Rep Power: 0

2001 Honda Civic EX Coupe, D17A2, 140k miles

Just completed major engine overhaul - timing belt, water pump, etc. and new head gasket, head machining and valve-job.

Followed DIY on here too a "T", everything went pretty smooth. Got everything put back together. Got ROCK brand gasket set from machine shop who completed head service (pressure test, machined, valve job). Installed ARP head studs, torqued to 80 pounds.

Buttoned everything up, motor started right up, didn't even hesitate. Let idle on jack stands for 15 mins to get up to normal temp, fan kicked on, everything normal. Put the wheels back on, took out for a test drive, everything running smooth, acceleration smooth and strong, definitely running better and quiter than before. Drove around for about 20 minutes, normal driving, no hard acceleration. About 2 minutes before pulling back into my driveway, noticed a "clacking" noise that changed with the RPMs. Long story short, very loud "clacking" coming from the intake-side of the valve-train.

Other symptoms I've observed:
- warm air coming from the breather tube coming from the valve-cover (this may be normal, just never noticed it before)
- still getting some white smoke from the exhaust - figured some is normal from all the crap that gets into the cylinders when removing the head, assembly lube from the valve job, etc...how long should this go continue
- complete radiator flush - no bubbles in coolant, so head gasket should be good...yes?

Please help so I can lower my stress level as this is my first time at this!

 
Rep Power: 811

clank? that doesnt sound good. idk what that would be. you did a valve adjustment i hope before starting the car?

 
Rep Power: 338

probablly got the valve clearance right.. but forgot the lock nuts?
how trustworthy was the machine shop?
did you bolt the rocker arms down right?
did you make sure the rocker pins were all present and accounted for? ive seen issues where someone lost a rocker arm lock pin for the vtec and ended up screwing up a rocker arm set... so i think you need to pull the valve cover gasket off, and turn the engine to see what is going on... check the valves again

 
Rep Power: 0

UPDATE - Machine shop did a complete valve job, clearances, etc. But...I only got into the VTEC range of the RPMs in the last few minutes of my test drive, and then noticed the sound which is present at all RPMs...

 
Rep Power: 338

well something is not right.. take a look