Strange sound after Front 60k

[Zap]

I just finished reassembly of the '94 for its Front 60k. There is a strange noise coming from the front of the engine that was NOT present before work started. :cry: I have even gone so far as to remove parts again. The engine currently has the upper timing cover removed, and both accessory belts. The noise is still present. The timing marks were lined up properly when the belt was installed, and the belt still looks fine. I drove it briefly and the engine feels immensely better than before, so I am confused as to what could be making the noise. It appears to be loudest when I am next to the wheel.

There was a bolt that got stuck in one of the holes for the crank puller, so I had a machine shop remove it, but that shouldn't have caused any problems with the crank pulley as it wasn't even part of anything critical to operation.

The noise changes with RPM, and it sounds like a faint, higher pitched metal sound? I am really at a loss, not to mention frustrated at this point. Any help from the experts will be greatly appreciated.

The only other thing I can suspect is something with the crank, CPS positioning, or timing belt tensioner, but like I said, nothing was wrong with the car prior to the 60k, and nothing happened that should have caused a problem like this! Thanks.

ADDITION: Upon further inspection, there is a whining noise that can be heard that increases in pitch as the engine is revved. I am not sure if that is something that may not be audible with the timing covers installed, but it may help with the diagnosis.

 

[ohfosho]

the water pump may make some noise, but it is usually the a/c compressor or alternator, but you have no accessory belts on so??

 

[Zap]

Okay, a small update, I went ahead, popped the cover and retensioned the timing belt, as I had not heard of the turning the crank procedure and it isn't in the SHOPP guide unless I missed it. The whining noise is pretty much gone, but the weird metal noise is still present. Has anyone heard anything like it before? It gets faster as the RPM go up. Slight metal-on-metal sound, and no accessory belts are installed. Upper timing cover is still off.

Could anything else be rubbing?? The washer for the crank sprocket is installed properly, and the timing covers are all on. Could an error in the CPS gap cause such a problem? I checked the gap a few times before setting the screws. I may pull the other timing covers tomorrow and rotate the crank to make sure it isn't brushing the CPS somehow. Looking down the timing covers with a flashlight, it appears to be fine and the vanes are clearing it, or it would be broken by now I would presume. Has anyone had this sort of sound from a mis-gap on the CPS? Thanks!

 

[Zap]

Eureka! Just as I ended up suspecting, the CPS gap was slightly off. There was really no sign of any wear, and the car never had a running problem, so I regapped it, put it back together and fired it up. It is incredible how much better it runs now. If the new timing belt makes this much difference, will I see a similar increase from new plugs and wires?

Onward to the next big project.... two Upper 60k's!