SM25T Posted November 24, 2019 Share Posted November 24, 2019 Sounds scary ! Link to comment Share on other sites More sharing options...
7 wonders of the world Posted November 24, 2019 Share Posted November 24, 2019 Keyless is standard of modern engines now.Have you checked eveything else on the driveline of the belt, guides tensioners and water pump.....? Link to comment Share on other sites More sharing options...
Scotland North AR Posted November 25, 2019 Author Share Posted November 25, 2019 Morning, all the items on the crankshaft are keywayed on since Premier Power upgrade.Forgot to add that the water pump was changed also.The only thing not new on the driveline of the belt is the crankshaft pulley, dropped the car off just now to get it changed.Strictly speaking the 11,000 mile old alternator is not new but has been away for stripdown and inspection. Link to comment Share on other sites More sharing options...
SM25T Posted November 25, 2019 Share Posted November 25, 2019 Aha ... so it could be brushes or bearings in the alternator ! Link to comment Share on other sites More sharing options...
Paul Deslandes Posted November 25, 2019 Share Posted November 25, 2019 A cracked alternator fan can make a terrible rattle, until it lets go and makes its way out through the bonnet. Just remember to duck.....I found mine before it flew apart..Paul Link to comment Share on other sites More sharing options...
Scotland North AR Posted December 4, 2019 Author Share Posted December 4, 2019 Well, it appears to be fixed...a few false starts over the last few days, ordered the wrong flywheel locking tool, then had the wrong crankshaft stretch bolt.... Engine rattle Changed idler pulley - thought I felt play in it Changed belt tensioner - as above Sent alternator away for checking - returned all fine from manufacturer Changed alternator drive belt and pulley Changed water pump Changed crankshaft damper pulley Fitted brand new alternator and pulley Rattle gone!The rattle came on 3-4 minutes after engine start originally. I can only assume something is warming up inside the alternator, expanding and then catching causing the rattle.The alternator will be going back to the manufacturer for a further check.The engine is 60,000 miles old, 11,000 after a rebuild and now everything one the front of the engine is brand new so not all bad.Good job this is December and not June i.e. mid driving season. Link to comment Share on other sites More sharing options...
Member Jonathan Kay Posted December 4, 2019 Member Share Posted December 4, 2019 Glad it's fixed. But I'm not sure why you're attributing the fix to the last change... did you listen for the rattle after each of the preceding moves?Jonathan Link to comment Share on other sites More sharing options...
Scotland North AR Posted December 4, 2019 Author Share Posted December 4, 2019 Hi Jonathan, the whole process ended up taking about two months and therefore each step was done as each bit was ordered and then fitted.....then being disappointed when it rattled.....again.... Link to comment Share on other sites More sharing options...
Member Jonathan Kay Posted December 4, 2019 Member Share Posted December 4, 2019 ThanksJonathan Link to comment Share on other sites More sharing options...
David Brown Posted December 4, 2019 Share Posted December 4, 2019 Glad it's fixed Nigel. I know how long and frustrating self diagnosis can take but you at least have the satisfaction of having resolved it yourself and added to your bank of knowledge. Link to comment Share on other sites More sharing options...
spikeinwarwick Posted January 27, 2020 Share Posted January 27, 2020 I had a Volvo V50 that developed an annoying rattle - a garage diagnosed a failing dual mass flywheel. Luckily, my Volvo dealer diagnosed a failed clutch in the alternator pulley - it was a new alternator (5000 miles) - and they were right. Has your alternator got a solid pulley, or a clutch/damper? Link to comment Share on other sites More sharing options...
Scotland North AR Posted January 28, 2020 Author Share Posted January 28, 2020 In the end, WOSP, who made the alternator, gave me a new one free of charge as a gesture of goodwill.The alternator was tested on another Caterham and rattled before going back to WOSP. WOSP tested the alternator in their factory a couple of different ways but couldn't generate the rattle. I suspect that this was because they couldn't replicate the amount of side load which the tensioner applies on their bench top rig. They also stripped it down again and couldn't find anything visually.The alternator pulley is solid (no clutch) aluminium. It exhibited very high wear after 11,000 miles so I'm just waiting for WOSP to supply a steel pulley which they also agreed to do FOC.You live and learn....and sometimes end up the poorer for it.Still, another trip to the Picos booked in the car plus the diary filling up with other car runs so not all bad. Link to comment Share on other sites More sharing options...
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