Strange scratching/tapping noise

[JJCaddy2024]

I have a weird noise coming from down near the alternator.
Noise only happens on cold starts, usually 5 seconds after starting and goes away once temperature reaches approx 50 OR if you increase idle to 1000 RPM or simply drive.
Thought it might be AC but doesn’t make any difference if I turn the AC off and fans off, still have a noise all be it slightly reduced.
I’ve attached a video, will get it booked in soon at a garage but given the time of year slots are limited.

https://youtube.com/shorts/Z4rQUQjDxXA? ... 0gqBX7snxf


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[STP]

Alternator clutch pulley. Get one off eBay and the tool to release it. Need to jack the engine slightly to access the spline in the middle. If it's a facelift MK3.5 then it's likely a 1050 stretch belt since you have air con. You could have a tensioner if it's older than 2015 so check the belt length you need. The belt needs replacing if you do the pulley. Single use only belt.

[JJCaddy2024]

Appreciate that pal, will look into getting it sorted, noise started the second I got off the ferry in Europe before a big trip, done a few thousand miles since and still been ok but will definitely get it swapped out in the coming week or two!


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[STP]

Yeah I did mine in September, had a random clack...rattle..clack..clack...clickety-clack sort of noise from the alternator and a new pulley has sorted it.

Worst part is getting the stretch belt on properly, it's a bit of a faff. There are magnetic stretch belt tools on eBay also but effing useless as it falls off every time. Just use something to lever the belt as you turn the crank pulley bolt. The crank pulley is not magnetic enough to hold the belt tool.

[JJCaddy2024]

Sounds exactly like what mines doing! Will be tackling it one day over Christmas once I’ve got the part numbers for the bits, seems relatively inexpensive, which a welcome change to the recent costs on that engine only recently fitted a couple of injectors for a hefty fee doesn’t look like it’s overly crap to get to, maybe a little fiddly but I might just whip the wheel arch liner out and work from that angle!


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[STP]

You definitely need the liner out. Impossible otherwise.

Pulley is
https://ebay.us/m/VJtc4J

Tool is
https://ebay.us/m/7KN0J2

Short belt (no Aircon) - 864mm from memory or something
https://ebay.us/m/F6F4m4

With Aircon you need the 1050mm belt.

[JJCaddy2024]

Appreciate that mate, will have a look after work and get the bits ordered!


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[JJCaddy2024]

Got the bits ordered and finally some time to do it, found the internal splines are rounded! Simple job turned into a 2 day job, lost daylight so taking the alternator off tomorrow and see if I can’t save it to prevent having to buy a new one!
Long story short, you were bang on the money, the alternator clutch pulley shit itself and the belt was indeed a 1070 on a tensioner, making removal easy!


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[STP]

Brilliant, luckily the big splines are part of the clutch pulley and not the alternator, it just has a threaded end on the shaft. The little multi spline part however is the end of the alternator shaft.

You should be able to get the pulley off, it's a standard right hand thread so unscrews anticlockwise.

If the clutch is buggered and the splines are chewed, get someone to put a weld on the pulley either side of the splined hole, to lock the pulley to the splined centre and then you can use a stilson to unscrew it. You can put a thin screwdriver into the alternator fan blades at the pulley end to lock it still. Then the pulley should unscrew.

Normal method is to put a multi spline bit (double square) into the alternator shaft internal spline end, and use a spanner on the black tool hex area to unscrew it. This turns the large spline part and unscrews the pulley while the smaller multi spline bit holds the alternator shaft still.

The bit you insert through the black removal tool is not a torx, it's a multi spline double-square bit (look that up if you don't know what those are mate)

[JJCaddy2024]

That’s the one, got the kit for a removal, the black larger multi spline as actually ok, it’s mainly the internal smaller spline that’s got the damage, as though someone’s been there before. Making me think it’s unfortunately new alternator job but I’ll know more in the morning when I get it off. Hoping whatever is up with it isn’t too major and still useable, otherwise it’s going to have to be a new alternator I assume! Will update once I get it off for a better look