Thanks for the link, jobo.
Under GM's definition, the noise may not be piston slap as there is no oil consumption or smoking and it runs like a rocket.
There were some links and I ran into this one on the 4 runner fourm and this post:
"Pistons rock as they cross TDC where the thrust load from the rod angularity shifts from one side to the other. This makes noise. Harmless, but it is the source of piston slap in most all situations.
To prevent this, pistons are designed with long, tapered, flexible skirts so that they can be fitted very tight in the bores when the bore and piston is cold. The taper of the skirt and flexibility of the skirt then prevents scuffing when the piston is hot. Also, the piston pin in OEM production pistons is always offset to one side....it is NOT in the middle of the piston. By offsetting the pin in the piston, artificial thrust load is created to control the piston "rocking" as it crosses over TDC.
Unfortunately, all of the above control techniques, common in past model engines to the extreme, create excess piston mass, cause friction and cost power and fuel economy. With the desire to build in as much power and free-revving capability and to improve fuel economy as much as possible thru friction reduction these design features are pushed in the other direction on modern engines.
Piston pin offset has been reduced over the years to a bare minimum today to reduce the thrust load generated and reduce friction. Pistons have been lightened up considerably by shortening the skirts. This creates less rotating/reciprocating mass which is good for power, free revving capability and fuel economy. Light weight pistons are great but the skirts, by necessity, are short making it hard to make them both strong and flexible and the shorter ckirts make them more prone to rocking.
Unfortunately, when the performance or fuel economy oriented pistons are run cold they are very prone to "slap" until they warm up to operating temperature.
The piston designers and development engineers are always treading the fine line between piston slap cold and friction and power/fuel economy loss when the engine is warm.
It is possible that you are hearing piston noise from an engine that is on the "high limit" for piston clearance so that it makes some noise cold. The good news is that the condition is harmless and that engine is probably a little more powerful (due to less friction) than a "quiet" counterpart. The bad news is that...it makes noise cold."
So when a dealer says "They all do it" he probably has no choice because they sure won't say, "Yeah, it's piston slap, but a good one"
I know what injector tick is and that doesn't bother me and it's really hard for me to discern lifter/valve train noise from the so call piston slap (knock). I don't hear it at idle, only on light acceleration when cold.
I probably will have my dealer listen to it. This also brings up another topic (unpopular), oil. Brands, types? I know that oil won't help a piston slap, but some are better than others quieting valve action? How soon can one use synthetic?
Any comments will be appreciated.
EDIT:
I just talked to two different dealers, not my local one and they both confirm the above except that true piston slap is MOVEMENT in the cylinder whereas the noise in the Highlander is mainly caused by the short piston skirt. FWIW: Both did recommend synthetic oil though.
So.... They really do 'all do it' and that's just how they are.