Hi Sean,
As Paul mentions and after watching your video something is either out of alignment or is allowing the belt to run a bit wonky. To ask the bloomin' obvious the belt, rollers and tensioner were all of the highest quality? Sorry to ask as I'm aware of your attention to detail. Obviously something is wonky and all I can think is that one of the components has failed. I wish you good luck.
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2010 D4 SE Executive 4.2 TDI
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