mazda dealership was excellent and there were no reliability problems - just normal servicing on each car
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
Hello again, Daiking,

I'm taking the time to respond again to you in particular because you wanted to be informed of any similar reports.

At the end of this current thread, you will note that a gentleman from the Czech Republic found my thread and responded accordingly. It transpired that he is the founder-member of the Czech Mazda forum, but that he had been running a similar query on other forums for some time (in fact, long before my own).

I contacted him directly via his Web-Master address and have since had the respective threads on his forum translated. I have to say, Daiking, that even I had no idea how common this issue really is. If Mazda themselves want to take the time to translate the many reports from Slovakia, Croatia, and here in CZ, they will recognise, instantly, the commonality between the issue I have described and those described in detail by the many, frustrated M3 owners on those forums.

Interestingly, I was also in touch with The International Mazda Forum (US) and had an almost instant reply from its Administrator (forum name, 'TheMan'). He was emphatic in his statement that he has NEVER, EVER heard of this issue on the M3 models in the US. However, he also stated that he was unimpressed by the incompetent 'repair' performed on my car, and the subsequent treatment received. He and one other from the US are convinced that the noise heard from the sound-files I sent to them is big-end/connecting-rod related, rather than piston-slap.

The American gentleman's advice was that I should contact Mazda Motor Munich (main EU Dist.) immediately, which I have just done. However, his opinions on the US Mazdas prompted me to question whether the models shipped/sold in the US are identical in every way to those shipped/sold in the UK/EU? Is that something that you are qualified to comment upon or confirm, Daiking?

Clearly, there must be differences, not least because of the history of concern on these Central-European forums. Noteably, though, the reception received by those who have written their complaints, is that all but one of their respective Mazda dealers have insisted that the noise is 'normal' and have done nothing about it. The one exception to this is a dealer in Zlin (Moravia) who, I am informed, is very concerned by the noise as two of his own vehicles are afflicted with the problem!

Your thoughts very welcome.

Kind regards,




Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
Sorry for not being able to reply before today, but your response interests me. Yes, the power isn't what I expected it to be and, in fact, there have been a couple of occasions when I've felt the car 'hesitate' when I put my foot down.

In truth, though, I don't know enough about sensor/ECU side of things to know if that's the cause.

I'll do some research! Many thanks.
Piston-Slap Issue, Katano 1,600cc Petrol. - cheddar
It might not be any help now though I would have insisted on a new car had those symptoms been apparent when the car was only a week old and certainly would not have accepted a short engine, a full engine change would have been the only other possible solution in my mind.

I say this now because it seems that at the early stages you were quite understanding and willing to accept the garage's proposed solutions and this very flexibility has backfired on you, could be worth taking this line in a letter to the Mazda UK MD.
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
Hi, Cheddar,

The short answer is, been there, done that.

As stated in my original mail, I actually DID demand a new car or a refund in full as soon as I detected the noise. I assumed that the Sale of Goods Act (merchantable quality etc) would prevail. Not so. I was reliably informed that the Dealer has the right to repair the fault.

Indeed, if you look at the warranty conditions (I suspect, all other manufacturers, too), I was obliged to report the fault, and Mazda are then obliged to repair it (assuming I comply with warranty conditions, which I did).

Two, separate Expert Witness have told me that I did exactly the right thing in allowing the Mazda dealer to 'repair' the vehicle. They pointed out that, all too often, a frustrated or angry Owner will deny the repair, thereby allowing the Dealer the opportunity to off-load any consequential damage. The repair failed, and could well have been the end of us, too!

Regarding writing to Mazda's UK MD. I have a plethora of mails and exhanges, none of which amounted to anything more than a waste of our valuable time. Moreover, to date, I have sent two Recorded Delivery letters to Mazda's CEO in Japan, his name and address being supplied to me willingly by Mazda UK.

I had already suspected that Mazda's policy was simply to 'mend' bits as and when they break (in our experience, at least). But when the expected response did not arrive from their headquarters, I felt that my suspicions were correct.

It takes only a few, short lines to win over or maintain a customer's confidence. Not replying to a letter, especially one written so soon after buying a faulty item supplied by that CEO's company is, in my opinion, extremely unprofessional.

At the time of writing this mail, our car has just come out of its first service. It knocks worse than a diesel when cold, and I have just found out that the history relating to the engine change is 'missing' from Mazda's Digital Service Record (DSR). Doesn't inspire confidence, does it! Hardly suprising, though, when you bear in mind that when we arrived back in the UK on our last visit, and went straight to the dealer's premises to see the Technicians about the engine, we were told to 'wait half an hour, as they were on their tea-break'! Doesn't inspire confidence, does it?

Many thanks for your thoughts. I hope, sincerely, that you or any other Mazda owners do not fall victim to the same treatment.
Piston-Slap Issue, Katano 1,600cc Petrol. - oilrag
Amazing that in the internet age, Manufacturers seemingly act as though it were decades ago and no one will see the way they treat customers.

I had a situation very like this in the 70`s where I foolishly bought a new Fiat 126 right after its UK launch.
I can still remember the Fiat dealer telling me it would be a long wait for new transaxle internals and their seemingly disinterested arrogance in declining me a loan car.

It was off the road twice for weeks for transaxle parts and while in the dealership part of the plastic engine cover handle and a grommit from the parcel shelf were stolen.
With a shrug I was told that these could not be ordered. Not ordered at all that is although it was a current production model....

In the end I was forced to sell it at a big loss as the transaxle started to whine again just out of the one year warranty.
I was only a kid really and can remember their faces, although I think I have had `payback`over all these years by telling people about it.

Sure I buy Fiats again these days but I`m in an infinitely more powerful position now to `return the favour with extra` if I ever get any more of that.

Something for Mazda to reflect on perhaps as they read your troubles now on the forum and no doubt later, spread permanently across the world newsgroups.

I wish you well,

Regards










Something for manufacturers to reflect on
Piston-Slap Issue, Katano 1,600cc Petrol. - SteVee
I'm not surprised that the short engine swap is missing from the service record.
This also happened with my MG - there was no paperwork to go with any of the warranty work (such as new gearbox, rebuilt top end of engine, etc, etc, etc).
The difference I had with my MG dealer is that they did actually fix each problem as it was reported - though there was another problem following.

Personally, I think you are doing everything right.
I would probably report it to Watchdog and I would seek out another dealer. If they can fix it, then that would be a big black mark for the supplying dealer.

Have you not had any questionnaires from Mazda, asking how delighted you are with the car and dealer ? My dealer was very keen that I answered these very positively and went to some trouble to make sure I was happy (after my faulty MG, I bought a Mazda 6, which I was very happy with, for the short time I had it).

I think that dealers have a big problem fixing rogue cars in otherwise very reliable models. For my MG, the dealer had plenty of experience of poor build quality. I would guess that a rogue Mazda3 is possibly a new experience - though your dealer sounds capable of wrecking a good car :-(

Keep telling Mazda - and the dealer - how unhappy you are.
Good Luck.
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
SteVee,

I hadn't really thought about using WatchDog, but it sounds like a good idea.

Yes, I did receive a questionnaire by post, not too long after taking delivery of the car. I was very honest in my judgement, giving top marks for sales, effort etc, but was equally honest in my assessment of the engine, and the way the problem was being handled by the dealer.

I posted it off and assumed that would be the end of it. However, not long before driving over to CZ, I received yet another of the same forms, advising that I had not returned the original questionnaire!

It's possible the original form got lost in the post, but I have no way of knowing. Anyway, I submitted the second form in exactly the same way, but didn't receive anything further.

I take your point re rogue dealers; a very apt description in my case.

Thanks for the vote of confidence.

Best regards.
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
Something for manufacturers to reflect on


Good of you. I'll keep you posted.

Best regards.
Piston-Slap Issue, Katano 1,600cc Petrol. - nortones2
The warranty conditions cannot override the SOGA, even though they often purport to do so, saved only from an offence by the usual get-out clause stating, soto voce, that the terms etc do not override statutory provisions. Take a look at HJ faq section, and speak to a lawyer, rather than a lay person re this. Expert witnesses may not be lawyers, indeed are unlikely to be as they are not expert in everything:)
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
The warranty conditions cannot override the SOGA even though they often purport to do so
saved only from an offence by the usual get-out clause stating soto voce that the
terms etc do not override statutory provisions. Take a look at HJ faq section and
speak to a lawyer rather than a lay person re this. Expert witnesses may not
be lawyers indeed are unlikely to be as they are not expert in everything:)


I take your point. I have the details of a Solicitor recommended as being familiar with similar cases and am in the process of compiling a package for them now. I had hoped not to have to go down that road, but the way things are going, I don't see any alternative.

Sincere thanks for the advice.

Best regards.
Piston-Slap Issue, Katano 1,600cc Petrol. - nortones2
Indeed, it seems they want to go to the wire. No alternative, until they see the opposition massed on the brow of the hill:)
Piston-Slap Issue, Katano 1,600cc Petrol. - oilrag
In my past experience the media has also been a mighty lever
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
Hi, Oil-Rag,

I think so, too. I contacted 'Which' some time ago and it was they who advised on the procedure I should follow.

I also mailed Milles Brignall (The Guardian) a few weeks ago, following his very interesting October article. In fact, it was he who suggested that I use the Honest John forum which, I must admit, I hadn't even considered until then. In his reply, Miles said that if I do go to court, he will put a story together around my case. I accepted, naturally.

I'm hoping it doesn't need to go that far, but if it does, then no doubt you'll read about it in due course.

Thanks again for the help and advice.

Best regards,


Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
Yes, in 'airing my experience' on this forum, my aim was to seek out those who had endured similar experiences.

I have, in writing, Mazda's own statement that a small number of other cases (piston-slap)' have revealed themselves in the UK. I had hoped to hear from that small number, in a bid to determine the severity and extent of the problem. Until I do, it's going to be an up-hill battle.

By the way, I scrutinised the FAQs suggested, and they really are helpful. In essence, they reinforce what I had believed to be correct from the outset, but I suppose I was swayed somewhat by the excuses received to date. No longer!

Many thanks for the help.
Piston-Slap Issue, Katano 1,600cc Petrol. - happy007
Hello Mossbridge.

I am "really happy", that i've finally found person who has the same problem with cold engine on Mazda3 1.6 since new. I have the same on-load cold engine knocking issue since 1500 km driven till now ... 27500km driven... stil the same ... stil worse and worse ... and I know about one worse exemplar which is even worse than mine. I personally know the leader of one of the Czech Mazda service, and he knows about the problem and there they try to do something with it but: as i mentioned: there is one worse car than mine is,- they completely demounted engine, were looking for valve damages or piston damages or so, and everything was perfect, even there was about 30 000km on that engine. But the knocking noise after cold start is still there and is terrible. Quite the same as mine. Please, try to listen to these 3gps:

www.mazda3.cz/video/1video.3gp
www.mazda3.cz/video/2video.3gp
www.mazda3.cz/video/3video.3gp

the quality is bad, but I believe you can find the noise there. It starts after 10 seconds after idling when cold, and remains until the engine warms up. Then it stops. On those videos the situation is not well ilustrated there, but I under load it's really terrible.

If you understand Czech, please visit us here: klub.mazda3.cz
register and let me know that it's you and we can chat and try to do something with it.

Hang on, ... I am looking forward to get a message from you.

Happy
webmaster(at)mazda3.cz

Edited by happy007 on 31/01/2008 at 21:08

Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
Hello Happy007,

Very good to hear from you and, while it's good to know that my car is not the only one to suffer piston-slap (in two, new Mazda engines), I offer my sympathies for the trouble you're going through.

I can confirm that the noise demonstrated in your files is EXACTLY the same as mine. It worries me, though, that my car is already as noisy, and in both engines!

I will register and contact your club address this evening. In the meantime, you might want to mail your files, together with your comments, to Mazda UK (I can supply you with a specific name). While I am aware that your car was not distributed by them, doing so may go some way to convincing Mazda that this problem really does exist and is not limited to 'just a few'.

Note, also, that the Mazda CZ representative (name available on request) was involved in my case (because of the PS failure and subsequent examination). So I know for a fact that Mazda UK and Mazda CZ have already discussed this issue.

I find it interesting that both of the dealers I have used (from two countries) are unable/unwilling to accept or resolve this problem; in fact, both have voiced that they 'could not detect the noise I describe'.

I'll contact you again in due course, but really do appreciate your getting in touch.

Best regards,

Piston-Slap Issue, Katano 1,600cc Petrol. - happy007
It's really sad that Mazda leaders and responsible people are closing their eyes and ears when someone is complaining about something. I though it would be better with this brand of car. I can tell you, that I wrote to Mazda representative in CZ (cell give the e-mails and names and whole communication but in Czech) and got nothing but slap on the face. The response was that I don't know about engines and they do, and that they cannot hear anything on that videos and that I am something like "crazy fellow" and so. But as i said. There are several people on the Czech forum with 1.6 petrol engines which have the same problem. They try not to hear it and drive. Yes, after 5 minutes of driving it's gone, but it scares me a lot and them too. And I am not the only one. (I also know about one in Croatia Here is something more about it: www.mazda3forums.com/index.php?topic=71232.msg1369...9).

I can tell you that I am glad thah I have founded the M3Club here in CZ, because I get the real opinion from drivers and immediate response on every problem.

Hang on and we will keep in touch.

Happy

Edited by Pugugly {P} on 04/02/2008 at 19:42

Piston-Slap Issue, Katano 1,600cc Petrol. - harleybhoy
Hi i sorry to here about your problems but i may be able to help...i am a mazda master tech an i have come across something simular. First there is a problem with the air tumbler flaps in the inlet manifold the noise u talk about could be from this your dealer can check if your car is in the affected vin range. at the moment i have 1 of these engines in pieces at the garage as there was a simular complaint having spent a few hrs trying to pinpoint this noise i decided to remove the engine i found the shells in no.4 to be badly scored i have since been informed that the injector seals on some cars are unable to seal completely therefore allowing exhaust gases to contaminate the oil which can restrict flow..and a short motor is a complete engine (head and block) but uyou do have to reuse manifolds etc
Piston-Slap Issue, Katano 1,600cc Petrol. - Billy Whizz
Welcome to the Backroom, harleybhoy, and thanks for this interesting update.

One thing though, when I was last fitting engines (a few years ago) a short engine was a block with fitted crank and pistons. It did not include the head.

A long engine included head and all internals but not alternator, manifolds, starter motor etc. Is this different at Mazda nowadays?
Piston-Slap Issue, Katano 1,600cc Petrol. - jag
short motor on both ford and vw does not include the head and valvegear. jag.
Piston-Slap Issue, Katano 1,600cc Petrol. - cheddar
I have always considered a "short" engine to be sans head.


MODS: Harleybhoy's post is likely to be of great interest to the OP, Mossbridge, perhaps you could e-mail him?
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
Hi Cheddar,

Thanks for the thought, but I've just read and replied to Harley-Boy's post. I don't think what he describes applies to my car, but I may be wrong. However, I also think that if he heard the noise/played the sound file, he would know for sure.

Thanks again.
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
Jag,

Same on my M3. Just the block, pistons, crank etc. Wish they HAD fitted a full-engine, though.......!

Many thanks.

Regards,
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
Hi Billy Whizz,

That was the case in my instance (please see my relpy to HarleyBoy).

Regards,
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
Hello Harleyboy,

It's really good of you to respond; I appreciate it.

I don't think what you describe would account for the noise I hear, which is a distinct, metal-on-metal knock. In fact, when I sent the sound file of the noise to the Mazda International Forum in the US, the respondees were adamant that the noise was low-end bearing or rod knock.

I can confirm that the short-engine fitted to my car was exactly that - a short engine, comprising only the block, crank, pistons etc. The original head and all such ancillaries were re-fitted from the original. If your theory is correct, however, and the noise is circa the inlet manifold, then that would account for the noise being evident on this, the car's second engine. I have to say, though, that I don't think that's the problem.

I noted that when the car went in for its first service a couple of weeks ago, the dealer replenished the system with 5W30 Dex.Ultra/208L engine oil (manufactured by Total). I know this oil is used on the rotary engines etc, but is it not a bit 'thin' for my M3?

Your thoughts welcomed and my thanks again for your advice.

Best regards
Piston-Slap Issue, Katano 1,600cc Petrol. - sillyboy
Hi,

I bought a Mazda 3 new from my local dealer in 2005 and reported the same tapping noise at 1st service. They picked-up the car from my house early in the morning on a cold October day and MUST have experienced the noise, it's unmistakeable. However, when they returned the car later there was no mention of any diagnosis for the tapping. When I phoned next day to ask they simply said "no fault found". Since then, the noise has got loader. It's so load sometimes that I'm embarrassed to accelerate down my street when it's cold as the neighbours would think I've got a bag of nails under the bonnet of my 'new' car.

Apart from the disappointment of having a new car that sounds terrible, what really worries me is that something is gradually wearing away in the engine and will go wrong once the car is out of warranty, which by the way, is up in 8 months.

I also just realised that my second service is months overdue and I didn't get any sort of reminder from the local dealer. I had previously owned a number of Toyotas for many years before changing to the Mazda 3 and Toyota never failed to send me a service reminder. I'm going to tackle my dealer again on this issue when it goes in for service and I'll let you know what happens.

Regards.
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
Hi,

Good to hear from you, but sorry to learn that your car is suffering the same fate as mine. By the sound of things, you're also suffering the same level of disinterest from your Mazda dealer!

First things first, since my last post, I've learned that we're far from being alone in this problem. I contacted the Czech gentleman (Happy007 - see forum earlier) and have since been liaising with his forum members here in the Czech Republic, Slovakia and Croatia. All have experienced the same 'piston-slap' issue (if, indeed, that is the cause of the noise) and all have received the same treatment by their respective Mazda dealers!

My most recent actions have been a letter to the MD at Mazda Motor UK (Darford), and also a letter to the MD at Mazda Motor Europe (Germany). However, I would advise that you also bombard tte Technical & Customer Services Manager with this issue(annoyingly, I'm not allowed to cite his name on this forum). Send him a recording of the noise, too, as I did. The more the merrier.

As for going back to the dealer, best of luck with that, but my feeling is that it's out of their hands. I really think Mazda needs to face up to the fact that there is a major problem with some of their cars and get it sorted, rather than to consistently deny its existence.

I'll let you know as soon as I get a reply from the two letters, but ultimately, it's going to be down to legal action in my case as soon as I've arranged a firm date with our Expert Witness in the UK.

Best of luck.

Regards.
Piston-Slap Issue, Katano 1,600cc Petrol. - Billy Whizz
Do you mean Chris Twine?
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
That's the man! We've exchanged countless numbers of mails since day-1. All responses have been courteous, but appear devoted to deflecting the issue, rather than to resolve same. It seems he can't hear the knocking noise in the sound files sent, even though everyone else has managed to detect the noise easily and to offer an opinion.

Any thoughts?

Thanks.
Piston-Slap Issue, Katano 1,600cc Petrol. - sillyboy
Thanks for the reply.

I'm no expert on cars but I have owned quite a few, mostly new, and NONE have ever made this sort of noise, (except one about 20 years ago which was a very old Ford Cortina when the camshaft was on its way out). To me it's a very similar noise, or like the oil isn't lubricating the camshaft and gets louder as the revs increase. It is quite loud too, I can hear it from inside the house when my wife pulls away outside. I should also mention that the noise on my car does stop after a couple of minutes driving and doesn't happen every time from cold start, only seems to be if its very cold or hasn't been driven for a few days.

Is that the same on yours or does yours knock all the time?

It's a shame because otherwise we like the car. We've had 4 new alloy wheels and a clock which Mazda changed under warranty without so much of a blink, so why be so unresponsive to this problem especially if its isolated to a handful of cars and not 000,s?

To be honest, I'm not sure I could go through all the hassle you've been through and would be more likely to part exchange it for another car. We particularly like the new Mazda 6, but I'm not sure I could buy Mazda again with any real confidence after reading the way Mazda UK is handling this problem.

I look forward to reading your update and also let you know what my local dealer says when it goes in for service.

Cheers for now.



Piston-Slap Issue, Katano 1,600cc Petrol. - whoopwhoop
apols if I've missed it, but weren't you going to upload the sound onto youtube or similar?

Would help a heck of a lot if we could actually HEAR the noise?

Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
Hello again,

Absolutely correct. Tried to download files from my wife's vid-phone onto our PC. While the vid was good, there was no sound. Turns out that they were MPEG4 files, and my player couldn't handle them. Downloaded a converter, but while the vid played, the sound was barely understandable. So, have bought a handycam and have yet to install the software, make a few recordings etc.

However, if you want to hear the sound now, it's available on the Mazda-3 forum (where attachment of files is made nice and easy). See my link: www.mazda3forums.co.uk/index.php?topic=940.0

The particular posting was made to Daiking (Forum Administrator) on Feb-4. You should be able to download it easily, but if you have any probs, please feel free to mail me and I will be happy to send it to you.

I leave you to judge for yourself after you've listened to the sound, but would welcome your thoughts on the cause.

Regards,
Mossbridge
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
apols if I've missed it but weren't you going to upload the sound onto youtube
or similar?
Would help a heck of a lot if we could actually HEAR the noise?


Hello again, WhoopWhoop,

Below, are the promised links to the first of many videos I hope to put on the You-Tube service. One was recorded yesterday (13-02-08), the other (showing the car in motion) was recorded earlier, but on a different format.

Both files give you some idea of the noise, but we have other (MP4) recordings where the sound is far worse, but which I have yet to convert.

Your comments welcomed.

www.youtube.com/watch?v=m8vdvgSIxZE

www.youtube.com/watch?v=1YuEzg0I7pU

Mossbridge
Piston-Slap Issue, Katano 1,600cc Petrol. - nick
Certainly sounds like piston slap to me. I wouldn't be happy with that.
Piston-Slap Issue, Katano 1,600cc Petrol. - cheddar
I wouldn't be happy with that.


Like wise though could it be the "air tumbler flaps in the inlet manifold" as posted above?
Piston-Slap Issue, Katano 1,600cc Petrol. - nick
It sounds like a solid metal-on-metal knock to me. I would have thought air tumbler flaps wouldn't sound so meaty. Could be wrong though.
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
Hi Nick,

That's exactly how I described the sound from day-1; as if the mains were runnng without oil for a time. Coincidentally, two US guys (who seemed to know their Mazdas inside out) both said that it sounded like low-end bearing or rod hammer. But on two engines????
Mossbridge
Piston-Slap Issue, Katano 1,600cc Petrol. - cheddar
But on two engines????


That's where the air tumbler flaps make sense because the manifold would have been swapped from one engine to another.

I agree it sounds more substantial though.
Piston-Slap Issue, Katano 1,600cc Petrol. - Lud
Have you tried using a big screwdriver as a stethoscope? One with a round wooden handle is best. Place the blade against the inlet manifold and your ear against the handle end. You may be able to discriminate better between the sounds by doing that. If the inlet manifold sounds quiet, then try the block or crankcase (if you can see them under all the plastic and stuff that is).

Crude, but sometimes effective. Of course if you're a doctor you could try a real stethoscope.
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
Have you tried using a big screwdriver as a stethoscope? One with a round wooden

Hi Lud,

Brings back memories of days long gone when my hands were either covered in Black oil or with Swarfega! Yes, I've used the stethoscope test on many an occasion in the past (Rover V8s with hyd. tappets especially), but not even thought about it on this.

To be honest, I'm not really too keen on pin-pointing the noise on Mazda's behalf, Lud. I bought the car brand-new and it developed the fault within two weeks. As far as I'm concerned, I've been sold a duff product and it needs to be changed or my money back. All involved have had the car in their respective possessions often enough and long enough. I'm not about to start doing their job for them.

Many thanks for the thought, though. If you hear of any similar cases, I would really appreciate the nod.

Best regards,
Mossbridge
Piston-Slap Issue, Katano 1,600cc Petrol. - Lud
But Mossbridge, just supposing these flaps in the inlet tract were making a sensational but harmless clamour, would you really want to go through the hassle of suing Mazda (!) rather than getting it cured with a dab of grease or whatever?

Perhaps it isn't piston slap and Mazda are right. If it is and they are lying, I look forward to the story hitting the financial or business pages some time soon. But if I had a nice new car that made an inexplicable noise, I'd hope it was a harmless noise rather than convincing myself that the engine had worn out in far too few miles.

Of course I hope you get an outcome satisfactory to you.
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
Hi, Lud,

Yes, I know what you're saying, but don't forget, I didn't diagnose the knock as that of piston-slap; Mazda's own Specialist did that. They also confirmed that there are other such cases in the UK alone (in writing). I assumed then, that they knew what they were talking about when they insisted that a short engine would solve the problem, even though I insisted that a full power-train should be the MINIMUM they offer, after a new car was refused (in writing).

I'm not 'convincing' myself that the problem is worse than it really might be, I'm relying on the expert advice of one of Mazda's own top men!

And what makes you think that a dab of grease or similar will resolve the problem? Last time they had the car apart, the results were life-threatening. We always buy new, rather than second-hand cars, simply to avoid any hassle or time wastage. Then we bought a Mazda-3!

Mazda has at least one Czech-speaking person working for Mazda EU (he translated some of my mails for me while over here). Mazda only has to translate the pages on the Czech forum (if they haven't done so already) to know just how many M3s have EXACTLY the same problem as mine; ALL have received the same response from their respective dealers. Why is that, do you think?

While I don't want to decry those who are (rightly) well-satisfied with their own Mazdas, there is a very real issue here and I don't believe that it's being addressed by Mazda, and I certainly don't have any intention of allowing Mazda as many attempts as they like to 'get it right'. Three is the accepted maximum, and they exhausted those a long time ago!

Many thanks for the response, Lud. It's appreciated.
Piston-Slap Issue, Katano 1,600cc Petrol. - Lud
Yeah, sorry, I haven't heard the noise of course!

I agree it must be very annoying to buy a nice new sewing-machine-sounding Japanese car with a good reputation and have it turn into a slapper in a couple of weeks...

:o}
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
I agree it sounds more substantial though.


Agreed. However, when the bonnet's open, the noise does seem to emanate from the block/lower half. As made clear earlier on, my original thoughts were big or small-end knock (in the first engine), but that was ruled out of court by the Mazda Specialist at the time.

Also, past experience on older cars leads me to expect the noise to increase with heat expansion, rather than to decrease. Whatever the cause, I've no intention of putting up with it as being 'normal for a Mazda-3!

Regards,
Mossbridge
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
Hello again, Cheddar,

Just responded to Nick to say that Mazda UK don't agree there's a problem at all. Piston-slap, air-tumbler flaps or other, there just isn't a problem; Mazda said so!

Best regards,


Mossbridge
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
Certainly sounds like piston slap to me. I wouldn't be happy with that.


Hello, Nick,

Thanks for that. Mazda UK have also replied today, after I sent the link to them. They say that from the recording, it's impossible to tell whether there is a defect at all! Maybe I'm missing something........

Thanks again.
Mossbridge
Piston-Slap Issue, Katano 1,600cc Petrol. - nick
>>They say that from the recording, it's impossible to tell whether there is a defect at all!

Well they would, wouldn't they?! :-)
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
Mmmmm.
Mossbridge
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
I look forward to reading your update and also let you know what my local
dealer says when it goes in for service.
Cheers for now.

Hello again,

The engine on our car is equally noisy when started from cold, but does go away as the bores warm. It also does happen on every occasion, although, is worse when the car has been standing for a few days.

I attached the problem to a fall in temperature while still in the UK, only a few days after taking delivery of the car. The ambient temp indicator on the car showed minus 3C, and it knocked terribly. I then suspected that the lower the temperature, the greater the degree of noise. While this is true for the most part, it is not a constant. There were occasions in the Summer months when it knocked just as loudly, but I suppose that could be allocated to not using the car daily.

If, as you say, it's the same on yours, then maybe there's a lubrication problem; e.g. does the oil drain away from 'vital' parts when standing for too long? But if that's the case, then why does it not occur on all M3s? And, what is 'too' long? Shouldn't happen at all!

While all this hypothesising is interesting, it shouldn't be necessary, should it?

Best of luck with yours. I look forward to any news you have and will update you with mine.

Best regards,
Mossbridge
Piston-Slap Issue, Katano 1,600cc Petrol. - focus mk2
Just spotted this thread and thought I'd contribute. I've got a 2005 23k mile Focus with the zetec s-e engine, it clatters with piston slap when cold, on the overrun at 1800 revs and when idling. I believe ford shares the same Yamaha design engines so I'm not at all surprised to hear about the Mazda problem. Two main dealers were unable or unwilling to diagnose the problem and its getting worse. Noise got worse about at about 5000 miles from new. The classic piston slap noise goes away when warm I'm told or at least lessens. I may put it on UTube just to get ford the bad publicity it deserves on this issue. Then I guess I go buy a Toyota which is a shame as the focus is a damn good drive :(
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
Hi Focus mk2,

Many thanks for that.

Yes, I was told early on in this battle that they share the same engine design and, I suspect, the same potential for flaws.

Likewise, I feel that Mazda has let themselves down with this model. The car is a nice drive (apart from that truly, damned annoying boy-racer exhaust resonator), but my experience of Mazda's dealership(s), coupled with Mazda's handling of this current problem is sufficient for me to know that buying a Mazda was a mistake. It won't happen again under any circumstances.

Yes, put it on You-Tube. I have many recordings yet to put on (as soon as I've managed to convert same). The noise you hear on my first You-Tube vids is fairly tame compared to some mornings. We have a neighbour who is some 50m away and he heard the noise one morning last Summer! Unfotunately, I didn't have that one recorded, but I've got others equally as bad.

However, I don't know about Ford dealers, but Mazda employees, it seems, all share the same hearing impediment!!!

Best regards and good luck with yours.
Piston-Slap Issue, Katano 1,600cc Petrol. - oilrag
Hello Mossbridge,

Glad you`ve found some support in all this trouble.

Waiting to hear more of your engine noises, are you going to do one with the bonnet up?


Thought i would just add a few comments about oil and engine noise while waiting and to keep your thread alive while we are waiting.

this is *not a solution to you* with your new car, but just a few thoughts on oil viscosity and engine noise.

I`m interested in what engine`s have been totally designed around the 5w30/0w30, oil viscosities and which have been designed for higher viscosity oils and then put on lower for other (commercial fleet) reasons.

But let me give an example with our 2002 Fiat 1.9 indirect injection Diesel. Very much towards the end of its availability at purchase, this old school diesel used oil and sounded noisy on 5W 40 as put in during a warranty service.

Recognising the engine type as allegedly typical of its generation ie 15w 40 viscosity, I tried it on that and the oil consumption became such that it needed no top up between services and so much quieter mechanically, cold and hot.

It just happens that I swapped out 5w40 last weekend (Spring service in that warm weather) and the engine found its self starting at minus -7C on the drive this morning on 15W40. No problem, but I have never heard the engine sound quieter due to the higher (cold augmented) oil viscosity.

As relevant to the Mazda, I just wondered whether the ring pack and bores had actually been designed around (is it 5w30?) or whether they were pre existing and the oils had later been specified?

As I said, no solution to you, but if you had an old engine with piston slap and no other recourse, I bet (hydraulic tappet designs excluded) a higher viscosity oil would greatly reduce that sort of noise, if it is piston slap that is.

Regards




Piston-Slap Issue, Katano 1,600cc Petrol. - whoopwhoop
I'm no expert, but those two youtube recordings didn't sound any different from a multitude of new cars I've owned when started from cold and certainly not bad enough to waste your life worrying over it! (though I do accept that it may sound worse in real life?)

You should have heard my Audi RS4 - that used to sound like a Massey Fergusson without any oil in it from cold! And that was a £50k car!

I really think you're piddling into the wind with this one... sorry.......
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
I suppose it's a case of what you're prepared to accept for your money, isn;t it? If you were content to accept ANY noise at all in your £50 car, then that's entirely your decision, But I think you'd find yourself alone in that standpoint.

And as for accepting noises worse than mine in a 'multitude of new cars' you have owned, well, print out the dealer list and at least I'll know where not to shop!
Piston-Slap Issue, Katano 1,600cc Petrol. - whoopwhoop
All you're doing is worrying yourself into an early grave with stress over something which you will never win!

Mazda sell car. Purpose of car is to get from A to B reliably. Car does this. Car makes a noise which Mazda say is normal. Car still works as designed.

Do you really think you'll get anywhere? Sure, I admire you for taking a stand, but has it occurred to you that maybe, just *maybe* the noise really *is* normal for this type of engine?

There are better things in life to spend your time on ;-)
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
Mazda sell car. Purpose of car is to get from A to B reliably. Car
does this. Car makes a noise which Mazda say is normal. Car still works as
designed.


Fortunately for the world, Mazda (and all manufacturers) lay claim to far greater demands of their products than getting from one point to another. You're forgetting that Mazda were concerned enough by the noise in the first engine to suggest its removal; viz it was, by definition, 'abnormal' and thus not in keeping with their own design intent.

The consequnces of their not doing so were that the pistons, quite feasibly, could have shattered (as has been pointed out to me by an Expert), or otherwise failed. Realising that the engine did NOT meet their own manufacturing standards, they advised the solution; i.e. a short-engine. All of that in mind, explain to me why Mazda now refuses to resolve exactly the same noise/issue in this, their second engine?

You're obviously extremely tolerant of faulty products. Does the same philosophy apply to other consumables you purchase, I wonder? I mean, if you go out today and buy a micro-wave oven, washing-machine or garden tractor, and it fails or makes an abysmal noise, your advice, it seems is simply to accept it? After all, the machine 'goes', as you say, so it must be OK, right?

I can assure you that I am not worrying myself into an early grave at all, but you're absolutely correct when you say that there are other things in life. This is why any and all Mazda-created delays are to form part of my eventual claim for costs (as has been stated to them). As for winning, well, that all depends upon one's expectations of the term, doesn't it?


Piston-Slap Issue, Katano 1,600cc Petrol. - whoopwhoop
You're forgetting that Mazda were concerned
enough by the noise in the first engine to suggest its removal; viz it was
by definition 'abnormal' and thus not in keeping with their own design intent.


or maybe their customer service is so outstanding that they changed the engine despite firmly believing that there was nothing wrong with it, in order to try to satisfy a particularly difficult customer? It's not unknown....
You're obviously extremely tolerant of faulty products.


no, not at all... I'm just realistic and reasonable, and if something does the job it's meant to do, then thats fine in my eyes (and those of the law, funnily enough).
Does the same philosophy apply to other consumables
you purchase I wonder? I mean if you go out today and buy a micro-wave
oven washing-machine or garden tractor and it fails or makes an abysmal noise...


1. Yours hasn't failed.
2. The noise isn't abysmal.

So thats a daft comparison.
This is why any and all Mazda-created delays are to form part of my eventual
claim for costs (as has been stated to them).


Best of luck.... you'll need it!
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
Hi WhoopWhoop,

We could go on ad-infinitum, but it wouldn't serve any purpose, so let's just say that we agree to disagree. A couple of final points in closing, though.....

When Mazda suggested changing the engine, I was far from being a difficult customer (as they would inform you). In fact, only one mail had been exchanged at that time and we met on very cordial terms at the Dealer's premises.

You cited the law, not me. But since you did, you should be aware that I am following that very guidance to the letter. (See, also, the very helpful and informative FAQs on this forum.)

Finally, my car did fail and has the potential for still further detrimental failure (as advised by two eminently qualified people). Irrespective of your own opinion, the noise is abysmal, as confirmed by numerous others; i.e. neighbours, respondees on this forum, the Mazda-3 UK forum, Mazda International (US), Mazda CZ fourm. In fact, there's only you and two Mazda dealers who don't seem to be able to accept that fact. I wonder why.

Thanks for your time, but I don't consider your input to be of any real value.




Piston-Slap Issue, Katano 1,600cc Petrol. - whoopwhoop
>>We could go on ad-infinitum, but it wouldn't serve any purpose,
so let's just say that we agree to disagree.


Yep, ok!
A couple of final points in closing, though.....


Huh, so we're not just agreeing to disagree then??!
the noise is abysmal as confirmed by numerous others;

>>i.e. neighbours

Um... your neighbours... very "expert" !!
respondees on this forum


Internet forums... where of course everyone's an expert on everything!
the Mazda-3 UK forum


ditto
Mazda CZ fourm


ditto
In fact there's only two Mazda dealers
who don't seem to be able to accept that fact.


So the only two people that don't accept it are the only two people that are qualified to offer an expert opinion!
I wonder why.


I'm sure the penny will drop and you'll work it out soon ;-)
Thanks for your time but I don't consider your input to be of any real
value.


No problem. Best of luck.. don't have a heart attack.. it's only a car :-)
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
As I said no solution to you but if you had an old engine with
piston slap and no other recourse I bet (hydraulic tappet designs excluded) a higher viscosity
oil would greatly reduce that sort of noise if it is piston slap that is.
Regards


Hello again, OilRag,

Your comments and thoughts are welcome.

I've had my concerns about the viscosity for some time, in fact, not long after the noise arrived in this, the replacement engine. My feeling is that the 5W30 is too thin for 'moderate' temperatures.

I recall looking through the 'net some time ago and finding a site which seemed to devote itself to anything oil-releted. There was some mention of 0W30 being tried in a hybrid, but I can't recall the details. It made sense when he advised that, of course, this oil should NOT be used in your average motor! However, he pointed out that 5W30 was OK for places such as Sweden, where low-temps are something of a norm. On that premise, I think a 5W it too thin across a 'moderate' temperature range (my opinion only).

This week, the original dealer who sold me the car and then bodged up the repair, finally responded to my request for the oil they put into the car after their 'repair'. It was Castrol GTX Magnatec A1 5W-30, whereas the oil used during the car's first service (Czech dealer), was Total's Dexelia 5W30. I'm advised that the latter is a semi-synth, but don't know if the first is synthetic proper or not.

I do know that when I put Magnetec into a Honda-engined Rover 600, it sounded absolutely awful. I chucked it out, put a good 15W40 mineral oil in and no probs, no sound, in all temps!

As for recording the sound with the bonnet up, will do asap. Thanks again for the support and your thoughts, Oil-Rag. Appreciated.

Best regards,
Piston-Slap Issue, Katano 1,600cc Petrol. - nortones2
You do realise that 5W is not the viscosity at 100deg C or running temperature? It signifies the cold (w=winter) flow rate of the oil. All 0W30, 5W30, 10W30 oils are of the same viscosity, more or less, when up to temperature. But, the lower the W number, the quicker it gets around the system, especially to the valve gear. Little table in this link shows how the viscosity (expressed in centistokes) varies with temperature: www.driverstechnology.co.uk/oil-technology.htm

Follow the makers advice re quality AND viscosity, is all I'd say.
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
Hi Nortones2,

Yes, I did know that, thanks.

Because the problem centres around the 'cold' value of the oil's pour-point, I'm only really concerning myself with that aspect of the viscosity.

Thanks for the link, but see also 'The Engine-Oil Bible', specifically, this part (extracted verbatim):

.......an idea where typical engine oils are used:

Oil type Typically used in....
5W-30 Cooler climates, like Sweden or Canada
10W-40 Temperate climates, like England
15W-50 Hot climates, like Italy, Spain, Egypt

My feeling is that 5W is too thin an oil for a moderate climate, hence the clatter when starting from cold on some cars, but not an adequate explanation for the hammer in my car.

Many thanks.
Piston-Slap Issue, Katano 1,600cc Petrol. - yorkiebar
"You do realise that 5W is not the viscosity at 100deg C or running temperature"

And the advantage of it being thin is that it gets there quick. The disadvantage is that it doesnt offer much protection when its there and so thin. Oils are a compromise.

Could it be lack of sufficient lubrication at start up? I havent listend to the sounds though!
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
Hi Yorkiebar,

I used to think that was the case, based upon the longer the car stood idle, the noisier it would be at start up. But it wasn't consistent enough to prove to be the case.

Equally, I thought, initially, that the colder the weather, the worse the noise. Again, that's generally the case, but not guaranteed. There were times in the Summer, for example, when we had used the car just the night before, woke up to a warm Summer's day, but had the same terrible hammering noise on start-up.

I take your point re the oil 'getting there', but have to offset that against the benefits of a more viscous oil hanging around contacted surfaces for longer (i.e. stickier). The most obvious example being running an engine with flushing oil (as used to be the norm in the good ol' days). I think that's about 0W if I recall?

Thanks for the thought. Watch the You-Tube vid if you like, or I can link you to a sound file (.wav). Best regards.
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
Sorry, Nortones2, didn't see your closing line until now.

Yes, you're absolutely right. Theories aside, I wouldn't dream of messing about with the oil at all, at least, not until this issue is resolved!

Many thanks.
Piston-Slap Issue, Katano 1,600cc Petrol. - MichaelR
I recall looking through the 'net some time ago and finding a site which seemed
to devote itself to anything oil-releted. There was some mention of 0W30 being tried in
a hybrid but I can't recall the details. It made sense when he advised that
of course this oil should NOT be used in your average motor!


Why not? Factory oil specification for my car is 0w30 - as a result, it runs exclusively on Castrol Edge 0w30.
Piston-Slap Issue, Katano 1,600cc Petrol. - oilrag
Following my earlier comments about ring packs and bores, it would be interesting to know when this engine design was specified 5W30 oil.
In other words does design of the pistons and rings precede the decision to specify thin 5w 30 oil, perhaps allegedly as a result of running a hydraulic tappet head?

I mean, were the block/piston/ring elements carried over from an earlier incarnation of the engine and was it at that time specified a thicker oil?

Pistons/ring packs design, versus, production tolerances or engine damage?

Does anyone know of an engine of any marque specified thin long service oils on a pre existing piston/ring pack that (allegedly) can`t handle it?

Not that this refers to the Mazda, but is perhaps of peripheral interest given the relationship between engine oil viscosity as a factor in noise from piston slap (and oil consumption) on certain engines where for whatever reason tolerances are excessive.


Regards








Piston-Slap Issue, Katano 1,600cc Petrol. - nortones2
At start-up a cold 15W50 oil is 76 times as viscous as it is when hot. Look at it in the real measurement for viscosity, in centistokes (cSt). At running temps (approx) an SAE 5W40 oil is 14 cSt, but the 0c viscosity is 811 cSt. Don't worry about the 5W or the 0W being thin: its still comparatively treacle like at 0 degrees C. As for water: that's 1.0038 cSt at ordinary temperatures, but approaching an infinite number at freezing point!
Piston-Slap Issue, Katano 1,600cc Petrol. - oilrag
Nortontones,
ACEA allow 0W40, 5W40, 10W40 oils to be a lower viscosity at 150C than 15W40. I think that`s open to be overlooked with an assumption that at high temperature any oil with `40` at the end will be the same viscosity.
You can reference it in the viscosity section (bottom PDF) here if you`re interested in more detail on oil specs.

Hence an engine running at normal temperature, if its ring oil control is marginal at lower viscosity, can have a significantly different oil consumption (and noise) between 5w40 and 15w40.

www.infineum.com/information/tables.html

regards

Piston-Slap Issue, Katano 1,600cc Petrol. - nortones2
Yes, there are variations. I was simplifying! I recall a comment on 15W40 - but where is the ACEA reference to this grade? I presume it is connected to the HTHS properties, but can't actually see where a comment on the grade is in the document.
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
As for water: that's 1.0038 cSt at ordinary temperatures but
approaching an infinite number at freezing point!


Understood and agreed. But it doesn't remove the fact that Magnatec in my former Rover engine sounded appallingly noisy. After the oil & filetr change, it was a different machine entirely.

I appreciate the science of what you're saying, but I wonder whether the M3 engine would sound/perform better with a 15W/40 mineral oil?
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
oil consumption) on certain engines where for whatever reason tolerances are excessive.
Regards


OilRag,

Understood and agree entirely! I would be very interested to learn the history of same.

Regards,
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
Why not? Factory oil specification for my car is 0w30 - as a result it
runs exclusively on Castrol Edge 0w30.


Hi MichaelR,

Thanks for your comment. Can I ask whether your car exhibits any noise at all at start-up from cold?

Regards,
Piston-Slap Issue, Katano 1,600cc Petrol. - MichaelR
No, no out of the ordinary noises on startup from cold. The engine is a bit noisier from cold, but other than that, its absolutely fine. 0w30 is manufacturers recommendation and all the car has ever had since new - it is now on 150k miles and 6 years old
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
No no out of the ordinary noises on startup from cold. The engine is a
bit noisier from cold but other than that its absolutely fine. 0w30 is manufacturers recommendation
and all the car has ever had since new - it is now on 150k
miles and 6 years old


Hi, MichaelR,

Many thanks for that. It helps reinforce our conviction that the noise we hear is mechanical, rather than the result of a viscosity concern.

Regards,
Piston-Slap Issue, Katano 1,600cc Petrol. - oilrag
"can't actually see where a comment on the grade is in the document."

Hi Nortontones, Its near the bottom on the last PDF file.

Regards

Piston-Slap Issue, Katano 1,600cc Petrol. - nortones2
oilrag: I see now. But, isn't that the SAE j300 viscosity document, which gives the range for each SAE number? Within these ranges, products vary. On the table given, the 2x 40 ranges have the same 100C value. They differ in the HTHS value minimum only, which is arguably the main issue for wear, at high loads. But I think we're getting off the point here BTW:)
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
OilRag,

Just a short note to let you know that I have just uploaded a short vid to You-Tube, demonstrating the noise with the bonnet open, as requested. (In fact, it's still being processed as I write 20-02-08.)

I'm afraid it's not as long as I would have liked; we were, literally, on our way to a meeting and so just threw open the bonnet for a moment or two before setting off. I might do another if time permits, but at the moment, the house renovation work is taking its toll.

I don't know if it comes out in the video, but with the bonnet up while making the recording, the noise did seem to emanate from the lower-half of the engine, rather than at the top end. I may be wrong, and I know that a steth might help, but on the spur of the moment, it sounded bottom end. I'll put my ear to a rod as and when I get the chance.

Also, when the thottle was blipped gently, the air-intake sounds too 'throaty' for my liking. It might be something I just haven't noticed before, but I'm pretty sure it wasn't as vocal in the past - maybe wrong. The worst part is towards the end of the recording.

Yours thoughts on the vid welcomed, as always.

Best Regards.
Piston-Slap Issue, Katano 1,600cc Petrol. - oilrag
Nortontones, (and others)Sorry for pulling things off topic.


Mossbridge, I think I can hear a normal camshaft and tappets, that noise seems like piston slap. If it were related to the bottom end it would still be there when hot.

Question is, what passes for `normal` these days?

I`m not a professional Mechanic by the way, just someone who has spent many years working on engines, mainly to avoid `the uncaring apprentice`

Regards

I found the link

tinyurl.com/2rhbq8
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
Question is what passes for `normal` these days?


SNIPQUOTE!

OilRag,

Appreciated. Just had a mail from the Dealer to say that he won't entertain my claims and that I should take the car to my local dealer if I am convinced there is a problem which, he insists, there isn't.

Coincidentally, Mazda UK have mailed to say that they are arranging another inspection at my local dealer here in the Czech Republic, to test the noise when started from cold. I'll post the outcome of the test, as and when it happens.

Best regards,

Edited by Dynamic Dave on 21/02/2008 at 19:34

Piston-Slap Issue, Katano 1,600cc Petrol. - js.b1
Read the thread in full.
Can not hear the noise (this PC has a server mainboard :-)

One thought...
o Mazda may use multiple suppliers for pistons
o It is possible one supplier/batch is on the edge re tolerance
o That is manifesting itself as piston slap on some engines

Roll on engine+generator+battery & electric motor cars.
Not the hybrid rubbish we have. Then again manufacturers
will cut something to the bone there (called engineering,
but done via accountants) & make simplicity into expensive.
Cars are a "widget" to sell finance, where the $ is made.


So...
o Stop screwing around - get an *RAC inspection*
o They will say if a) present b) long detrimental c) acceptable

If RAC say acceptable then trade-in against a "quiet version".
That may be cheapest, just check HonestJohn if another Marque
as some use a "customer-operated customer-funded R&D program".
Piston-Slap Issue, Katano 1,600cc Petrol. - Dynamic Dave
js.b1,

Do you have some kind of problem that doesn't allow you to use the full width of the message box and you have to press the enter key when you reach half way across with your words?
Piston-Slap Issue, Katano 1,600cc Petrol. - js.b1
Sorry, typed elsewhere and then pasted from a Sun box to Windoze box.
In so doing the message got converted to hard carriage returns.


Trying forums, YouTube, dealer techs, marque engineers is pointless.

The buyer needs an independent inspection by the RAC to rule in or out "turbulator" in the intake, piston slap, big/small knock, injectors, injector cold-start programming, camshaft, timing tensioner etc.

An auto stethoscope may be useful, but not as much as a trained ear.
Piston-Slap Issue, Katano 1,600cc Petrol. - L'escargot
Stop screwing around - get an *RAC inspection*


That was suggested 8 weeks ago, so I assume that Mossbridge has already rejected the suggestion.
Piston-Slap Issue, Katano 1,600cc Petrol. - daiking
That was suggested 8 weeks ago so I assume that Mossbridge has already rejected the suggestion.

I don't think that Mossbridge is over here at the moment
Piston-Slap Issue, Katano 1,600cc Petrol. - Adzam1
I am new to this site and I was looking for Mazda 3 piston slap issues as this is what my Mazda 3 1.6 auto suffers from badly (2006 model).

From cold is very noisy, reminded me of an Cortina camshaft tap years ago. It does go off when warmed up but it's very embarrassing to listen to. On top of this I have had an incurable metalic knock/tap from the nearside rear from new.

The delaership cannot sort either problem and as mine is a lease vehicle I am going to keep it for another six months , pay some cash up front and then get shot of it quick. I am very disappointed with the car and the dealership.

Incredibly when I took the car back to cure the rattle a few weeks after taking delivery, they stripped out the rear interior trim and then rang me to say the car had previously been a serious accident and the tailgate was out of line. As the car was only three weeks old I furiously rang the bank who supplied it to me and went to examine it at the dealers. They pointed the tailgate out to me and some welding joins which looked OK to me but then two hours later retracted the whole story and said they'd got it wrong.

In any case they didn't cure the rattle, it's now worse than ever and I'm convinced it is the rear shock absorber but they say no, it must be trim...but I know it isn't.

If this was my 'own' car I'd be mortified, at least I can wave goodbye to it and the Mazda dealership. Just goes to show that depsite a car's reputation for reliability you can still get a bad one. I wish I'd kept my old Rover!
Piston-Slap Issue, Katano 1,600cc Petrol. - focus mk2
Its good to see we are not alone with this one. My 2005 Ford Focus has been a Slapper since new. The useless field service engineer from the Bridgend Engine plant diagnosed camshaft flat spots and had the cams changed.

Needless to say the cold piston slap is still there. Even the dealer said they could hear the noise but then backtracked the next two times the issue was raised. I don't want a replacement block fitted just to get the noise back in 5000 miles down the road.

I think there are many more low mileage Slappy engines out there but many people are ignorant of what an engine should sound like, or they just cant hear them.

I would advise anyone buying a modern car with its short piston configuration to have a good listen when the engine's cold and only buy it if its quiet, regardless of its age, mileage, or make.

Piston-Slap Issue, Katano 1,600cc Petrol. - L'escargot
My 2005 Ford Focus .........


What engine?
Piston-Slap Issue, Katano 1,600cc Petrol. - focus mk2
1.6 Zetec S-E (with cam belt, not chain) identified with plastic cam pully cover.

Same engine used on Mazda's i believe.
Piston-Slap Issue, Katano 1,600cc Petrol. - myslap
I have the same problem on my 55 plate Mazda 3 Sakata.

I have been fobbed off from the local agent with no fault found - even after writing to them leaving it with them for several nights for for cold start test. I have provided them with video of the problem - KNocks when cold and driving away for approx 30 seconds. I have now compiled a number of video examples. Latest advice from the agent is to ring them when it is cold ( they dont know this!!!?) and they might be able to send an engineer. This is not easy as the car is in use and cant take time off work to wait for an engineer when it migth be cold enough.

Having seen your message I am most concerned and will redouble my efforts to get the problem resolved
Piston-Slap Issue, Katano 1,600cc Petrol. - Mossbridge
Sorry to hear about your probs and my apologies for not being able to reply before today.

In the months since starting this thread, I've come to learn that a number of Mazda engines tend to have this knock when started from cold, albeit to a greater or lesser degree on each car. As the responses to my thread have illustrated, though, some owners are prepared to accept piston-slap as being part and parcel of the Mazda engine. If they're happy to live with that noise, then that's up to them, but I certainly was not.

The feed-back received from the Expert Witnesses I contacted support my view that piston-slap should NEVER occur in any engine, least of all, a new engine. Some of the respondees to my thread don't agree and consider piston-slap to be tolerable. All I can say in argument is that when I motor across Europe at high-speed (which I do often), with cars flying past me at infinitely greater speeds, I find it very difficult to relax in the knowledge that one or more rattling pistons is not about to shatter. Again, others seem quite happy not to worry about such things, or even adopt that somewhat naive philosphy of 'it's only a car'.......!

I am happy to inform that my long-running battle with Mazda UK is at an end. They eventually complied with my requests and, after handing over my full purchase price, less a small amount for mileage, but plus an amount for compensation, the car was shipped back to the UK yesterday.

Mazda UK could (and should) have done this right at the beginning, and would have saved us both a great deal of time and money. For whatever reason, their decision not to comply did not change until I contacted the Director of Mazda EU, coupled with instatement of a few sample recordings of the engine noise/video onto You-Tube. I plan to remove those files this week, as my own battle with Mazda is over.

For those still suffering the battle, I hope you are able to resolve your own situations with a little less aggravation!

One thing I have learned which I haven't seen anywhere else, is correct procedure regarding 'Acceptance'. If your car is new and you are convinced of a fault, return the keys to the dealer and DON'T drive the car. It was put to me a specialist (Lecturer in Consumer Law) that while every case of Acceptance is assessed individually, by and large if you continue to drive the car, you are deemed to have 'accepted' it.

Many thanks to all those who supplied positive, supportive comments.

Best regards,