The upper timing belt cover on my 1990 765T has worn/burned through because the camshaft pulley is rubbing against it. I recently replaced the headgasket and the timing belt and then buttoned it all back up. The engine is running fine, but I noticed the TB and camshaft are contacting the plastic cover and burning through it. Is it common for the camshaft pulley to not seat properly, causing it to contact the cover, or did I somehow force the TB cover too far back toward the engine. This ever happen to anyone else out there? thanks for any insights.
chris in vermont, 244, 765, 945

I believe the camshaft pulley and the intermediate shaft pulley are the same. Sometimes one of these pulleys has a little spacer washer behind it to square up the belt on the pulley and provide alignment. If you removed both pulleys while changing your timing belt, and accidentally moved a spacer washer from the intermediate shaft to the camshaft, -that could be the source of your problem.

Otherwise, it's not uncommon for the plastic timing covers to warp a bit from excessive heat, -especially on the turbo vehcies. My 245 has a warped plastic backing plate and the next timing belt change I preform will include replacing the backing plate with a better one from a salvage yard vehicle. See what you can do to move the timing cover forwards. You may find it possible to shim some material between the aluminum head and the plastic backing plate of the timing cover. Be careful that you don't push it into the pulley from the opposite direction.

God bless,
Fitz Fitzgerald.
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'87 Blue 240 Wagon, 248k miles.
'88 Black 780, PRV-6, 145k miles.