Your engine can develop a sticky valve lifter or two due to several factors. Sticky valve lifters are a common source of cold start noise that is frequently referred to as a knock, but it is more of a loud ticking sound.
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If you are experienced in engine work, you may be able to do this yourself, but if you have not done it previously, you will probably want a professional to perform the work to ensure there are no issues. The rebuild, while much more expensive, will also allow you to inspect and replace any other potentially worn parts. You can certainly just deal with it for a time, as the piston slap itself is not a potentially catastrophic failure, but the damage with the piston skirt and the cylinder walls can be. The proper oil pressure will often be enough to fill the excessive clearance, but if not, there are two options, you can deal with it and baby it, or you can do an engine rebuild. If the excessive clearance is minimal, it will also frequently go away as the piston head heats up and expands. This is one of the reasons why the sound of the slap will go away a short time after starting. If the pistons and cylinder bores are set up and machined to the correct specifications and tolerances, the piston slap should not occur. This can happen due to physical wear on the cylinder walls, the cylinder being out of round, or it can be a design flaw.
Piston slap is what happens when the piston and the cylinder wall no longer have the tight tolerances of a new engine and the piston “rocks” side to side on a slight angle inside the cylinder instead of smooth up and down motion. It generally will not develop in engines that have less than 150,000-200,000 miles on them. Piston slap is an extremely common cause of cold start engine noise.
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