Serpentine Belt broke while driving - new belt won't install!

[Shanestrait]

2002 S60 5 cyl 2.4

My serpentine belt AND my tensioner pulley broke while driving. I replaced the whole tensioner assembly with a brand new one. Went to install the new belt, and it would not fit, after 10+ attempts. With a friend assisting. Went back to parts store, replaced the purchased belt with a different one after verifying part number.

The belt was closer to being installed, but still didn't fit, and was stuck HALFWAY on. It broke off a small part of the edge of the power steering pulley it was so tight!

Any ideas on what to do with this belt install? And I'm assuming the power steering pulley is shot?

[SuperHerman]

You need to back track and check that nothing else was bent. Any pulley or related that takes the Serp Belt may have bent.

How does the rotation look of everything spinning on the Serp Belt path when the car is running? What noises are you hearing if any.

[Shanestrait]

Thanks for the quick response!

When I start the car (no serp belt on) everything sounds normal. No abnormal noises. Pulleys all appear serviceable.

[RickHaleParker]

Did you make sure the belt was in the grooves of each pulley?
What brand of tensioner did you get?

[Shanestrait]

Yes to belts in groove.

First belt was Duralast, wasn't close to fitting.
Second belt was Continental. Close, but not enough.

[RickHaleParker]

And the tensioner. If they gave you the wrong belt to start with, it stands to reason they may of given you the wrong tensioner also.

[Shanestrait]

Tensioner appears to be exactly same as originally installed part.

Link to part - https://www.autozone.com/external-engin ... y/764611_0

[RickHaleParker]

It may look the same but that does not mean it has the same range of travel. It is not a OEM part.

[Shanestrait]

True.

I'll take it off tomorrow morning and compare to the original, and will post an update. Thanks

[SuperHerman]

You need the Serp Belt on to see which if any of the pulleys are out of wack. You have the following on that circuit: Crank (check the harmonic balancer), tensioner (which you replaced), A/C, Power steering, and Alternator.

The harmonic balancer you can see if it is true with out the serp belt on - it should not wobble with the engine running. The A/C, Alternator, and power steering pump pulley all can be turned by hand to see if they wobble or if they are crooked. You are looking for something bent that increases the distance.

The funny thing here is that any bent part should have been pulled in when the serp belt failed. Even so as they rotate the distance should become shorter - so putting the belt on should be easier.

This leads to four possible scenarios: 1) You have the wrong belt, 2) you have the wrong tensioner, 3) you have the tensioner installed incorrectly; and/or 4) you are not installing the Serp belt correctly.

I know when I have done them it was not easy - if I recall the power steering bottle gets in the way. Once you get the extra movement on the tensioner the belt slides on very easy. Maybe try turning the tensioner without the belt on so you get a feel for the limit - then position your wrench accordingly - if I recall the starting point is further towards the back of the car than one would think. Keep the belt properly seated on as many pulleys as you can - having a helper hold the tension will help - depending on your tool - adding a cheater bar will help. Just be careful with your hands in there. It should slide right on.

As to the power steering belt pulley - I would replace it. You may be able to use it, but it may either wobble or ruin the belt. It depends how the break is.