[BlackZR1]

Just wanted to close out this post with a few tips to add to Dave Hetrick’s excellent tensioner rebuild instructions:
1. Create space to remove tensioner from engine by loosening the “L” coolant hoses from the coolant outlet pipes and pull the hoses back but not off the outlet pipes. This creates enough room to sneak the tensioner out from the top and doesn’t leak any coolant.
2. I used a Harbor Freight press (we all have one right?) and a large bearing separator to remove the cover by making a pressing tool out of a 12mm bolt with the head ground down to about 0.600” diameter. See pic below. Note I had to use a smaller diameter bolt on the right hand side of the separator to avoid interference with the tensioner arm.
Mission accomplished!
Attachment 5434