The belt should be easy to get to 45 and about as much as you can do to get it to 90 with a finger and thumb. It would be much better to have it too loose.
timing belt NEEDS to be changed(you know this). there are a total of 3 seals that are good to do, the crank seal, the cam seal, and the intermediate seal. intermediate shaft also needs to be checked for end-play, when you pull seal cover off you can see flange on im shaft that controls endplay and some belt movement (side to side).
I set torque values at 150ftlbs for crank, 45ftlbs for cam, 40ftlbs for injection pump, and about 45ftlbs for im shaft.
by the way I found timing belt that twists to 45degrees is way to tight, you want closer to 75-85 degrees. see vince waldon site for correct way to time, as adjusting belt tension can change timing some if done incorrectly.
you could also consider doing inj pump seal too.
you need a new tensioner. replace water pump when doing a new timing belt.
I don't run motor with out having timing cover(s) secure, maybe consider new covers (upper and lower, can help). belt should ride on about center of pulleys or you got problems.
by the way nice helper!
you also need a special o-ring for im shaft cover, and a crank flange gasket. I use some rtv on outer edge of seals. some grease on lips of seals, and the crank flange gasket needs to be re-tightened after 12 or so hours (its paper/cardboard and it compresses after a few hours), don't over tighten(I like to get new nuts/bolts/washers can be 6mmx1mmxlength, or 8mmx1.25mmxlength. all need to be 8.8 grade).
a timing belt adjustment tool and a water pump tool are needed too
Thanks for all the help gents!!
Car is running, ip bushings were causing the timing belt wear. The timing belt is running straight.
Also put on the na ip, advanced the timing ( engine sounds a bit sharp, like a old school diesel) turned up the fuel screw ( I get some black smoke by revving the engine up) but it seems to work well.
Actually the old pump must have been screwed, as jetta now runs like scared rabbit,
, when compared to before. I'm into the pedal far less to get the car up to speed.
So road trip here we go!