thanks duke!!!
i was looking for this thread last night when i was wondering what was happening, and you summed it up pretty good. in this sentence.

"Job number 13-3452 describes a tensioner functional test. It impllies that in the unloaded state, imaginary lines from the two flats on the back side of the inner bushing should pass equidistant on each side of the pulley axis."

so i jump up from the computer and run down to the garage to look at the tensioner.. i pull the adjusting rod bracket off and eyeball the flats, and the axis they form with the pulley. they are nowhere near parallel since i didn't have a compass in the garage, but i do have 20 yrs experience as an engineer i estimated the deflection as about 30 degrees. i took a picture.

well next i come back up and read the next section of you post...

"Then, using the pulley as a hand hold, rotate the housing about 30 degrees off line in each direction, which should take a good deal of force. (This is the approximate angle the pointer moves through during tensioning, which indicates the relative angular displacement between the inner aluminum bushing and housing). If the pulley does not return to its original position after being displaced this angular amount in each direction, it is not serviceable. DO NOT USE IT!"

Well that settles it the thing is crap, crap , crap truly shot and this is difinitive confirmation, albiet of a technical sort of nature.

so now all i need to do is get the partzzz and put it back together, of course this little job has created the need for a condensor as i twisted the copper fitting off while loosening the fitting by the bumper.. oh well live and learn.

i'm glad i found this place cuz i haven't found a good mechanic in central or southern ohio that is less expensive than the dealership.