Well I got it all put back together and started it up only to discover a new sound! It's a very loud clatter and it doesn't sound like the valves. It actually sounds like it is coming from the center of the engine, like right around the fan. I don't see that I have dropped anything down there when I was putting it back together. I took video but we don't have power right now cause of the storm.

How did you turn the engine when you were adjusting the valves? Drop what down where?  You shouldn't have had to take anything off in the fan area.

No.No,No, Check the center bolt for tightness on the hub and also the 3 bolts holding the fan to the hub. From what I'm hearing, it sounds like maybe a loose fan/hub .NEVER,NEVER,NEVER,NVER turn the engine with that little center bolt. They can "pop" off in the crankshaft.  The easy way to turn the engine is be sure the alt. belt/pulley nut is tight and press your thumb down on the belt and turn the engine counter- clockwise (when adjusting valves) with a wrench on the alt. nut. DO NOT drive until you find the problem. That fan hub is mounted on a taper on the crankshaft with a small woodruff key and a wimpy 13mm bolt. You could do BAD stuff like wobble the key -way out of the hub(junk then) and worse yet total the crankshaft key -way.

Did you not have the "Bug Me" tape on Type-4 engines ?  Come on Russ, This is just common sense. You can't tow a aircraft carrier with a piece of kite string    Rotating the engine doesn't mean you remove the engine and roll it over and over again on the ground or swapping engines with your Audi. . Did I not say Counter-clockwise ? (just messing with you)  OH,   Did this noise show up after you put the plastic screen back on. Just notice the first time you ran the engine after the valve adjustment and said it was much better, the plastic screen was not installed. Hmmm. You might look at that. You could take it off and see if the noise goes away if you can't find anything by looking.

I've watched the Bug Me video but they are tearing down a type 4 and that's about it. I'll go back and watch it again and see if it shows how to turn the engine. I can follow directions and I'm trying to learn how to do it correctly but don't assume I know the simple stuff Before this weekend I had never adjusted valves before.

Also, yeah the sound showed up after I put the fan guard back on and put everything back together. Before I did that it was sounding great. When I get home today I will go over it all very carefully. What should that 13mm nut in the middle be torqued down to? Is it in the Bentley?

13mm bolt torque should be in the Bentley. I can't remember. Its been awhile. You are doing just fine. Just trying to keep you out of trouble. Just because I hate these things doesn't mean I haven't  worked on/rebuilt a pile of these lovely things.

I'll add that to my list of things to check. I do have a torque wrench and I know how to use it! Just so you know I'm parking this thing in your front yard when I get it fixed so I can look at your computer.

That sounds like a threat      You are coming after dark aren't you ? If not I do have two large green garbage cans I can drag around front 

Hey, you know what that sound was? My fancy aluminum timing scale. Apparently I tightened my fan guard on so tight that it was rubbing against the nuts on the fan.

Sure enough! That was the last thing I touched.