Pretty sure I am routing it correctly, I have 2 Focuses (Foci) so I am able to look at how its been routed on my other ZTS, and I have a printed out diagram that NAPA said was correct. NAPA confirmed last night that the belt is the correct size (I took it to them with the old belt). I think maybe the old tensioner might not be swinging open all the way? I have tried slipping it on on all the pulleys and it doesn't even come close to slipping on.
I am heading out right now to pick up a new tensioner.
edit* both my cars have the same 2.0 Zetec DOHC w/AC motors in them, the ZX3 is an auto trans and the ZTS is a 5 speed manual.