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The pin that the belt tensionor pivots on fell out of the block at some point during re-assembly. So the car stayed in time because the belt is toothed but the lack of tension allowed it to slap against the cover.
I had to take the timing covers back off and I actually found the pin in a strange place on the block. I'm pretty happy about that since it saved me a trip to the dealer trying to find one, three days waiting for it to come in and another trip to pick it up. I actually posted a thread here about what it was called and where to get it.
So I put some red Loctite on the pin and re-installed it. I put everything back together and now it's good to go.
I guess the upside is the first time I did this belt I had probably ten hours into it. This time I had it apart and back together minus pulling the motor mount and the water pump change in about five hours. So I've got better at it, it would probably be a four to five hour job taking my time to do it again. This was the first timing belt I've ever done. Now I have to do my Subaru sometime soon. Theirs a lot more to get right on that motor then my sisters Toyota.
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