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"Another possibility is that they perhaps removed the tensioner and did not seat it properly upon reinstalling it. That would cause the belt to track incorrectly and rub on the plastic cover."
i agree.
or the noise could be as simple as the timing belt cover rubbing on the water pump pully. did that on my first timing belt change on a 240.
the timing belt DOES NOT have to "set" or "wear into place". no way. no how.
the belt could be going f.u.b.a.r as we speak. get something in writting from them, or keep the paper work in your car, since they did the job.
it is not hard to do a 240 timing belt as long as the individual has mechanical skills. read next sentence.
this is an excellent reason for having a bently or chilton manual (for your car) in the trunk. just incase an unfimilar has to work on it -they'll have a point of reference.
in your case, something is not quite right and needs to be adjusted. the front will need to be torn down again, inspected, and the issue addressed.
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