Dust cover? You can pull the top half of the front cover off, that is where the timing marks are. You did that when you changed the tensioner pulley, right? Based on the questions you have, I would get a repair manual. It is possible to do severe damage if you don't know the proper procedures.
I can't remember if these are interference engines or not. You might be right. Hopefully the knock sound our friend had was nothing more than the tensioner slapping around. If I understand correctly, it sounds like he did not tighten the bolt that locks the tensioner down. Others have taken stabs at it, I could be just as wrong. The descriptions are a little ambiguos.
Is it possible the belt is not tensioned correctly? There is a proper way to do that. If you turn the crank by hand , does the belt get loose depending on what direction you turn the crank?
You can move the crank manually by putting a socket on the crank pulley, or putting it in gear and push/pull the car a bit.
Take off the valve cover and take a look. Maybe having the belt slap around due to the tensioner not being tightened has done some other damage?
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