| the primary reason is due to stress. It's a common problem whether the tensioner was adjusted incorrectly at a service or whether the stress was caused over time (probably due to poor tensioner function over time). Idler studs break in many makes of cars and cars that have never had any work done. But as you said, incorrect adjustment of the tensioner at service will speed up the problem. I think the space between the (Z) tensioner arm and tensioner body should be somewhere around 4mm but I could be wrong.
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