Carrera chain tensioner chain box cover fitment issue

[dpetterson]

Has anyone ever ran into a fitment issue with the aluminum chain box covers that come with the pressure fed Carrera tensioner upgrade kit?

The right side (passenger) cover went on without any issues but the left side (driver) seems to be hanging up close to where the tensioner exits the chain box cover. The tensioner itself fits through the hole in the chain box cover without any issues (see first image below), but it appears the hole with the aluminum cap (just above and to the right of the tensioner exit hole) isn't quite lining up with the idler arm / tensioner shaft (see images below).

Wondering if this is a manufacturing / tolerance issue with the chain box cover itself or if something might be wacky with the tensioner / idler arm shaft alignment?

If anyone else has experienced this issue or has any workarounds, I'd love to hear them. Thanks!

[Rick Cabell]

Sometimes you have to tap the area around the tensioner feed exit with a soft faced hammer to get the cover to fall into place.

[Stretch32]

I’ll caveat with: I’m not a professional engine builder but I have put 2 ‘71 engines together but my experience was:

One of my Carrera tensioner chain box covers on my ‘71E takes a little bump or two with the palm of my hand or a very light non-marring mallet. In my case, the o-ring on the tensioner is a very tight fit. My issue looks / sounds similar to your problem on my car but is definitely the o-ring in my case.

Stretch

[dpetterson]

Sometimes you have to tap the area around the tensioner feed exit with a soft faced hammer to get the cover to fall into place.

Thanks Rick, yeah I was tapping it lightly with a rubber mallet but to no avail. Tensioner is fully exited out the cam box cover hole - it just seems to be binding on that shaft circled in the above photo. I would assume the covers are machined to good tolerances but I’m not 100%.

[dpetterson]

I’ll caveat with: I’m not a professional engine builder but I have put 2 ‘71 engines together but my experience was:

One of my Carrera tensioner chain box covers on my ‘71E takes a little bump or two with the palm of my hand or a very light non-marring mallet. In my case, the o-ring on the tensioner is a very tight fit. My issue looks / sounds similar to your problem on my car but is definitely the o-ring in my case.

Stretch

Yep, gave it some taps with mallet and the o-ring wasn’t too much of an issue. That shaft circled above seems to just miss the hole it’s supposed to be going into.

[Rick Cabell]

I have installed probability a hundred of these kits and never saw that problem.

[dpetterson]

I have installed probability a hundred of these kits and never saw that problem.

That's good to hear Rick... I'll give it another go later today. Hoping it just needs some additional taps to get it to seat.

[Rick Cabell]

I’ll also admit it sometimes takes more than a tap, more like a couple firmer hits, common sence will be on your side.

[dpetterson]

Sounds good Rick - thanks.

Update - Finally got the cover on!

Instead of putting the cover straight on and tapping with my mallet, I tilted the top portion of the cover a bit so the shaft would clear that hole a little better (i think it was just barely scrapping it) and was able to tap it on.

Thanks for everyone's feedback. I knew about having to give a tap, but this one involve just a bit more massaging.