We're right in the middle of installing the new belt but can't quite get the belt over the tensioner. I don't think we're off any teeth. Does anyone have any ideas or tricks?

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2005 CRD Sport
Samco hoses, GDE Ecotune, Fumoto drain valve
Winter mods: air box snorkel removed, front grill covered, viscous fan and clutch removed

You can actually get a lot of room by turning the tensioner the other direction (loosen - left/CCW I think).

Make certain the slack is gone everywhere else...

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2005 Liberty CRD
2004.5 Cummins 5.9L TD, F1s, NV5600 6-speed in a '93 GMC Suburban

When geordi and I worked with lgoodbar on his tbelt replacement we found it best to place the belt on all the locations with "lips" then use the tensioner to provide the maximum amount of slack in the belt and slid the belt onto the last idler pulley as those pulley's don't have a lip. In the case of the tbelt that last idler was the left front IIRC. If there is not quite enough slack to slid the belt over that idler pulley you can remove it, relax belt tension, carefully install the idler pulley being careful not to cross thread its bolt and use the bolt to "pull" the pulley behind the timing belt.

Be extremely cautious about losening the tensioner bolt and DO NOT do so if there is any belt tension on the tensioner. On geordi's engine and lgoodbar's that bolt was screwed into a helicoil which is easily dislodged. We don't know if that's stock factory but lgoodbar's engine was box stock new in his vehicle and twice with a helicoil makes us wonder....

When the belt was finally on the belt teeth meshed on the various gears just fine but was 1/2 a tooth off on the bottom (crankshaft) gear (e.g. would not quite seat into the gears) so we put a wrench on that gear, got the belt onto the tensioner with tension relaxed and rocked the bottom gear just a hair until the belt teeth popped into place at which point all was tight except the portion of the belt from the bottom gear to the tensioner which was slightly loose as appropriate

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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

Is the water pump timed? We're off one tooth on the wp pulley and the belt is on. Do we need to adjust this?

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2005 CRD Sport
Samco hoses, GDE Ecotune, Fumoto drain valve
Winter mods: air box snorkel removed, front grill covered, viscous fan and clutch removed

No, water pump is not timed.

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http://www.Colorado4Wheel.com
"Its not about what you can DO with your Jeep, its about where you can GO with your Jeep."
Knowledgeable - But Caustic

Thank you, all, for your help. We completed the timing belt job successfully and it feels really good to have that done. Overall things are coming together. I put some new samco hoses in at the same time, black was out of stock so I went with the bright green, and they actually look pretty cool under the hood. The little diesel seems to sound "tighter" and quieter now than before and seems to be running very nicely. Now it's time to start saving towards an eventual GDE tune and TC upgrade.

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2005 CRD Sport
Samco hoses, GDE Ecotune, Fumoto drain valve
Winter mods: air box snorkel removed, front grill covered, viscous fan and clutch removed