Manual Tensioner

Manual Tensioner

The first time I built this for my car I didn't take pictures since I wasn't sure if it would work well. Right after it went on I knew it was going to be much more reliable then the Mitsu automatic version! It's perfect for people who can't keep their hands off their cars and don't mind taking the top timing cover off once in a while to make sure the tension is fine. It's far more adjustable then the automatic tensioner, more reliable and way cheaper then replacing it every timing belt change (never needs replacing)

I wouldn't recommend this to anyone who has someone else change their timing belt then thinks they can ignore it for 3 years.

Click any photo for larger detailed version

	This is the tensioner as an automatic unit. It is filled with oil that is under pressure once the top pin is compressed. It is impossible to rebuild these without the factory tool that applies a block plug type seal to the side of the tensioner.
	First thing is to remove the set screw and let the oil drain out.
	Drill the hole in the bottom larger to accept a 10X1.25 tap. (17/64??) You will just clear the spring that is in the side of the tensioner The bottom of the top pin that is 40mm from the bottom of the tensioner assembly.
	Tap the hole you just drilled with a 10X1.25 metric tap. If you can't find a 40mm bolt with the threads tapped right to the bolt head you will have to use a die to extend the threads.
	Here is the assembly together. If you use a 50mm bolt you can put a nut on the bottom of the bolt to reverse it into the tensioner so the bolt doesn't wiggle loose. I prefer using the heavy loctite myself.
	Here's the tesioner on one of my dead engines. You can see that the bolt clears all pulleys with lots of room for adjustment. It is well out of the way of the timing belt as well.

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This page was last edited March 08, 2001 03:33 PM