I can see why you replaced the tensioner. This is the most common cause of this problem and you might not believe how many questions I have been getting about this problem! This is a long shot but, it's worth a try. Spray some silicone lubricant into the body of the tensioner. there is usually a spot in the back of the body. This problem can even happen to new tensioners if they have been sitting on the shelf for a long time. If that's not it, then it's possible to replace the power steering pulley with a special puller that is available at most part stores. you might have to take the pump off to do this, depending on the location of the pump. Before you do that, look at the condition of the other pulleys if there are any more. Look at the belt, even if you replaced it. I hope this is helpful and it keeps your husband from going crazy. I feel his pain.
There is one more thing that I forgot to add. This procedure can help you determine what the cause is. Take that same can of silicone lube and spray a small amount into the direction of belt travel (clockwise when looking at the front of the motor) with the engine running. Always wear safety glasses when performing this procedure. If the noise goes away, then it's not the belt tensioner. Look for something wrong with the belt or one of the pulleys. If it doesn't. then it could still be the tensioner or possibly the AC pump pulley and clutch assembly. Good luck!
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Misaligned belt.
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