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!