Help Needed w/ Timing Service!!!!
 

Hey guys, this is my first timing service I've ever attempted and I am having issues. I got into this just to replace a thermostat that was leaking coolant at the o ring seal. While in there, I figure I would install a kit so everything would be new. Well, I bought the cam lock bar and the crank lock pin and using the ECS tuning installation instructions, I did everything correctly to my knowledge. I first started the car and it was fine but I noticed it had some vibration in the low rpm range. I thought maybe that was there and never noticed it. Well, while trying to bleed coolant I left the engine at 2k rpm's as the bentley suggests and when I dropped the rpm back down to idle, the car sounded like a diesel engine with clicking or clacking. I put one end of screwdriver onto valve covers and other end to my ear and valves sound ok. The first time I tore it back down the timing belt was loose and timing was off. In addition, the serpentine belt's inner rib was starting to get shredded. I put the old hydraulic piston tensioner back in and replaced the serpentine belt tensioner. Start it up....sounded fine....after revving...back to diesel sound. Tore it down again and belt was tight, almost too tight, but still in time. Any direction?

pictures.

Did you replace the hydraulic part of the timing belt tensioner? If not thats the issue. or you got a defective one. You are doing it like this, cam pulleys loose, bar on, belt on, pull pin, then use allen wremch to move belt tesioner pulley up some to tension the belt more, then tightened down the cam pulley bolts. Andthen reassemble? if your not breaking the pulleys loose to tension the belt than you will never tension it correctly.

THANKS FOR QUICK RESPONSES.....Yes, I broke the cam sprockets loose every time with the Metalnerd 2 arm puller. After tensioning the belt to 15NM, I can see why it is required to loosen them. I think the new hydraulic tensioner grenade is defective and I think the new lever is defective. It isn't EXACTLY the same shape/size as the old one.....by a miniscule amount. It is the right part though....Febi 078109487A. I just reinstalled the entire old tensioner setup. I hope it works. I cannot see what has gone wrong. This is probably a stupid question but coolant pressure/flow wouldn't be causing the diesel sound right?