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Well the good thing was I discovered all of this before I finished my headgasket job; the bad, my belts had been doing that for about 10k miles before hand. I replaced the rollers and the belts, so no worries about them having issues. The old belt was definitely worn where it had been rubbing, and belt dust was everywhere. Its a good thing I replaced it or else there probably would've been premature belt failure. As for the rollers, they could've been original. There were places on them where you could see the ball bearings in them. They definintely needed replacing.
So after switching the two tensioners, the belt now lines up well, and there is no rubbing! Whoo-hoo. So instead of 4-5 hours, it was only a couple extra hours of switching the two rollers, and re-tensioning. I've had the car running several times since then. No noise, no slipping, and no rubbing!
Cking, you're right on the money though. Something was off, and I'm like you, I'd rather have it right, than do it wrong and pay a pretty penny later to fix a simple mistake.
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