Cam tensioner interferance?
 

So im changing the idlers, cam belt and tensioner on my 1990 EJ20T.
But the tensioner that I took off is fowling on the crank case as you can see in the pics. The new one (which is exactly the same) seems to fowl as well and when I hold it (the new one)in position over the mount bolt holes it only seems to sit flush when pushed all the way to the right. As I slide it to the left as recommended, the lip where the pin hole is, hits the case almost immediately.
Can anyone advise they have seen this and whats the solution as if I leave it all the way over to the right I doubt the cam belt tensioner idler wont have the necessary tension on it.
I suspect I will need to grind the case slightly, has anyone done that ?
Cheers for any help,,
Mark

They can hit there if forced to the left before tightening and releasing the pin best way to avoid it is to make sure the bolts are finger tight enough that the tensioner can slide from right to left once belts in place and all the idlers are on push the tensioner across with a screwdriver don't use a pry bar or be heavy on it it should move with relative ease .
Tighten the bolts to hold it in the left position and use a torque wrench to specs otherwise you will pull the thread. . Then remove the pin holding the piston .The crushing of the tensioner usually happens when some one is heavy handed with a prybar trying to push the tensioner to the left because they pulled the pin out before realizing that it has to be moved across and tightened beforehand . ;)

Thanks Mate
Ill give that a shot

Torque specs are first 17 ft lbs then 20 ft lbs for those two bolts on the tensioner.

Thanks Amtrapid

I put the new tensioner on today and it could barely move 1mm left or right.
But it seemed to be all the way over to the right looking at the bolts relation to the slots. So i ground the housing a little, now it will move about 3 or 4mm to the left. That should work as it will move a similar amount as the old tensioner but without crushing the lip.

On another note my cam wheels seem to all sit still and line up freely with no tension on them. The book seems to imply the left cams will be on lobes and need to be held in place, is this normal.

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The drivers side of the engine cams hold still and move with little resistance . The passengers side generally move off the marks when the belt is removed as they are on the lobe of the cam in the marked position .Top intake cam should only be wound clockwise to reline up and bottom exhaust cam only wound anti clockwise to reline up as per the manual as this is an interference engine design.
I use a breaker bar and socket to hold the cam in place as I put the belt on then if the belt is kept taught while you run it over the top and bottom cam wheel as well they usually hold in place just with the belt and some slight tension from your hand on the belt as it is put on . Start the belt on the drivers side first then work across the top over the passengers side and down. The manual outlines this.
If there is no tension on the passengers side cam wheels that moves them off the timing marks sounds like something is wrong . Only the drivers side is off the lobes and stays exactly where you put it.
Do you have a manual it clearly has diagrams and fully explains it if you follow its hard to go wrong . Once the belt is on dont turn the engine till you count the teeth between timing marks as outlined in the manual to make sure you spot on and not a tooth out.

This should help.

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I am sure you know this,

But you're missing an idler on the drivers side.

[QUOTE=matto20v;791161]I am sure you know this,

But you're missing an idler on the drivers side.[/QUOTE]

Yep I havent finished the job yet, thanks.


Amtrapid, I do have the manual and yes I can see it says to rotate the cams.
Strangely they didnt move when I released the old belt. And they have all stayed in the exact same spot. I will check today if there is any tension on that side (passenger) cams. Seems not so far.
Ive had that engine in my car for about 16 years and it still runs great. Strange. I will count the teeth today as you suggest.
Cheers
Mark

How did you go mate all sorted ?