I need to replace my belt tensioner. I bought a Goodyear tensioner and installed it. On this new tensioner the bolt for the pulley is covered by a silver cover which sticks out past the edge of the pulley. I could not for the life of me not get the belt back on past the pulley and timing cover. It's too tight.

I went to Napa and bought a Gates but low and behold it is the same part. Has anyone else ran into this ?? I shouldn't have to take the tensioner assembly off to change the belt ?? Ideas

 

It's been awhile since I've changed my tensioner and belt, but if I am picturing what you're describing, then I turned the belt sideways and slipped / worked the belt past that nut.