Well,
from what you've provided I don't see the pump as the source of the issue, you've stated that it is capable of delivering 60lbs. pressure, 60 is the pressure point where the relief opens, not having any more info on the *replacement* crank *was it a fresh reman crank that had been turned earlier, was it a new never used crank that came off the shelf*. Not having the rods resized isn't the end of the world but the shop would have/should have checked the bearing clearances with the bearing shells installed into the big ends against the rod journal (crankpin) dia to ensure that the clearances were within spec, the same goes for the crank main clearances as well.
Was the valve train also rebuilt? .........the cologne 4 has a weak spot where pushrods are concerned & the rockers should be rebuilt as well, the clatter you mentioned could be a result of what the following describes....... any place where pressure can be lost will show up on the gauge
*to quote a source *
The pushrods and rockers on the 4.0L tend to show a lot of wear, even on engines with low miles. We suspect that there are two reasons for this problem: (1) The material in the rockers appears to be too soft, so they wear on the tip, and; (2) there’s not enough oil getting to the pushrod socket, so it gets worn out, too.
There’s pressurized oil at the rocker shaft to lubricate the rockers, but there’s no direct way for that oil to get to the pushrod sockets. There’s a passage in each rocker that allows oil from around the rocker shaft to migrate out to the small hole in the top of the pushrod socket, but it’s wide open on the outer end so there is no pressure there to feed the oil down into the socket.
Apparently the small hole in the pushrod socket that intersects this passage is supposed to meter oil down into the socket somehow, in spite of all the motion that’s trying to sling the oil out from the open end of the passage in the rocker. It’s hard to believe that any oil can actually get into the sockets, so it’s no wonder they wear out prematurely. Rebuilders should expect to rebuild or replace most of the rockers. The tips can be ground if they’re not worn too badly and the sockets can be repaired by installing a special insert that’s available along with the tooling needed from Silver Seal (800-521-2936) or Goodson (800-533-8010). Or, if you prefer to have someone do them for you, rebuilt rockers are available from Delta Camshaft at 253-383-4152.
You may want to consider flame-hardening the tips, too. Ed Davis at Waterhouse Motors in Tacoma, WA, has been doing this for awhile to eliminate wear on the tips. He found that the wear on the tips was loading the valves so hard to one side that they were wearing out the guides and causing other problems in the process
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