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!

[proporsche]

did you lubricate the o ring? Looks like you did not go deep enough with the cover.How does the cover look on the inside-picture?


Ivan

[Rick Cabell]

Yes, lube o ring and tap in that spot with soft faced hammer

[boyt911sc]

First, try to install the chain housing cover without the hydraulic tensioner and observe the fitment. Next, try with the Carrera hydraulic tensioner installed. Do you have a new hydraulic tensioner? Try to install an old tensioner and compare. The new batch of tensioner might have changed a bit.

Tony

[dpetterson]

Originally Posted by proporsche

did you lubricate the o ring? Looks like you did not go deep enough with the cover.How does the cover look on the inside-picture?


Ivan

Hi Ivan - o-ring was lubricated and as far as I can tell, the tensioner is exiting through the hole in the cam cover far enough. See photo below for where I think the issue is occuring...

[dpetterson]

Originally Posted by boyt911sc

First, try to install the chain housing cover without the hydraulic tensioner and observe the fitment. Next, try with the Carrera hydraulic tensioner installed. Do you have a new hydraulic tensioner? Try to install an old tensioner and compare. The new batch of tensioner might have changed a bit.

Tony

Hi Tony - yep - they are new tensioners. The cam cover doesn't have any issues going on and the tensioner itself comes through the hole in the cam cover without issue. It's the other hole that the idler arm shaft doesn't want to fit into cleanly, or so it seems. I may have to remove the tensioner / idler arm assembly and see how it fits the cover...

[proporsche]

measure the shaft-that should be just like any other shaft ..after measure the hole on chain housing cover.Again it should fit .I just did today the same engine as yours...

new tensioners -they look totally the same --Did not see any difference as Tony has mentioned?

Ivan

[Dpmulvan]

That hole looks a little funky hard to tell from your pic, is there a bevel around the hole concentric to the hole? Area where your arrow is looks a little odd.
If you want to see how far off it is heat the area around the plug pop it out and assemble, that way you can see through the hole where it’s getting hung up, then go from there.

[dpetterson]

Originally Posted by proporsche

measure the shaft-that should be just like any other shaft ..after measure the hole on chain housing cover.Again it should fit .I just did today the same engine as yours...

new tensioners -they look totally the same --Did not see any difference as Tony has mentioned?

Ivan

Thanks for the feedback Ivan - I'll take some measurements and see where things stand.

[dpetterson]

Originally Posted by Dpmulvan

That hole looks a little funky hard to tell from your pic, is there a bevel around the hole concentric to the hole? Area where your arrow is looks a little odd.
If you want to see how far off it is heat the area around the plug pop it out and assemble, that way you can see through the hole where it’s getting hung up, then go from there.

Yep - there is a bevel around the hole, and the bevel appears to be centered (concentric) with the hole itself. I might look into removing the plug so I can get a better idea of where that shaft is hitting as you said.

[theiceman]

if i remember correctly that post is removable and epoxied in. I seem to remember rotating mine so it would wear on the other side. But i might have misremembered that lol... If so take out post and repoxy it a .5mm over a bit

[theiceman]

if i remember correctly that post is removable and epoxied in. I seem to remember rotating mine so it would wear on the other side. But i might have misremembered that lol... If so take out post and repoxy it a .5mm over a bit

i find sometimes there might be just enough play with these kinds of things

[PeteKz]

Off the top of my head: Make sure you have the tensioner all the way in, and that the sprocket is all the way in, and that the chain is centered on the sprocket. Did you leave the installation clip in the tensioner?

[dpetterson]

Originally Posted by PeteKz

Off the top of my head: Make sure you have the tensioner all the way in, and that the sprocket is all the way in, and that the chain is centered on the sprocket. Did you leave the installation clip in the tensioner?

Hi Pete - yep all that was checked (and I had pulled the installation clip earlier as well). I finally got it on. I had to tilt the cam cover a bit towards the top figuring it would give me just a bit more clearance on that hole. That was all I needed to do. Then just a few taps with the mallet and it was on. Guess the tolerance on that hole was just barely off a bit.

[proporsche]

Originally Posted by PeteKz

Off the top of my head: Make sure you have the tensioner all the way in, and that the sprocket is all the way in, and that the chain is centered on the sprocket. Did you leave the installation clip in the tensioner?

the pin is out as you can see the tensioner is open;-)
Ivan

[proporsche]

Originally Posted by dpetterson

Hi Pete - yep all that was checked (and I had pulled the installation clip earlier as well). I finally got it on. I had to tilt the cam cover a bit towards the top figuring it would give me just a bit more clearance on that hole. That was all I needed to do. Then just a few taps with the mallet and it was on. Guess the tolerance on that hole was just barely off a bit.

good;-)

[dpetterson]

Finally got the cover on - had to tilt it a bit towards the top and then give it a couple of light taps with the mallet. That tilt helped the shaft get the clearance it needed to get in the hole.

Thanks for everyone's input. Tapping and angling the cam cover (as needed) seems to do the trick.

[theiceman]

great to hear...