I have had this issue with my car which is getting progressively worse, it occurs on idle only and when the engine is loaded up, worse with air con on and when pulling away just using idle revs. Its a rattling noise but sounds like a clicking type rattle. Ive replaced the aux belt and tensioner and the alternator and pulley, no difference. Its very hard to find where the noise is coming from ive tried with a stethoscope but cant locate it.

It sounds as if its coming from the top left of the engine. No loose covers or anything like that ive already checked.

Could it be the cambelt tensioner making the racket?

@JWvrs25 - The cambelt (and aux drive belt) tensioners on the 1.9D are both on the right hand side of the engine.

 

Does pressing the clutch pedal have an effect? If so then I'm afraid this may be coming from the flywheel.

Definitely not the flywheel , just been replaced recently as well.

Disconnecting the alternator positive lead the noise cant be reproduced. Dont know if thats because theres less load on the engine when its disconnected.

Its baffling me at the moment

 

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Disconnecting the alternator positive lead the noise cant be reproduced

I thought that was bad for alternators and not sure why you would do it. Sure run for a couple of minutes without the alternator belt to rule out rattling in the bits the belt drives, A/C, alt, idlers.

Sounds like it might be the alternator drive pulley freewheel ?

ive had new freewheel pulley and even tried a brand new alternator, made no difference.

Any chance there is too much load on the alternator if thats even possible, might be causing the noises?

If i take off the aux belt then yes the noise shuts up, but i was also clarifying if the alternator is disconnected from the electrics the noise stops as well.