Hello everyone,after a number of years,I'm back on the 954 project.when I bought this engine,it was obvious that at some point it fell on its left side,cracked cover and broken bolt hole.at the time I got it the cover lacks touching the case about 3/16 ths of an inch,give or take a 1/16 th.I have removed and reinstalled the rotor numerous times and even bought an aftermarket alternator cover.I've checked the rotor and crankshaft runout,both are well within spec.the engine rotates effortlessly which leads me to believe there is no crank damage.the only uncertianty is the whether or not I have the correct rotor.looking at pics,I think I do.any ideas regarding this problem are appreciated.thanks

 

Hard to say without knowing what you got. Could be the aftermarket cover or something as simple as the wiring bracket not on correctly.

 

Fixed

 

And what was the solution?

 

demon,somehow,someway the engine had the wrong rotor on it.i bought a known 954 rotor off ebay and it worked great.