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SignUp Now!Considering the fuel pump is ten feet away from the engine and it is the tank surrounded by fuel I don't think it is the fuel pump. If it is I will eat my hat. If a fuel pump is that loud that far away it would definately be ruined. I still say starter.

I did have the downpipe out to get more room to work and changed to my gutted cat. The fit was tight but I didn't tighten up the band clamp or bolts to the exhaust on the back of the cat till after I did the turbo and it is still tweaked a bit.It's just weird that it began doing it after a starter change and front cover change. You weren't even messing with the downpipe, right?

Remove the serpentine belt. That will tell you if it's external.
The exhaust wheel sits inside the exhaust housing. No way it can contact the DP. Are you bolting the DP to the housing and then bolting all of that to the center section of the turbo? I just can't see how contact is possible unless some extreme twisting of all these components together is happening. The DP has to sit flush against the housing (both sides are flat, machined surfaces) unless it is contacting the header, frame or heater box first. Something is not adding up. Forget the catalytic converter. Lay it on the floor and just hook up the DP with nothing attached to it.
x2, this will rule out anything belt driven on the front of the motor. Also try unplugging the orange ecu wire near the battery, crank the engine. See how it sounds cranking without the engine running. Should be easier to hear the location of the noise.