Serpentine belt - am I crazy?

[Russianblue]

When i cranked the 2003 M54 for the first time after the head gasket change, i was greeted with a screeching noise of epic proportions. I thought it was coolant or something on the brand new serp belt and figured it would go away.

It DOES go away after the car warms up. But if it cools down for a minute, it's back. and it's entirely too loud for the neighborhood. Anyway, i took off the serp belt and cranked it this morning and ran the car for 20 seconds. No screech.

Conclusion, it's either the water pump, the alternator or the PS pump.

Strangely, all three pulleys spun like new. I was expecting to feel some shaft play at least. But this thread is not about that problem yet.

It's about this: I went to put the belt back on and it will NOT go on. Spent 2 hours trying different techniques. For most of the effort, I even went back to the OLD serp belt because it's stretched nearly an inch longer.

I have no idea what to think. I MUST be missing something simple.

Good question. Glad you asked. Here is how i have it routed. I would LOVE for this to be a routing issue.


Routing:


and HERE is my install technique.

https://youtu.be/V2DcOH068wE


the only way that loop is getting around that tensioner is if i PRY something in there and i don't even think THAT will work. I honestly think i need another full INCH or two of slack.

I have unbolted and reseated the idler pulley and checked to make sure everything is lined up properly.

I remember this being a little difficult to install initially. nothing like the videos online where they just slip it over the tensioner. i had the radiator out and had room to shove it onto the pulley with the heel of my hand. then i started thinking...is it possible that the tensioner being SO tight (at the end of it's range) contributed to the screeching noise? several problems going on here. feel free to address them as you will. What am I missing?