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Why does my car sound like it's popping popcorn made out of steel? Also runs rough, no relevent OBD codes.?

2003 Intrepid ES - 3.5L

It does it whether the car is hot or cold. I start the car up and it immediately starts making this noise. It seriously sounds like it is popping metal popcorn inside of a metal can. The fluids are all fine. The first time I noticed it, I drove home from work and it was running just fine and quiet. Minutes later, I got back into my car to run to the store and it made the noise and idled roughly right when I started it. I tried starting it this morning and it does the same thing so engine temperature is unrelated. It starts right up, no smells, just runs rough and makes the noise.

I am getting OBD codes, but that's for the EVAP system. Had those for a couple months and haven't gotten around to fixing them yet, and won't until the popping issue is resolved. The popping frequency does increase when the gas is applied whether in gear, neutral, or park. Any ideas on what it could be or where I should start checking?

Update:

it sounds like this: http://www.youtube.com/watch?v=Py3XiC9euWM

That's NOT my video, but it sounds very much the same.

Update 2:

The exhaust system can't be overheated when the car has run for less than 5 seconds the entire day, could it? I thought about exhaust, but because it doesn't matter if the engine is hot or cold and the starts up immediately, I assumed it wouldn't have anything to do with overheating exhaust.

Update 3:

Since the gas has been mentioned, I want to add that the gas is fresh and I had about 1/8th of a tank left and then filled up at Costco with the 89 Octane rating fuel. I am now at about 3/8th of a tank when the sounds have shown up. So I've gone through more than half of a tank without any trouble.

I'm not so excited about investing time and money into the EVAP system when the sound could very well be a rod knock and the whole thing is hosed. As I stated earlier, the EVAP codes have been on for a couple months as it is and the only difference I've noticed in anything is that there is a check engine light lit up on my dash.

6 Answers

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  • Anonymous
    9 years ago
    Favorite Answer

    check your spark plugs and ignition system. sounds like your problems might be pointing in that direction.

  • Anonymous
    9 years ago

    you obviously are not getting any codes for an ignition type problem so therefore it is not relating to the primary side of the coils or any of the other sensors needed to fire off the intrepid's motor. so now let's look at the physical side of the equation, popcorn sounds - also known as pinging. your knock sensor is either not hooked up or is shot. the best way to check this is to is to tap the motor close to the sensor and see if the idle changes, if it does good. chances are you have a bad gas situation, water in the gas maybe. the timing is set at the factory and by the computer.

    Source(s): x-mech
  • 9 years ago

    If I were you I would find the time to repair the EVAP and then worry about the sounds.

    They sure can be related. Especially if this is the exhaust system overheating making

    this sound.

  • Anonymous
    9 years ago

    A bent or broken pushrod hitting the underside of valve cover could do that,or is it popping though the carburetor?Maybe broke distributor-rotor or it jumped timing? -

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  • Fred F
    Lv 7
    9 years ago

    Maybe the timing is off or poor grade of gas.

  • 9 years ago

    Timing chains can make that noise.

    Source(s): Mitsubishi Master Tec h
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