164 V6 Lower Cam Belt Cover / Idler Pulley Interference

["Richard Lasner" <rlasner@domain.elided>]

My 92 164S hasn't had one of its lower cam belt covers since I bought
it. After replacing the timing belt, water pump, tensioner and idler
pulley assembly, I decide to get the cover and bolt it in place. I found
that the head of the bolt that holds the cover in place is tall enough
to rub the back of the idler pulley and effectively stop it from moving.
After removing the cover and bolt, I had my mechanic look at it: He had
never run into this before. To get the cover and idler pulley to work
together, the mechanic installed a threaded stud with a nut in place of
the OEM bolt. He then used a cut-off wheel to grind the nut down enough
to provide safe clearance for the idler pulley. Has anyone else had to
deal with this problem? I'm assuming that the PO didn't have the cover
in place because of this problem. The fix works fine, but I'm sure the
parts were originally designed to work together without any shop floor
engineering.

Rich Lasner
92 164S
ARA
AROC
Mill Valley CA

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