As things went along - i gained more knowledge and some factoids about these 1.9 TDI 1Z / AHU. Just to share in case it helps anyone.
The tensioner marks that i thought meant it was way over-tightened, actually were just the opposite. It was WAY too loose. During some pre-emptive testing - the Inj Pump jumped 3 cogs on the belt - when i was cheating by turning engine some with Inj Pump bolt.
I've used the cheat many times before - but never jumped the belt.
So thats when the pre-emptive tests stopped and i got more involved with the tensioner / belt specs. lol
To refresh - this is where the existing tensioner was set.
This is where the tensioner should set initially - with cam sprocket loose.
This is where it moves to, after cam bolt is torqued.
This where it settles to, after about 20 revolutions.
And this is the tension spec - after about 20 revolutions - with the idler/roller removed from belt path. Practically a perfect 13 units.
For reference - 1.6 spec is 12-13 units.
Luckily for this 116k pristine low miler , this condition was caught.
New Belt, Tensioner, and Roller for a fresh new start.
And an intermediate shaft seal too.
8V have you checked your tensioner setting yet ??