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Discussion Starter #1
Belt slips off the top air conditioner pulley - was tight and right but on start up failed.

Is the clutch the problem or the engine pulley?

Alternator and power belt seems OK.

All are new belts

The engine pulley seemed comes out with a rubber seal or is there an anchor bolt?

Frustrating - any ideas before spending a fortune at the dealer?
 

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03 H6 OBW & 06 WRX Sportwagon
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after you put the belt on and adjusted it, did you re-tighten the mount bolt too?
 

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Discussion Starter #3
Yep - tightened the center pulley bolt - after adjusted the belt to tight. Seems to happen most often when first start the car. Very strange.
 

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. . .

The engine pulley seemed comes out with a rubber seal or is there an anchor bolt? . .
If I understand what you're saying, that's not right.

The crank pulley is two parts, a round center, and an outer ring (with the belt grooves) around it. They're held together by a rubber compound. The outer ring should not move in any direction relative to the inner circle. If the outer ring moves, the compound has deteriorated and isn't holding the two parts together. Replace the crank shaft pulley asap -- if it separates it could lead to the timing belt cover and the A/C compressor clutch connector being damaged, as well as loss of alternator and power steering.
 

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Belt falling off is most often due to mis-aligned sheaves. It may be possible that the idler (adjustment) pulley has a bad bearing and is not staying aligned.

A loose belt may slip/squeel... but will not fall off.

Here is something to try.... make CERTAIN the AC-clutch will not enguage by turning OFF the knobs... then start engine. With no load on it, the belt should simply rotate the outer portion of the AC-compresser pulley. If the belt cannot do the simple task of rotating WITHOUT a load on it... consider looking at the condition of the idler-pulley.

ADDENDUM: I do not understand why you are talking about REMOVING pullies?!? There should never EVER be a need to remove pullies when replacing belt. Can you please explain WHY you are REMOVING pullies?
 
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