Also, the pulley is correctly mounted. As the removal spline is facing the front of the car.

 

Depending on the pump, they dont always line up when pressed on flush. you have to keep pressing it on until the pulley lines up with the rest of them. otherwise you will be replacing belts quite often. my best advice is to use a level, place it flat against the nearest pulley, and press it on until its as close to being level as possible.

 

i had this issue as well with the cardone pulley. mine went on almost all the way, but its around 1 mm off, and wont push on any farther, i get squeaks when the belt is cold, it looks like its flush with all the other pulleys, but it is off just that small amount, it drives me crazy. one day i may swap it again, especially since rockauto has them for $8.

 

The correct mounting for the pulley is to align it with the belt, not put it on flush.

 

lol i guess to that end then, my belt is aligned to where the pulley would be if it were sitting perfectly flush, as the one before it was. its so close to being lined up, but the pulley wont budge on anymore. so i kind of let it go for now.

 

Here's something GM is famous for, not sure about jeep.....

The pump is mounted to the bracket with a couple studs. There are washers for each stud. But the washers aren't really washers, they're spacers.

To the casual observer they go under the bolt heads, resulting in pulley misalignment. To the sharp observer they go between the bracket and pump making things line up perfectly.

If you're not paying close attention it's an easy mistake to make.

good luck

 

Totally different set up on the 5.2 than gm. It's all in the poor quality replacement pump. Cardone is not known for great products.

Press it on harder, I nearly broke my pulley tool doing mine years back.

 

I figured it needed to be pressed on to be lined up and not flush. I'll have to tear it down tomorrow. Any suggestions on how to press the pulley on further? As the pulley press puller tool I have will only press it as far as the mounting spindle, which is flush. Ideas?

 

Did you ever get this answered, I have the same issue with a 94 WJ 2.5, already pressed as far as I tool will let it but off about 1 rib

 

Way old thread, that guy hasn't logged in since 2013, and there's no such thing as a "94 WJ 2.5" The WJ was made from 1999 to 2004. Neither the WJ or the ZJ came with a 2.5 engine.

 

The ZJ came with a 2.5L turbo diesel outside the US.

But the mounting brackets and parts are very different.

 

I'm happy for old threads, they are still relevant today!

My 5.9L is stripping the first 2 ribs off of the serpentine belt within a minute of putting a new one on. The pulleys don't line up the PS pump pulley stick out further than the rest by about 1/4". I need a new pump anyway so I'll order one and a new pulley, and push it as far as I have to, to get the pulleys to line up.