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New serp belt

2000 V70 SE, N/A, Denso, AW55-SN, 261K miles

Having a heck of a time getting a new serpentine belt to go on. It's a new Volvo belt, p/n 2458376.

The tensioner is the "new" style with the torx receptacle and I have a long bar with the torx head on the end to fit. The old belt came off O.K. (this is a 60K service replacement).

At full travel-release of the tensioner, the new belt won't slip over the tensioner roller. Basically the belt is too short or it seems that way. A new belt will be tight of course, but I'm lacking about 1/2" - 3/4" for the belt to clear the roller and slip over. Just to make sure I'm doing it correctly, I reinstalled the old belt - no problem - it slipped right on.

I don't really want to pry or force the new belt. Any tricks or methods out there? Warm it up in the sun? (Works for mounting stubborn motorcycle tires).






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