when i did mine. I thought it was all lined up but when the tensioner took the slack up, the pasenger side cams went out. took me about 3 goes b4 i finaly got it right. it just takes a lil patience.
as for your tensioner problems, I never had that. sounds like the shaft may have got damaged n is preventing it from taking up the slack in the belt. when u take it out n let it come out, can u prevent the tensioner from extending with your hand? cuz if you can, its 2 wee, which would explain why its not taking up the slack when installed and you need to replace it.
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