After going through three air conditioning compressors and being sick of seeing my mini van not running in the driveway for months at a time I put on a by pass pulley just so I could drive it around town.

All went well until I tried to put the belt back on. It does not seem to fit. The pulley is the same size but I can't seem to slipthe beltover the idler when the tension is released. I've changed quite a few of these belts over the years and have not run into this problem before. I'm baffled.

Anyone ever have this problem ? Anyone have a solution or explanation ? Thanks in advance.

 

Do you have a belt diagram?
I did the same thing whenI replaced a belt once.It would almost go on but not quite.

 

Yes I have a diagram. The one on the vehicle and several from various manuals. I have routed these before and had them be wrong and am not above making the same mistake several times. I believe I have it routed correctly. I'm beginning to think that the last compressor freezing up may have damaged the belt some how possibly. I am going to measure it against another belt today.

 

Since nothing has made the path longer apparently, the tensioner must not be releasing fully when you twist it.
Didn't happen to replace an alternator as well, did you? Make sure you have the right pulley on that. Newer ones (2001 up) have a clutch pulley.