1HD-T Engine noise

[jylan]

I've got a nasty sounding noise in my car - have a listen: http://www.youtube.com/watch?v=Gvu6JBMBJNs

The noise is persistent in neutral, every gear, and every gear with the clutch in. Comes in at just before 3000RPM as the video shows, and ends ~100RPM later.

The noise/vibration also comes through the clutch pedal. At 3000RPM with the clutch in, the noise gets heaps worse and I can feel it through the pedal. If I'm driving and change gears above 3000RPM, there's a sharper version of the sound as the clutch pedal goes in and out.

Noise History

Came on suddenly one afternoon while accelerating past 3000RPM. It wasn't there the day before... I first noticed it a few weeks after the new harmonic balancer was installed, but before the new clutch was put in (see car history below). This would seem to rule out the clutch being an issue.

Car History

The engine (short block at least) was completely replaced with a reconditioned model at the start of 2012. Fuel pump was overhauled at the same time.

Around October 2012 the fuel pump was modified to suit my Gturbo, injectors were fully reconditioned (shop can handle the 2 stage design) and I had the car dyno tuned.

A few weeks later I had a new harmonic balancer installed as the old one failed. A month after that I got a new HD clutch installed, along with new flywheel & spigot bearing.

Troubleshooting

Haven't done too much myself due to limited mechanical knowledge...

It stumped my normal mechanic (the guys who installed harmonic balancer and clutch). Also stumped a friend of mine who's a diesel fitter. Both played around with the clutch pedal.

One diesel specialist in town reckons he'd heard it before in other 80s, and it's the timing gears chattering (either around the timing belt, or further behind - where the injection pump and oil pump drive gears are located). I forgot to tell this guy about the feeling through the clutch.

Another diesel specialist (guy I got the car tuned through), reckons it's something to do with the timing in the injection pump, and nothing to worry about at this stage. Again, he only listened to the engine and didn't feel the clutch.

This is the closest issue I could find while searching the net for timing noise: https://forum.ih8mud.com/diesel-tech-24-volts-systems/228428-1hd-t-noise.html.

Another guy on an Australian forum reckons his failing harmonic balancer created very similar symptoms to what I'm experiencing.

I've got the car booked in at the Toyota dealer in town for next Tuesday. Hoping I can get a master mechanic or someone with a bit of experience with this engine, who may have heard it before.

Sorry for the monster post, and any help would be very much appreciated!

 

[jylan]

The mechanic at the Toyota dealer reckons it could be a faulty throw-out bearing causing the noise. They're recommending I take it back to the mechanic who completed the clutch installation, and get them to pull the gearbox again and make sure nothing was missed. Any opinions on this or the noise from my video?

 

[lcvidar]

I've got some noise, different one, more through the 22-2800 rpm.
Video here
Sounds familiar? Can it be main bearings? Or is it just normal?

 

[roscoFJ73]

If you take it back to the mechanic who did the clutch installation and its not their problem ,you pay, but its worth consulting them. Was the flywheel machined when the clutch was installed. I was wondering if its a flywheel that has not been correctly tightened. Heaven forbid.
It really sounds like the noise comes on as you you hit the high rpms and ease off,like there is some slop in something.
Are your engine mounts good?
The harmonic balancer is easy to check and its also hard to not fit correctly. Worth checking but most likely not the problem
The timing gears up front are a possiblilty, you should be able to hear that with a mechanics stethascope.

Does this engine go beyond 3000rpm very often? Its not really their comfort zone.

 

[ForealBoreal]

When were the last time the valve shims were done?

 

[ozcrusier]

When was the last time the timing belt was replaced or how many mile on it.

 

[Jan-78FJ40]

If you take it back to the mechanic who did the clutch installation and its not their problem ,you pay, but its worth consulting them. Was the flywheel machined when the clutch was installed. I was wondering if its a flywheel that has not been correctly tightened. Heaven forbid.
It really sounds like the noise comes on as you you hit the high rpms and ease off,like there is some slop in something.
Are your engine mounts good?
The harmonic balancer is easy to check and its also hard to not fit correctly. Worth checking but most likely not the problem
The timing gears up front are a possiblilty, you should be able to hear that with a mechanics stethascope.

Does this engine go beyond 3000rpm very often? Its not really their comfort zone.

Timing gears make no sense, as wrongly aligned timing would make a ruckus at all rpms.
J

 

[Jan-78FJ40]

Do you have the problem only under load or always at the same rpm, even with the gear box in neutral?

Edit: you say clutch in. How about transfer in neutral an d gearbox engaged?

 

[roscoFJ73]

Timing gears make no sense, as wrongly aligned timing would make a ruckus at all rpms.
J

I wasnt suggesting bad alignment. His mechanic mentioned "chattering" in the gears and that he had seen it in other 80s . I took that to mean wear between the teeth. The engine has been rebuilt ,so we dont know how many klms it had done previously.
I think there is something that is loose or has excessive wear in that engine.

 

[Jan-78FJ40]

Thanks, now i understand.
Cheers
J

 

[Adam VX 100]

Hi Jylan, did you ever sort the problem out? I had the same problem after I rebuilt my 1HDT (new pistons, Rings (oversize) and bearings. I was in a long trip and the vibration got worse and eventually all lights came on (as if the fan bets broke) I checked and the harmonic balancer (pulley) had come loose on the crankshaft and broken, I replaced it with another 2nd hand one and the vibration went away, it was smooth up past 3500! and then about 100km later the vibration came back and am still looking into it.

 

[roscoFJ73]

The problem with used parts like harmonic balancers is that they have probably done as many klms as your engine.

 

[ozcrusier]

I will repeat this the timing belt tension pulley on 1hdt engines will cause a rattle under some RPM ranges so if cheap parts or it's getting old replace as it's cheap warranty compared to a rebuild.