[HELP] Car eating timing belt tensioner

[Crepi]

Fiesta mk4 1.25 swapped to a MHB 1.7 engine

List of mods:
Shawspeed port and polished head (neil ropper)
Lightning motorsport uprated spring valves
FRP cams
FRP ECU
oil cooler with thermostat
oil filter spacer for gauges
oil catch can
shawspeed lightened flywheel
Lightning motorsport inlet
Focus mk1 1.6 gearbox ratio with RST S2 LSD
Lightning motorsport head bolts
Cometic head gasket

So, after i've done the swap a few years back the car was running great. At this point i only had the FRP ECU and some other things i think they're not important to this (exhaust, frp airbox, etc)
I then got a spare head, send it do Shawspeed to port and polished. They coulnd't get better springs nor head bolts so i got them from Lightning motorsport.
Also got the oil cooler, oil catch can, lightened flywheel and the gearbox.
Once i got everything with me, i've changed everything alongside with the cambelt kit. I used the FRP timing tool and the car started but made a weird sound at the start.
We've finished everything because the car stopped doing it.
After i took the car home, when i started it made the sound again (videos at the end). So I came to the conclusion that when the car is long periods of time without running, when I start it, it does the noise again
After this, the car started making the sound like that one but at 2000rpm. Then i asked in groups and everyone told me it was the cambelt kit... So i've changed it (this was back in january), but the sound at start was still there...
the only thing done after this, was the LMS Inlet...
After that i've done a trackday, a trip of 600km and the car was ok... Then i did a trip of 500km at around 140/150kph and when the car stopped... It was doing the sound at 2000rpm again. I've checked a few foruns and some said that could be the VCT... So i bought the VCT pulley and the VCT Solenoid... And the cambelt kit!
Changed it... And made a trip... 500km again... When the car arrived....... It's doing it again! This is driving me nuts, don't know what else to look! The sound at the start is always there and when the car doesn't run for some time, and I start it... Can it be the Oil cooler for some reason? Along with the oil cooler i have the thermostat and the oil filter spacer for the gauges aswell...
Other thing that doesn't seem ok to me, is the fact that i can hear the valves too much, maybe cause of the cams and the uprated valves? I think you can hear it on the videos...

Help needed... Don't know what to do...

Videos:
https://youtu.be/GTCoMtBpTDM
https://youtu.be/HhDLymk7TXY
https://youtu.be/JSUl8uHcVqg
https://youtu.be/8LHDoGn9wp0
https://youtu.be/tsp0x07et-E


Old and new tensioner in attachment

 

[DOH]

Very unusual noise and unsafe to use unless fixed due to cam belt failure. Do not drive until you get this resolved.

It would be worth removing the upper timing cover and running the engine with an assistant bringing the engine speed up to the point where it makes the noise.


1)Is the cam belt tensioner or the tensioner you previously fitted a genuine Gates Tensioner?
I note on the old tensioner photo there is a wear mark on the black pulley, that is not correct and has either been contacting something or the belt hasn't been running in alignment.

2)Provided it's either a Gates or Ford/Gates tensioner, did you follow the Gates bulletin for the setting of the tensioner?
(I reckon the following is the most likely cause of that noise)

That sounds is like there is too much slack in the belt and the kickback plate on the tensioner is hitting the stop.
The way you have the tensioner set appears wrong.
After following the Gates bulletin and pulling the pin approx 3mm you should have a clearance of about 3-4mm from the kickback plate, importantly the tensioner should not be touching the kickback plate.


3)Failing that It also sounds like a rotational pulley or tensioner pulley is possibly touching possibly because it is running out of true. However there should then be some markings where it's touched and some metal filings ?

4) The inlets VCT moves as the revs increase due to the oil pressure. Are there any visible signs of it making contact with the cylinder head?