I have a 2004 XC70 with ~112,000 miles. Took the serpentine belt off the other day because it was cracking, and couldn't get the new belt on. Then I tried putting the old belt back on just to see if I could and I couldn't. The two belts are as close to the same length as I can measure, and I think I'm using the correct routing (see diagram below), and as far as I can tell the belt is seated correctly in the pulleys when I try to slip it on. It's not all that close to going on, even with the tensioner fully de-tensioned.
When I took the old belt off, I removed it from the PS pulley first. I have tried slipping the new belt over the PS pulley last, and also slipping it over the tensioner last.
Any ideas? Can't figure out why I can't even get the old belt back on.
Belt routing I'm using:
