Hi gozz (& slavrenz),
Yes, I would certainly like to have that shop manual. Can you put that up somewhere for me to download? Otherwise, I can provide you with my public email address (I'll make it non-harvestable) and you can use the sendbigfiles.com way of doing it.
Problem solved. It was that new tensioner !
Recall that I had used the hex key to turn it closkwise to get the spring on (the standard procedure). I also said I had to use the hex key to turn it counter clockwise about 1/8" to keep the spring from falling off the pin.
When I disassembled everything again on Saturday, I saw that the tensioner was in the same exact position that I left it in. Additionally, it had some rubber from the belt embedded on it. Here's a pic looking down from the top:
http://cid-0ba9610cbd3ba347.skydrive.live.com/self.aspx/Protege%202002/tensioner^_with^_rubber^_from^_excessive^_tension.jpg
I put the hex key back in, and when I started to manually turn it another 1/8" counter clockwise, it "popped" by itself counter clockwise. Like it was stuck, and I unstuck it. Now I could see the spring coils were extended a little, as one would expect they should be. Here's a pic viewing from the top down from inside the engine compartment:
http://cid-0ba9610cbd3ba347.skydrive.live.com/self.aspx/Protege%202002/tensioner^_with^_spring^_coils^_extended.jpg
If you zoom your browser to about 200% you will see the the spring directly underneith the roller (remember that the pic is upside down), with it's little black rubber cap, and a couple of the brass colorerd cad plated spring coils slightly extended. Just to make sure it was tensioning the belt properly now, I grabbed onto that roller with my had an put as much passure as I could to manually move it clockwise into the belt. Needless to say, it didn't move much clockwise at this point, because it was already tensioned enough.
Just to make sure the problem was resolved, I carefully used a little solvent on a cloth to remove that caked on rubber off the roller, then put the crank pulley back on, then put the spark plugs and valve cover back on, and started it up: whining noise gone at all rpm ranges. Hopefully obvious CAUTION: do not run the engine at very long with the water pump belt removed or you will overheat the engine and get a steam bath.
I made a couple other observations during the second disassembly:
1) The old belt was .99" wide. The new belt was 1.02" wide. The new belt was rubbing just slightly on the crank pulley washer facing the belt. Here's a pic where you can see the black rubber marks from the rubbing:
http://cid-0ba9610cbd3ba347.skydrive.live.com/self.aspx/Protege%202002/crank^_pulley^_washer^_rubbed^_by^_belt.jpg
When I removed the bottom plastic cover, I noticed a very small fine line of belt dust on the cover form this rubbing. I can hazzard a guess that perhaps this is the source of the whining that you mentioned some people experience the first week with a new belt. In this pic, I've circled those dust particles in red:
http://cid-0ba9610cbd3ba347.skydrive.live.com/self.aspx/Protege%202002/bottom^_cover^_with^_some^_belt^_dust.jpg
2) I previously mentioned that the crank pulley washer rubbed on the new bottom plastic cover. Here's a pic showing where it wore itself in (not to worry about this wearing in):
http://cid-0ba9610cbd3ba347.skydrive.live.com/self.aspx/Protege%202002/bottom^_cover^_with^_crank^_washer^_wear^_area.jpg
Here's a pic showing how the bottom cover is not exactly designed correctly to allow the washer to be perfectly centered (yes, I have the cover's locator pins in the block correctly before putting the bolts in) :
http://cid-0ba9610cbd3ba347.skydrive.live.com/self.aspx/Protege%202002/crank^_pulley^_washer^_wear^_in^_off^_center.jpg
I have some more pics and observations, but I need to go for today. Thank you and everyone for the help again and for putting up with me this long.
Regards,
Brcobrem