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968 Timing Belt Tensioner

Hi,
halfway through a timing belt change on my 968. I am concerned about my hydraulic tensioner - I have it off the engine, and it's not apparent how it should work. The 'plunger' is out about half an inch from the body of the tensioner, but it will neither compress back into the body, nor come out any further - like its seized in place. The little cheese head turns round but thats about it. Is it knackered? How to set it up to tension when I replace it if not? Thanks for any clues!
DK

Old 05-16-2007, 07:22 PM
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DK-my guess is that is is siezed and needs rebuilt/replaced. You might post your question on the tech board at 968forums.com
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Old 05-17-2007, 10:42 AM
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The 968 tensioner is a different beast than most tensioners. You are suppose to very very very slowly push tensioner in with a C- Clamp, them pin it thru the hole in the sides of the body and plunger, this is necessary for reinstallation. Itís impossible to push the plunger in by hand.
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Old 05-17-2007, 10:54 AM
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Thanks jg,
thats encouraging to hear as I just tried to push it back with hand pressure and it felt solid. Do you know how far out it will travel when fully extended? My belts were definitely overdue, esp the balance belt, and its position didn't change after I removed the tensioner. I am wondering if it was already at full tension? It was out about half an inch or so..
cheers
DK
Old 05-17-2007, 11:33 AM
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If there is no pressure on the piston, you ahould have already seen full travel.
According to the maintenance manual, you also can't apply pressure to the raised part on the back of the tensioner. I went to the local hardware store and bought a couple of washers of the correct size, compressed it VERY slowly with a C Clamp and pinned it with a nail.

Micah
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Old 05-17-2007, 11:47 AM
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1/2" sounds about right. I've never seen a failed tensioner yet. I replaced mine lately due to time / mileage. Pelican has a picture of one pinned. I've never attached a picture. So if the picture of the tensioner fully extended doesn't show up email me at jgporsche@yahoo.com.
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1994 968 "Totaled during practice for GBRS / PCA 2009 Race season"
1989 944 Track car replacement. Complete with 968 running gear.
1988 911 Carrera "Friday / Weekend Driver"
1988 944 Daily Driver now.
1973 911S "In storage"
Old 05-17-2007, 12:13 PM
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got it - good picture, thanks. Yep thats about how far mine was out - not actually doing much tensioning. My tensioner lever (the bit the tensioner pushes on) has a small light coloured pad attached to it where the tensioner pushes - don't see that on yours?
DK
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Old 05-17-2007, 01:52 PM
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Mine has the pad also. This picture came from one of the 968 forums I glance at occasionally. There are a few 968 only forums that really have a lot of info. I bent a few valves last year and the INTERNET was more useful than the factory manual. If you pull the camshafts, mark everything to make sure you get it back where it belongs.

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1994 968 "Totaled during practice for GBRS / PCA 2009 Race season"
1989 944 Track car replacement. Complete with 968 running gear.
1988 911 Carrera "Friday / Weekend Driver"
1988 944 Daily Driver now.
1973 911S "In storage"
Old 05-17-2007, 02:41 PM
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