i stripped 2 thread in all, doh. Yes that pump tensioner is wierd, took me a few minutes to line it all up. Thing that took me the longest though was working out how the serpentine belt was routed as the one i took off had come off and snapped. But after that it was as sound as a pound.
I also had trouble with the plastic cover, i heard a ticking noise and though the timing must be out (which i knew deep down it wasnt as i had checked it before everything else went back) anyway the cover had been banging against the crank pulley, i need a new one also but repaired it for now, seems a spacer is missing from it. i had trouble with the waterpump top bolt too, but i wasn't in a good mood at the time so i got the screwdriver out and broke a piece off the casing big enough to get a socket in there, lol.
Glad you got it all done. other thing i noticed, i had a lot of black oil crap on the drivers side of the engine, seems one of the injector return pipes was leaking so i gotta fix that also, think i used a whole can of gunk cleaning the engine off, looks all shiney now though (not that you can see it!!)