Problem refitting lower timing belt cover

[ducatirider]

Just replaced cam belt (2.0l 1993 206cc SE) and got to the "replace lower timing belt cover" bit, however it has 5 bolts holding it on, two have location sleeves over holes, when the cover is placed over these the other 3 bolt holes are offset clockwise by about a bolt width. there does not seem to be any way of distorting the cover (other than the size 10 Frog boot at factory) and no sequence of putting in bolts that works.

Having wasted the best part of a day am I missing some obscure clip fitting or manipulation to allow clockwise rotation of the cover, I cannot see anything to do?
My options are, 1.. put some studs in bolt holes to locate cover, 2.. file out bolt holes to fit holes.

Any suggestions gratefully received.

[gazza82]

I don't remember forcing it into place so just double check as they crack very easily.

When I did ours last year, the lower one went on easier than the top .. that one has the hidden screws and they are a nightmare to get to given the lack of space between the engine compartment and the covers. Which is probably why ours had most on them already undone (or missing) when I got to it!

Not a job I relish revisiting!

[GrandadMonkey]

This might sound trite but it is not. Have you got it the right way up? If you have, then the holes should line up without forcing.

[ducatirider]

Thanks for the replies, finally got it on, left out one bolt (cludge!) in the end. I think there must have been a bad batch go through, no doubt possible to get it on with the engine out but just a very bad fit. Agree with the top cover remarks, ours had one screw missing as well, which was strange since I could not find any record of timing belt change in service record or bills. Just got the two lower screws in the upper cover to do up tomorrow. I have come to the conclusion that ritual suicide may be preferable to ever doing this again, I may never play piano again with the damage to hands!
Thanks all for comments and help.

[GrandadMonkey]

Well done, now count your fingers and make sure they're all there!

[gazza82]

Thanks for the replies, finally got it on, left out one bolt (cludge!) in the end. I think there must have been a bad batch go through, no doubt possible to get it on with the engine out but just a very bad fit. Agree with the top cover remarks, ours had one screw missing as well, which was strange since I could not find any record of timing belt change in service record or bills. Just got the two lower screws in the upper cover to do up tomorrow. I have come to the conclusion that ritual suicide may be preferable to ever doing this again, I may never play piano again with the damage to hands!
Thanks all for comments and help.

I bet the screw that's missing was where the previous guy gave up ... or ... the last time it was changed that's all they did to make it LOOK like it was replaced ...

Oh and my hands did heal ... but avoid citrus fruit for a few days