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Alright, I literally spent all evening trying to get the tensioner set at 4 mm. I've taken the belt off a couple times just to start over, set and reset it at least 20 times altogether. I cannot get it to set at 4mm, it seems to always rest at slightly less than 3. Here is what I have tried:
1) FSM procedure (set arm to 4mm 1st. Put tensioner in place, attach bolts, tighten nut, left bolt, right bolt. Loosen the 10mm holding the arm back.)
2) TTZD method - pretty much the same as the FSM
3) Loosen both bolts and the nut, remove arm retaining bolt altogether - this puts the tensioner at about 6mm. As soon as I tighten the front bolt, regardless of whether or not I do it first, the gap narrows to about 4 mm. I then tighten the other bolt and the nut, crank the engine by hand 2-3x and the gap moves to 3mm or slightly less.
4) Various tightening methods of the bolts and nut. Nut first, then left bolt, right bolt. Left bolt, right bolt, nut, etc.
5) Apply pressure from the drivers side towards the passenger side while tightening.
6) Apply pressure from the passenger side (sort of upward) Nothing seems to work. The only thing I can think of is that it takes a fair amount of pressure to even thread the left bolt into the hole. Perhaps the slot isn't quite large enough, not allowing the tensioner to set properly? Any help is greatly appreciated.
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