Sounds like a timing cover rattling around. Do you have the tensioner bracket for the a/c on there? It may be the cover rattling against that.

When I did my timing belt job I had a verry similar sound, ended up my timing cover was slightly off and was rubbing the belt. Not sure if it's your problem but i removed the cover and ran the car ,it no noise then. May help good luck

Start removing things and see if it goes away. Start with the accessory belts, be careful not to run the car much though as the water pump won't be working.

tametalon92 said:

Sounds like a timing cover rattling around. Do you have the tensioner bracket for the a/c on there? It may be the cover rattling against that.

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This was my suspicion, like I didn't tighten down one of the bolts

donniekak said:

Start removing things and see if it goes away. Start with the accessory belts, be careful not to run the car much though as the water pump won't be working.

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I'll do this, thanks!

I typically start the car with covers off just for 20 sec or so before i button up all the covers. I got bit once when i missed a teeny piece of waterpump gasket. Easy fix when it's not totally buttoned up. If you do this DO NOT not forget the crank bolt first.

So I found that my idler pulley is slightly cock-eyed and wearing against the cover. I'm assuming this isn't normal. I'm gonna take it apart and inspect further

so i took the idler pulley off and found that the bolt was rubbed raw on one side. I assumed this is why it was cock-eyed so i replaced the bolt, installed and tensioned the belt, and low and behold, it is still cock-eyed. Is the idler pulley bad? its an after market piece with barely 1000 miles on it.

Is there a special type of bolt that goes to this pulley that i overlooked?

This pulley sit flush against the tensioner arm bracket assembly:



The bolt should not wear unless it is not fully torqued allowing the pulley base to move/wobble. The bolt should be fully seated against the inner portion of the pulley as shown below:



Should you need a replacement bolt:

http://www.streettunedmotorsports.com/parts/oem_evo_dsm_idler_pulley_bolts_mf241281.htm

If there is no defect in the pulley inspect where it mounts.

pauleyman said:

If there is no defect in the pulley inspect where it mounts.

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i did have to run a tap through the hole to clean it up a bit because i suspected the bolt was getting tight before the pulley sat flush. So i checked the mounting surface, its ok. I re-installed the pulley and it was flush. As soon as i tensioned the belt, it went cock-eyed. Im guessing the pulley is bad. i wouldnt expect it to fail so quickly though

i guess this is another one of those parts that "you should only use the OEM equipment" for?

If the suface is truly flat that hole is probably bad. Replace the mount. If the pulley is bad should be obvious just holding it.

Is it a no name china part or a reputable bearing compqny?

pauleyman said:

Is it a no name china part or a reputable bearing compqny?

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I bought it off RockAuto, brand is Dayco.

pauleyman said:

If the suface is truly flat that hole is probably bad. Replace the mount. If the pulley is bad should be obvious just holding it.

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Im going to pull it back off and check it for looseness now. i didnt even check it once i saw the bolt worn to hell i just made other assumptions. Thanks

I meant bearing brand. Will be stamped on it. Ntn. Nsk. Or somethong like that