Metallic clicking noise from timing belt pulley on 1HZ (1 Viewer)

[Blade]

I installed today a new timing belt, idler and spring on my 1996 1HZ.
When turning the engine to BDC with the OLD parts I already heard a metallic clicking noise, like a spring would release and hit a metal part. I thought it's the old idler.
Now with all new parts when I turn the crank with my hand I still hear every 20-40degrees this metallic clicking noise, sometimes louder, sometimes less.
I tryed to localize it and it seems rather to come from the No. 2 camshaft timing pulley, the one that bolts to the injection pump.
Is this noise normal or what could it be?
Thanks for any tips!

 

[ForealBoreal]

https://forum.ih8mud.com/threads/ad...-this-turbo-thanks.605157/page-9#post-8458187

could this have anything to do with it?

 

[Blade]

it's when I am turning the engine SLOW by hand! Turbo is not running then...

 

[ForealBoreal]

Read the thread link. Has an issue with a bearing that could be the culprit.....


...via IH8MUD app

 

[Blade]

I saw it now, thanks!
Man, I hope it's not that! I will keep an "ear" on it!

 

[Blade]

Ok, I am stuck in Quito and working on the car.

I observed that when turning the crankshaft the timing gear (where the injection pump shaft is attached with the big nut) moves in and out and makes this noise when it does!

I first thought the injection pump is bad. I called the diesel specialist in Vancouver and he told me to check the overflow banjo bolt on the injection pump for metal chips, but it looks perfectly clean, so I guess the IP is fine. He also said it's normal that I can move the injection pump shaft in and out a few millimeters. I first thought that's not normal.

Then I removed the timing cover, what a pain, had to fabricate lots of tools myself.
Now it's out... the bearing looks good, but very shiny on the outside. I measured 84.9mm OD.

The aluminum cover itself is what worries me!!!
Where the bearing sits in the aluminum cover you can feel on one side (the side where the timing belt PULLS) a groove. I measure at this area 85.1mm ID! Where it's good I measure 85mm ID.

Is that normal?? When I install the timing gear with the bearing in the cover you can rock it very easy, it seems odd that this would be normal???
Also something I find weird is that the bearing doesn't sit all in the cover! About 2mm of the bearing outside surface is in the air. Look at the picture of the groove, you can see that there are 3-4mm left towards seal that are NOT used.

So my questions:

Should I get a new cover? (NO chance to get it here, I will have to order it somewhere with DHL express)
Or maybe install a brass sleeve? What do you suggest?

What can I do to avoid this in future? Should I put a shim below the bearing to push it further into the timing gear cover?


THE NOISE: I now reattached the timing gear and installed the IP nut hand tight and turning the crankshaft it makes the SAME noise!!! So I guess it really comes from the injection pump! ;(
But the injection pump didn't make any metal chips, so what is making this noise??

Thanks for any quick input, I need to decide tonight what do to and order what I need!

Thank you!

 

[kevinmrowland]

My bearing looked and felt fine as well, but it wasn't.
Replace it, only a $13 part.
Past that the fit of the bearing into the timing case is surprisingly loose on the multiple engines I've dealt with (by no means an expert here) but that seems to be the way they are. Your bearing looks as though it has caught and slipped at some point. As long as there in NO (and that means none, zero, unmeasurable) radial play in the injection pump input shaft then you are probably fine there. Replace the bearing and call it good.
Getting into the case is relatively easy with a few of the right tools on hand if you need to go back in for something else.
KR

 

[Blade]

13$ in USA, here it might be a 100$ part. I will check today in Quito if I can find this bearing. I also will see if we will sleeve the timing cover, the bearing was slipping and is very loose in the case. As said, I measure now 85.1mm at the worn spot and the bearing is 84.9mm (in the internet it's written it's supposed to be 85mm??), so I got 0.2mm play, that's a lot I feel.

BUT the noise is coming from the pump! I had no noise with the pump removed, attached it again to the timing gear and here is the noise again! But I found 0 metal chips in the overflow banjo screw filter. So not sure where it's coming from??

I installed now the timing gear ONLY with the pump input shaft nut and turning the pump I can see how the complete timing gear pulley is PULLED against the pump and as soon as I hear the click noise I see the pulley snapping OUT again, so I guess this makes the noise. HOW can that be? Is that normal??

 

[Blade]

I made a video of the injection pump shaft. Watch after second 13...
You see how it goes in when I turn and pops out (making the noise) and then when I keep turning it will turn quickly by itself to the next cycle where it gets hard to turn again...

http://www.pawsontour.com/Raj/

 

[Blade]

I also installed a new KOYO bearing. It seems to be a little bit tighter than the NSK bearing. NSK was 38$, the Koyo 42$. Little bit more expensive than in the USA! ;(

 

[roscoFJ73]

When I had a 1HZ engine and pump rebuilt a few years back ,both the engine rebuilder and diesel mechanic who rebuilt the pump warned me about how the pump mated to the timing cover.
Both if them offered to do it for me but it was a drama getting the engine and pump to them ,so I did it myself as per their instructions
After 8 years I forget the nature of the problem but from what I recall it was all about getting the pump all the way into the cover.

 

[Blade]

that's the 2nd time I unbolt the IP, I don't see why this should be a problem? I just tightened the bit nut on the IP shaft to 98Nm and will attach tomorrow the 2 nuts that hold the IP to the timing housing.
The IP shaft did move when everything was removed and only the nut was on. (see video) It does also this clicking noise while going in and out. The diesel specialist who rebuilt the pump told me today that's normal so I guess I just never heard this noise before when cranking the engine by hand?