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Have you tried the new routing as Tina indicated (Volvospeed link)? I know that Klaus seemed sarcastic to you but really, he has helped many many people here. I imagine you're at a point of pure frustration and it rubbed you the wrong way. The tensioner is tricky, and I believe there are two types. If you did the new routing, you may want to check the tensioner once again. If it doesn't flex like it's suppose to, this could be your issue and a new tensioner is in order. Just a thought.
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1998 S70 T5 Emarald Green Metallic, 2004 V70 2.5T Ruby Red, Previous Owner of Black '94 850 Turbo Wagon
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