2002 explorer noise after chain replacement

[chicows18]

So i have a 2002 explorer 4.0L. Originally the car turned off and would not start again. Pulled off the motor, bought the tools, bought the kit and replaced all the chains, guides and tensioners. Pulled the heads off and sent them to a machine shop and had them shaved and pressure tested to make sure the valves did not bend. Replaced everything according to threads, forums, videos, and the good old timing chain book. Put everything back together and started the car at which point there was a fairly loud knocking noise coming from it. Pulled the motor off again and checked the timing chains again and repeated the whole procedure. The only fault i found was the timing chain tensioner from the front crank to the jackshaft was beat up badly. Almost as if something was scraping against it. Ordered another one from the dealers and set it up again. Put the motor back on and now the knocking noise is quieter but still there. The engine also vibrates almost as if it was not firing up on all cylinders yet they are all good. Any ideas? I don't know what else to do. Im very handy when it comes to cars and can pretty much do anything and have a variety of tools to get the job done. By the way, the kit i bought from rockauto.com . I think it was the DNJ kit since mines has the balancer shaft. Any help would be appreciated.

 

[chicows18]

Also, the kit came with a little plastic rod and plug that go on the side of the head. What is that for?

 

[chicows18]

Bump

 

[RickOTR]

That little plastic rod is used to increase oil pressure with the new front tensioner. You need to remove the small plug next to the front tensioner and put the rod into the hole, then put the plug back in. Not sure, but this could be the cause of your noise...

 

[2000StreetRod]

volume reducer

The plastic rod is a volume reducer. It will not alter oil pressure. It decreases dry start time by reducing the volume of the galley chamber that provides oil to the front hydraulic tensioner.

Did you test the movement of the hydraulic tensioner piston before installation? Some are defective and don't move freely.

Did you time the balance shaft after replacing the balance shaft chain and tensioner?

The abrasion to the primary (crankshaft to jackshaft) timing chain tensioner is unusual. Did you remove the locking pin? Do you have a photo of the damaged tensioner?

Does the knocking noise resemble a stuck hydraulic valve lifter? The hydraulic lash adjusters drain during an engine rebuild. If they are not prefilled before engine start they may be noisy. It takes about 30 minutes of mid range engine running for the noisy ones to quiet.

Edit: If you PM me your email address I'll send you a copy of the SOHC V6 assembly instructions. You might notice something you did incorrectly.