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Re: Too much timing belt travel...
The pulley can be freely rotated both counterclockwise and clockwise, no apparent issue there. When I grab the sides of the pulley and move it back and forth (towards the engine and then away) there is a bit of play in that it moves slightly. I am uncertain as to whether that is normal. Have you viewed the video, do the camsprockets seem to be rotating fluidly to you?
I inspected the new and old tensioner's prior to assembly and they looked identical. The old had a washer to place on the back of the pulley as did the new one. Both new and old bolts were exact. I even thought that may have been allowing the slack, nope. I reattached the pulley with the old bolt and still had play.
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