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[joe kumpel]

OK, Here's the question...
Timing chain tensioner popped a small hole in cover.
Took me a while to identify oil spray, but hole was
covered successfully with aluminum patch and epoxy.
Driven most of the summer this way with no apparent
other problems. Do I have to remove radiator to replace
or repair the cover.... Is it worth the effort as long
as the patch holds? All opinions welcomed.

[charley fitch]

I would remove the cover as soon as possible including before you try to start the car again. If the tensioner has worn a hole in  the cover that means that it is not in the correct position and has been grinding away metal pieces that are getting into your engine oil.  This will ruin an engine !!!!!

You will need to remove the fan and nose piece of the engine to get behind the timing chain cover.  This may be possible, though difficult, without removing the radiator.

Seriously I bought a parts car many years ago that was partly disassembled,  as it was not running correctly and somebody was trying to find out what was wrong with it.  After I removed the timing chain cover I found the tensioner was in pieces.  There were metal pieces in the timing chain cover as well as some in the oil pan. I would consider that engine a goner as far as all the bearings and likely much more.  Hopefully yours won't be that bad.  But don't push it any further than you have already.

Charley Fitch

[joe kumpel]

Thank you Charlie. I'm convinced that I should
let a pro tackle this one.
Your response very much appreciated.
Joe

[joe kumpel]

Thanks Charlie for the good advice. Bottom line is timing chain, etc.
has been replaced and she's running fine. Bring on Spring.