Hi All

Forgive me for asking potentially a ridiculous question, but I am kind of at a loss. Due to a failed serpentine belt I just replaced all of the following:

-2 idlers, tensioner, belt (ordered idparts kit)
-alternator oad pulley (replaced with litens 920834 per discussion here: viewtopic.php?f=5&t=78875)

Now, what I immediately noticed was that I was able to just slip the new belt on without even holding down the tensioner. Obviously too loose to stay on. I triple checked the belt routing and confirmed the belt part# was correct (K061130). I understand this new alternator pulley is slightly smaller than the original one but it seems many have used it no problem. I did not expect it to be this loose with such a minor change. The only thing that caught my eye was that the original tensioner's pulley was angled up higher than the new one, but it was also toast (rubbing against power steering pulley and the pin in the side was missing) so probably not a fair comparison, but the old one would have kept the belt tighter. Im not sure if I should try finding a smaller belt or return the oad pulley or if I am completely overlooking something else.

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2006 CRD Stock with ORM and a clean MAP (always)

Obviously something is wrong. Possibilities
1. wrong belt - is Gates K061130 actually printed on the belt? It's not impossible the wrong belt got packaged in a K061130 sleeve. Is the belt 113 5/8" in length, I think that's the outside dimension.
2. are the new idlers the same diameter as the old
3. the Litens 920834 is only 2.5mm smaller in diameter than stock so that should not cause a problem.
4. is the serp belt tensioner properly mounted; see image 4 at viewtopic.php?f=98&t=74594 for proper "relaxed" position.
5. I know you triple checked but did you really route belt correctly or did you for example place it on the wrong side of the driver's side idler (between alternator and AC). See sticker of radiator cross member and/or page 7-32 of 06 FSM that you can download from http://colorado4wheel.com/manuals/Jeep/KJ/

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Sold to LOST member my 05 Ltd, GDE Stg II turbo + TCM tune, SunCoast TC w. Transgo kit, Steiger window regulators, Samcos, Fumoto valve, 2nd gen filter head with Lub. Spec. bleeder, Hayden clutch & 11 blade fan, inverted spare, P-1 battery, BF Goodrich Long Trail TAs, Etecno1 glow plugs, timing belt at 50K miles/8 yrs

OK I think i may know what the issue was but would like confirmation if possible. If you view the image of the tensioner here:
http://www.idparts.com/serpentine-belt- ... -2826.html
There is a locking pin on the right that is holding the tensioner in the "loosest" position. I have never installed a new tensioner before but my guess is that this pin eases the installation keeping the belt loose, and that after I have routed the belt, i should put a wrench on the tensioner clockwise, then remove this pin so it will tighten up corrent? My old tensioner I took out did not have the pin but it was also thrashed so I just want to make sure here that is it's purpose.

Also thanks for all of the many and frequent replies papaindigo.

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2006 CRD Stock with ORM and a clean MAP (always)

correct just go clockwise with your wrench ( NOT HARD ) pull that pin out and you are good to go .

And per the FSM don't let the tensioner slam back against the stop. If you lack a 3rd set of hands put the wrench/socket on the tensioner; rotate enough to pull the pin; slowly rotate the wrench/socket back to let the tensioner move back to the stop; now you can do the belt. Probably easiest to route the belt over the tensioner but not over one the upper easy to access pulleys, perhaps one without a "lip"; then use the wrench/socket to relax the tensioner while you route the belt over the final pulley; slowly relax the tensioner and all should be good to go.

Thanks rankom I was not aware of that pin having never installed a new serp belt tensioner.

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Sold to LOST member my 05 Ltd, GDE Stg II turbo + TCM tune, SunCoast TC w. Transgo kit, Steiger window regulators, Samcos, Fumoto valve, 2nd gen filter head with Lub. Spec. bleeder, Hayden clutch & 11 blade fan, inverted spare, P-1 battery, BF Goodrich Long Trail TAs, Etecno1 glow plugs, timing belt at 50K miles/8 yrs