I found what the noise was. The harmonic balancer is hitting the plastic timing belt cover. I don't remember a gasket being on the cover.

 

Thanks for updating your post.

 

can anyone think of how the cover would not seat correctly ?

 

The cover can warp over time as the number of bolts are few and far between.

The gasket material is similar to rubber weather stripping. It fits into a groove on the cover. It can deteriorate with time or be incorrectly reinstalled (or not reinstalled) after repairs requiring removing the cover.

See link below:

https://www.rockauto.com/en/moreinfo...c=1759&jsn=428

 

On every single belt timing car I've ever owned, I leave the covers off. I've never had premature failure of any timing component due to not having the cover.

Back many years ago, I owned two SVO Mustangs [turbo 4, 2.3l with a timing belt]. Many of the guys on the SVO forum tracked their cars, and I was lucky enough to be at one of their reunions at a local road course track. All of the guys there ran the track without timing covers. The guys I talked to said that their reasoning was that the timing belt ran cooler [they said they were able to run more track time without belt failures vs with a timing cover]. Second was they could adjust cam advance/retard quickly, adjusting for different tracks. Third, if something in the timing failed [mostly the factory two piece tensioner pulley for which they made a one piece in the aftermarket later on] they could see what had happened quickly, and fix the issue.

So, if the timing cover is rubbing, I would just pull it off, and store it in the trunk in case you want to sell the car one day.

Also, it makes timing belt changes a breeze. Not to mention if your tensioner starts going bad you can actually see the slack in the timing belt before it breaks, or if the belt starts looking frayed, or cracked, you can see it.

Of course some people say to run the timing cover as it protects the belt so its really your call.

[FTR, I really like this forum as I know of other Toyota forums the above would surely be challenged by some of the forum "experts"]