Lets start by saying, I changed the bearing in the pulley because I had a loud squeak. Turned out to be the harmonic balancer. But anyway I replaced the Harmonic Balancer, the Idler Pulley and the A/C pulley bearing. Well I bent the A/C pulley but was able to half *** it to make the clutch engage without squeaking. Its been fine for about 2 weeks and 500 miles. Well I was driving home from work tonight and heard a tick/Knock so when I got how I popped the hood to investigate. at first I got scared cause I though it was an engine knock. well I cycled the A/C on and off a few times and noticed there is in fact a noise difference with the A/C on and off. Check out the video so you can hear it. My question is...Does this sound like A/C or something more horrible?

https://www.youtube.com/watch?v=TxnyF4Ezcgg&feature=youtu.be

I'm really starting to hate this car.

 

I get that sound once in a while and I tap the gas and it goes away. I think it's the idler pulley but I can't be sure. Did you use an OEM idler pulley or aftermarket?

 

when you replaced the AC pulley did you use the same shims that were inside, sounds like you are missing the shims for clearance ...

 

UPDATE: I removed the clutch to find this.

 

bad bearing....