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Could be that the tensioner isn't flush and is at an angle causing the belt to "ride" off the gears. There is a knob on the back of the tensioner that needs to be placed into the divet/hole so that the whole thing is flush. Even the slightest angle will cause the belt to come off. Also did you replace the tensioner? I had a tensioner that the bolt hole had been stripped from the PO and caused the tensioner to not hold the belt properly. Had to use a helicoil to fix the problem. Could even be simple as some dirt build up behind the tensioner....
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