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thats what the soapy water was for but i see you figured it out

shouldn't, i just did mine while it was handy

too short on the belt and you will have problems with it dropping between the halves of the pulley, my belt that came in a set was a pain to get in the groove and that was with the radiator out, soapy water will allow the outer pulley to slip against the belt as you tighten the pulley against it

loose is fine, yes it widens the gap, this should help with part numbers https://docs.google.com/spreadsheets/d/1fetlT06G7eO_aKOzME_VqusYIMdXdyKkeSYW80JaVQI/htmlview

the inner pulley is secured to the shaft of the compressor, the outer should spin assuming rust has not welded it solid, the two bolts just cinch it to the shaft so it doesn't turn and loose adjustment, you may need penetrating lube, i ran my outer pulley completely off the shaft and cleaned up...

the compressor has its own belt and the pulley is a two piece arrangement that serves as the adjustment, loosen two bolts and the outer half of the pulley spins closer or away from the inner half changing the gap between the two, without the special wrench you will need soapy water to help the...