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Coastr,
I hate to be the bearer of bad tidings, but looking at your photo I think I see a slight problem. After a fresh rebuild, the upper aluminum sealing plug should be protruding above the steel cap. The upper chamber thus created between the piston and the sealing plug becomes an oil reservoir. As the tensioner slowly loses oil, it can then be replenished from that reservoir up until the point the sealing plug bottoms out against the housing. From then on, the loss of oil starts to soften the tensioner. Even with renewed seals, there will still be some slight loss of oil past the seals. So your fresh rebuild will not last as long since there is no reservoir of oil above the piston.
Creating this reservoir makes it trickier to install the sealing plug. You get the piston all filled with oil and bled, then top up the housing with oil to the point that you can just install the sealing plug, spring, cap, and circlip. Too much oil and the circlip won't fit. Too little and you don't have as much reserve oil capacity. When full, the spring above the sealing plug gets about 100% compressed, so you have to press pretty firmly to get the circlip in. If it is too full, the bleed screw on the side can be opened, but just the tiniest amount. You are working with a very small volume of oil in that reservoir to start with, under a fair amount of pressure from the spring, and it will come out that bleed port pretty darned quick. You may have to fill and bleed it a couple times to "get the feel" for doing it.
DG
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