Dr.Diesel,
Thank you for your quick reply. I did read on one of your previous posts that the plastic clips could fall into the intake on the head when removing the manifold. I watched for this and look into the ports with a light before installing the manifold. I even order 7 new clips and replaced the old ones. The center intake ports had about 1/8" of carbon build up and some of them were wet. I had to replace the rubber pcs. that attach to the intake manifold also. Most of the holes were blocked. When I scraped some of the carbon away(like black goo) form the intake ports some pcs fell into the head. But I really tried to keep it out.
What about the timing chain being loose?Does that impact the noise I heard?
How can I check the timing chain stretch? They changed the oil every 5-7K miles at the dealership.
Also does the IP ever leak from the middle gasket or am I missing a leak up by the heat exchanger at the head?

Thanks again

Mike S.

__________________
1983 300DT 173,000miles sold
1983 300TDT 320,000miles sold
1985 735i 189,000miles sold
1986 528e 210,000 miles sold
1991 740 Volvo 250,000 miles
2002 VW Jetta TDI 32,000 miles sold
1995 E300D 137,000 miles
2004 Dodge Sprinter 26,000 miles
1986 325e BMW 94,000 miles
1986 325e BMW 148,700 miles
Mike