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interestingly, i've just changed a cambelt on one of these. i decided to use a contitech kit as opposed to the oe VaG parts and found the supplied belt and rollers to be identical in manufacture to the originals on the engine (eg. tensioner made by Litens).
i had no problems whatever in doing the job but two factors relating to your problem came to light. The contitech kit includes the tensioner (and roller) studs, wheras the VaG kit does not. Presumably contitech regard this stud as a weakness - it's M10 in the engine, necked down to M8 for the retaining nut. There is no washer.
The other factor is torque. The specified torque for the tensioner wheel nut on a PD engine is 20Nm + 45deg. on reassembly, i tightened the nut to the specified torque, feeling that a reasonable tightness for the M8 stud had been almost reached. To finish the job, rather than using my angle tightener, i used a long ring spanner and a 45 deg "protractor" made by folding a rectangle of paper so that i could feel what was happening.
i decided that it would be most unwise to tighten this nut to the full 45 deg and stopped at about half the angle. There it sits - without problems and i have checked it a couple of times since.
i just wonder if the specified 20Nm + 45 deg was for the earlier tensioner which used an M10 stud of constant diameter. The tightening data is actually moulded onto the cam cover - it seems almost inconceivable that VaG would get it wrong - until you remember the debacle over special oil for the PD engine... any other feedback welcome.
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