First off--I have to admit--although I've done a zillion B21/23/230 timing belts (maybe a slight exaggeration) I've only done one (my 2002 S40) of the newer motors. It would seem to me, being that you feel you have to "stretch" the belt from the crank to the intake cam, you are leaving that part for last. The belt tensioner, being on the exhaust cam side, should be the last area. Question - have you relaxed the tensioner completely? I think you need to start the belt on the crank, run it over the intake cam, the exhaust cam and then slip it over the front (of the car) gears with the tensioner relaxed. It took me a few tries and rereading directions over and over before figuring out how the tensioner works. Another question - given the nature of the TB job and the minimal cost of a new belt - why on earth would you reinstall the old belt? -- Dave