ouch.

I always replace everything but the spring, when I fix the tensioner assembly.

I have noticed that the washer is a pain to get aligned when reinstalling the tensioner, because the washer doesn't fit snug inside the pocket, moreso if it's all greasy.

new parts go together smoothly, and having everything clean makes a big difference.

I'd be worried about the timing case cover if the steel washer is that deformed. you mentioned the shop changed the cover...

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John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 560SL convertible
1987 190D 2.5-5SPEED!!!

1987 300TD
2005 Dodge Sprinter 2500 158"WB
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!

I was able to source a washer from a local craigslist seller (Used but still in good shape) I used the spare tensioner which I had with part number 601 202 06 28. (Which is most likely my original 350SDL tensioner)

I got everything back together and ran the car without the fan to make sure everything was fine and SUCCESS! No noise, no belt fraying and I was able to get the belt on no problem. I backed the tensioner out a little after the test and put a few drops of Loctike 271 thread locker onto the tread and called it a day! I had no problem with getting the washer back into it's socket (I held it with two fingers while my other hand was on the torque wrench.)

I'm throwing the older tensioner and washer into my scrap metal box. No way i'm going to subject anyone to that thing!

Many thanks to everyone! (The proper measurements were a huge help!)

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1982 300GD Carmine Red (DB3535) Cabriolet Parting Out
1990 300SEL Smoke Silver (Parting out)
1991 350SDL Blackberry Metallic (481)

"The thing is Bob, its not that I'm lazy...its that I just don't care."