verslagen1 wrote on 05/04/14 at 21:36:40:You should cut the roll pin flush with the housing, not sure how close the case is, but it's not far.
and you should deburr all the edges, those burrs can get caught in between the plunger and housing and cause it to stick.
if you feel the roll pin is loose, try and pull it out, if it comes out easy try another, they do vary in size. if all else fails, clean well and add some permanent locktite.
Loctite, that's a good idea! I did debur it on the inside. I see from my pictures that I neglected the burrs on the outside
The problem is I don't know what would be considered "easy" to pull a roll pin out. I have to put the end of the pin in a vice and I can twist and pull it out by rotating the tensioner and pulling on it. I tapped the pin in until it started pinching the spring, then backed it out a fuzz. Aside from some slight rub on the spring from the pin the plunger moves freely. I imagine it would be difficult but not impossible to pull the pin with a pair of pliers. I'm guessing it would probably hold but I don't know how roll pins do with vibrations in an engine. Maybe I can grind my tungsten really sharp and tack the roll pin in there
I'm half joking half serious, I'd be tempted to try it but I am quite the novice and would likely destroy a good tensioner. Think I'm being overly paranoid here?
Oh yeah, it's only sticking out about 1/8" I would think that should clear the inside of the cover but maybe not. I'll take another look at this... Thanks for pointing out stuff I hadn't thought of.