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I would replace only the pulley unless the tensioner was no longer providing tension. I have not messed around with this tensioner, though I have installed the UD pulley and removed and reinstalled belts then and when I did rod bearings. On some tensioners there is a spacer behind the pulley. If there is one and it went missing, it could cause issues like you have. Check realoem for the parts diagram to see if there is one. Whenever I have problems after doing work on a car, I suspect my work first.
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