[Mr.Chevy4x4]

I fought this same battle today but fortunately my pulley came off as it should. I put headers on a truck with the same serpentine setup a while back. I just determined the space difference between the factory manifold and the header flange. I then cut a spacer from a piece of thick wall tubing and used a longer bolt to cinch it down. Worked like a champ and I never lost a header gasket.

Mike