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Discussion Starter #1
Anyone shed any light on this? I get it between idle & about 1200 rpm in any gear. It's more of an irritant than a real problem but I would like to kill it off if can. The car is an '04, it's recently had new engine mounts back & timing side, new tensioner assembly & a new belt last week when I fitted a Kavs & precedes those parts & it's running on a new stock clutch & flywheel.

I've been around the engine bay & made sure everything is buttoned down - ps reservoir, expansion tank etc & I can't see anything obvious?
 

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do you have a hole visible in the tensioner safety strap, above the tensioner body? Checked the crank damper? Alternator free to spin?
 

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Discussion Starter #4
No visible hole in the strap - the tensioner assembly is brand new. Alternator is free & I checked all the other pulleys when fitting the Kavs, I have no iffy bearings that I can detect. I should mention it's only in gear, never in neutral which points at the other end of things but it also has a brand new clutch, flywheel & release bearing over there.
 

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It's probably the wrong belt then, or stretched. For what it's worth, and it might seem far fetched but the bypass perhaps closes as you begin to move off, loading the charger that small amount, enough to chirp the belt. Regardless, in my experience it rarely pays to set aside something you know to be wrong and then ask what else it might be. If there is an issue then optimising things by dealing with it is best.
 

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Discussion Starter #7
That's interesting. The belt is a Dayco 6PK 1365 supplied by 1320 with the Kavs pulley. You think it's the wrong one?
 

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Discussion Starter #9
15% It was bought as a kit from 1320. Pulley, belt & plugs. Everything on the car for a week. Prior to fitting, the noise was intermittent, now it's constant.

To recap, on that side of the engine in the past month, I've fitted a new engine mount, belt tensioner assembly, Kavs pulley & belt. It's pretty shiny down there.
 

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1368 is common with a 17% and even a 15%, different manufacturers have different lengths and the same belt might fit on two different cars of the same spec but that might have had pulleys, tensioner, or damper changed and the tensioner strap can read differently, minor differences but they can affect how long before the tensioner strap bottoms out. Ultimately this belt new might have shown only part of a hole but with a new belt this won't last long, so you will find the belt that might look and last better is a 1353, maybe even shorter. If I had fitted it and not seen much potential for stretch I'd have tried a different belt, it happens. I'm not saying this 'is' your problem but it does need to be good.

Does your crank damper look like this?
98172
 

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Discussion Starter #12
Id assumed the belt would be right. I'll try a shorter one & see if it does the trick. Thanks Mac & CoB. On the crank pulley, that does look like mine. It's an August 2004, so should be the revised design.
 

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Discussion Starter #13
Ok, Changed the belt & it's not that :/ Someone talk to me about chirping bypass valves? I've tried mine by hand & it springs back positively. While the belt was off, I span all the pulleys, nothing rough or squeaky. This is getting on my wick now.
 

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If only in gear, is this actually during take up of drive, or moving with clutch fully engaged?
 

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Discussion Starter #15
In gear moving. Specifically not when taking up drive - the clutch action & engagement is spot on. I can reproduce the noise in any gear as long as I'm between 900 & about 1200 rpm.
 

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right ok, should have asked before perhaps, could you replicate it if the car was on stands do you think? Transmission mount is still original? Could you observe at walking speed in first gear perhaps? Bonnet up in an empty car park or something daft like that? Would you hear it externally? If with clutch engaged and it existed prior to any clutch work and you're certain the crank pulley isn't delaminating I'd be looking at mountings, or exhaust, and possibly shield related I guess, check all heat shields are clear first, not rattling/loose, especially under expansion tank and PAS reservoir, starter shield on properly, top exhaust shield not fouling, rear coolant hose assembly still mounted, the bracket to the lower starter bolt for it not snapped, and rubber anti rattle sheath on them near the PAS pipes close to the steering column is still in the right position etc, and that the tray under the battery box isn't fouling, tunnel shield hasn't dropped onto the rear of the exhaust at the rear subframe mount locations as they rot out there, or nearby shields, or that any sliding exhaust joints aren't loose, it happens, or exhaust or mounts touching anything, centre floor brace or bump stops etc, engine mounts all still tight, try to get a decent video up perhaps? ;O)
 

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Discussion Starter #17
Plenty to think about there!!

I'd thought of walking along side it, bonnet up in gear. That certainly is daft! Might be able to get a pal to help with that. Prior to the clutch work, it was intermittent & now it's constant. In general, I've renewed so much on the car, I'm struggling to see what it can be. Right & rear engine mounts are new. Tranny mount isn't but is in good nick. Crank pulley is sound. In the box, I changed the seal & even the release fork bushes & greased everything up.

Last week, I had the dash top off to line the contact points with felt (which is one of the best things I've ever done to it
btw) & had a poke around behind the dash & I'm certain it's in the bay & not the interior. At the back, the starter bracket is ok but I think I'm missing a bolt for the coolant lines. Up top, the airbox self tappers don't bite & that's all I can think of out of the ordinary.

I'm about to take the head off & renew the rings & con rod bearings so I'll be able to get under the thing again shortly & have a decent poke around the back of the lump & see if anything is awry. Also fairly sure the various shields are on ok but I reckon the flexi joint is a good shout in the sense it's definitely up there for vibration. Otherwise, the car drives brilliantly, I've put loads of effort into making it that way & that's what's frustrating - it's so close to being bob on & I can't find this one fault. Grrr!
 

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Discussion Starter #18
Right, I got to the bottom of it. I've just done a bottom end rebuild & while it was apart, I noticed the Kavs pulley a few degrees off perpendicular. Must have been the tosser who installed it...
 
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