A complete nightmare: shop rag left in intake

[Marvin]

I have a 2004 Wrangler 4.0. I accidentally left a rag in the intake and here I am. I pulled the head, installed new lifters rods replaced the head and torqued it.
Now, I'm getting this knock/tick from the engine. Do I need to run this for a while to let the lifters set in or am I just FUBAR?

 

[CodaMan]

WOW! bad break. It really depends on if it's a knock or a tick. Ticks are usually lifters and it will stop once the lifters fill with oil and may take 30-60 seconds. Knocks are WAY worse and are caused by metal slapping metal. Knocks generally do not go away and will lead to catastrophic failures e.g. rods or pistons.

 

[CodaMan]

Questions —

- Where did the rag end up? Did it get sucked into a cylinder or what?
- What was the condition of the pistons and cylinder walls when you removed the head?
- How did the valves look? None hanging?
- You did remove the cylinder head are not referring to the valve cover correct?
- What made you replace the lifters and the push rods?

 

[Marvin]

Thanks, it initially started fine but then started the ticking sound. The rods we're bent so I replaced them. The lifters were not expensive so I figured I would replace them to.
As for the valves, the rag got wrapped around the intake and exhaust valves. Some of the rag was in the cylinder. I discovered all this when I pulled the head. The Pistons looked great after a non non abrasive cleaning and rotation.

 

[CodaMan]

Was it running fine before all this happened? and how long was the engine running after the rag got sucked inside?

We need to determine what caused the push rods to bend, that is not a common occurrence. How many were bent? or was it just a couple and were they the ones for the valves that had the rag wrapped around them? Also, it is very possible that the rag bent a valve and now that valve isn't closing causing it to knock against the piston ... that would be bad.

 

[Marvin]

The valves and head is new. That's all replaced.

 

[Chris]

If any of that shop rag made it's way into the block, it could be wrapped around the crankshaft, rods, etc.

Personally I would drop the oil pan and inspect the bottom end. If the noise doesn't go away, you most likely have a problem down below.

 

[CodaMan]

I would also want to know if it's a tick or a knock. Very different creatures.

 

[Marvin]

I believe it is a tick. The rag was contained in the valves and above the Piston. I guess my question is, what can I do to get that tick stopped? How long can it take for those lifters to "set in"?

 

[Squatch]

If any of that shop rag made it's way into the block, it could be wrapped around the crankshaft, rods, etc.

Personally I would drop the oil pan and inspect the bottom end. If the noise doesn't go away, you most likely have a problem down below.

Not sure how any of the rag could get into the oil pan area via a cylinder, as the cylinder is blocked by the piston and rings, and the intake/exhaust doesn't lead to the lower end at all. However, I would think it's possible, though not probable, that he may have a broken ring or a cracked ringland, though I am uncertain what kind of sound that would result in. Also, a wrist pin can make a ticking sound, for what it's worth. And finally, if the OP has enough mechanical aptitude to have done this work (but is human enough to have made the mistake of leaving the rag in the intake), he probably would be able to tell when he has developed a slight exhaust least. But that could also be the source of his ticking sound. Hell, belt noise can result in a ticking sound. As @CodaMan has said, it makes a world of difference whether or not it's a tick or a knock. Let's hope for a tick!

 

[CodaMan]

I believe it is a tick. The rag was contained in the valves and above the Piston. I guess my question is, what can I do to get that tick stopped? How long can it take for those lifters to "set in"?

If it's just a lifter tick it should go away in a minute or so. If you're comfortable let it run at idle for that long go for it. Also, like @Squatch mentioned, an exhaust leak most times sounds like a tick as well. Try re-tightening all the intake/exhaust bolts.

 

[CodaMan]

I believe it is a tick. The rag was contained in the valves and above the Piston. I guess my question is, what can I do to get that tick stopped? How long can it take for those lifters to "set in"?

Were any pieces of the rag missing when you got it removed?

 

[xackley]

Do a compression check. Just because it is an all new head doesn't mean you don't have a valve sticking.

 

[Marvin]

Were any pieces of the rag missing when you got it removed?

No. It's all out.

 

[Marvin]

Do a compression check. Just because it is an all new head doesn't mean you don't have a valve sticking.

Compression test was done and all ok.

 

[Marvin]

I can't express the pain that reattaching the intake exhaust caused me. I will look into that. It's a possibility

 

[Marvin]

I

Not sure how any of the rag could get into the oil pan area via a cylinder, as the cylinder is blocked by the piston and rings, and the intake/exhaust doesn't lead to the lower end at all. However, I would think it's possible, though not probable, that he may have a broken ring or a cracked ringland, though I am uncertain what kind of sound that would result in. Also, a wrist pin can make a ticking sound, for what it's worth. And finally, if the OP has enough mechanical aptitude to have done this work (but is human enough to have made the mistake of leaving the rag in the intake), he probably would be able to tell when he has developed a slight exhaust least. But that could also be the source of his ticking sound. Hell, belt noise can result in a ticking sound. As @CodaMan has said, it makes a world of difference whether or not it's a tick or a knock. Let's hope for a tick!

Don't know about aptitude. I'm just a pretty smart dumbass

 

[Marvin]

If it all matters, when I put my hand on the valve cover, all I felt was a smooth running engine.

 

[dimension12]

Take a long screwdriver or broom handle and put one end on the valve cover bolt flange and the other end to your ear and locate the tick sound location. Or just buy an automotive stethescope. I have located many exhaust and vacuum leaks with my stethescope. In a pinch I’ve used a length of vacuum hose.
The broom handle method will get you to the cylinder the noise is coming from.

 

[dimension12]

If it all matters, when I put my hand on the valve cover, all I felt was a smooth running engine.

I would be willing to bet it’s an exhaust leak.