Belts and Pulleys

[KPW]

After my Water Pump pulley debacle, I had put on a new Continental Belt, #4060802.

Popped the hood the other day to take a look around, and noticed the belt was sitting on the alternator pulley a little funny. Pulled the belt off to inspect it, and saw this nice split lengthwise on the belt:

https://lh3.googleusercontent.com/_R6xEDrYp4biowWdlOD9m9q_xUAU7sDG-SIUAIJ6tOPAz89Zlh46m2pW3GWVrq0bK8dDWuRnGpRC768sLmq EQ9I4ykuhQRtF9HXgtaNodcnGtJSlLKgY3wb3uHcWrmPOFQQLu n518bnZTojf28oEx-DYonBVbJAvpiCG_X-dOfarfB2CsgBGxfI4wWX4E8iLN7a_jDt6WzdxmQGoblc6WdNzX 11L197eJkLJ7zLSwtNT8OyBOFBF1Ry8AsR5GdVAfn9hi_4d-ZhIk6GTQ2m6vIYb1nVbFknjy7-sFny5guDLmafQBAEqYYA2maX28JP4PPHdWUgQ4kPuJWixZH6z5 OospmGekRePfUaj_Ua6VGSCc4G-DMM1B0qLPzO7vgv3-VkCzk7hfbIa8EqmjuPie65_lXy9mqdXtiC6jx4rWKfF47npHzT y6gQgUBP1ARk9q5Lv-XRymt3AktS1mlZ64NuNbpvMeUynW8ydCMFZiTEfrDxjOYMXrcf bOvVqTca_YOCAVi3N8Ag8tw2wJrA5Ioj31pZHIK3gEpSas2RBn HZlTCT-EFMBpbIR4YxwLjsA46Y0rqXoEhNTggNGhouEX96052fQmUWkth wvK5CGLWnecSlb=w579-h771-no

So, I've got something eating up this belt. I'm inclined to say pulley alignment or something like that. However, I did notice that the alternator pulley has 4 peaks and 5 valleys. All other pulleys have 5 peaks and 6 valleys. Belt matches the 5/6 pattern.

https://lh3.googleusercontent.com/F2dIdii1MU2Bsx3LXTpyHSUhEwic1JPqbXy2ULVah8N6-TTtebkOmxsegbRe6ypm48dSlfS9S3NBbY8Z4QBCx8v3ADypxPD Y2FRzW2sVkld51019PHpSDIF5H400PYRIaLY-LI9yPGTzun3aJ7ussTphL3xBmeZN55tobjvazzw81JRWZ3tQkX 1kG7D5RUagmy9DQg43IOMx3OqODEq3Mj_w9yoGrRul_U70eezx Ba3Gl_Yu1IXUea8sPPiqtWbNL9oJuLXmmoOH5aYusmtNK2ig9q nh4Iw_kr3WGPgdoGPJ0SbxdRg2WGWtj90jsr2dMy_T-d5wvrlyO-n8ZXKV0rNwDG7AET1qdRHjRuRO0fioypve7LmyNs31rYgb8Wm5 iYdEElcRRez5DJ0C15eoPjthr7otg4Iz57QUNyy8Qy4T91_7UQ 9_WAszahgjAhDqfP7xyfZHOQ1RdB7DwRdTKBe-5Zz6U1Dg2Uim-ZDfEbQXCc2PM3VfWP5Yvh6_FeY-iUTccVoIpPM3IMPF7dfy9AkDF1SPh5dQ1xn0wyUeR-oAxb6p3WxJK-eGeIiYKmXhh8vsKKlsUUrMf-XuHbu21yeSwHGrwsqGt9LZigIhbHdSQWiu=w579-h771-no

I took a look at the alternator picture at Jerry's Gaskets, and it looks like that pulley has the 5/6 pattern.

What do we think? Do I need a new pulley, a new alternator, or just a new belt?

[Dynomite]

Install new alternator pulley with 5 peaks and same diameter.

Use a 15/16 inch offset box wrench and 8mm allen wrench to remove altrnator pulley.



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[KPW]

Thanks. Went out to double check the 15/16" number and noticed that there's a current rating stamped on the alternator. Mine says 108A. Aren't the alternators for these cars supposed to be 120A? Any issues running a lower max current?


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[KPW]

Fair enough. I've had the car two years (seasons) now and it's done OK. Some voltage gauge fluctuations at idle, but I've chalked that up to normal C4 stuff up to this point.

I may swap the pulley in the short term, then look at swapping the alternator over the winter. Thanks!

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[KPW]

When I received the replacement alternator, the pulley was too small in diameter (56mm vs the needed 62mm). You can howver remove the pulley off of your old alternator with an impact wrench and swap it to the replacement :thumbsup:

I did this replacement without pulling the plenum or throttle body. [Tools used in square brackets]


Disconnect negative battery cable [5/16 wrench or quick disconnect]
Remove intake duct and airhorn [8mm Nut Driver, T-25 Torx]
Remove oil pressure sender [oil pressure socket...$8 at O'reilly (http://www.oreillyauto.com/site/c/detail/LIS0/13250/N1694.oap?ck=Search_oil+socket_N1694_1041297_3434&keyword=oil+socket&pt=N1694&ppt=C0195)]
OPTIONAL: Remove serpentine belt and belt tensioner (tensioner got in the way of the lower driver side alternator bracket, however it's possible to get to it without removing the tensioner) [1/2 Ratchet/Breaker Bar, 18mm ratcheting box wrench]
Remove upper passenger side alternator bolt and fan guard [13mm socket]
Loosen lower passenger side alternator bolt [13mm socket]
Remove driver side alternator bracketry and bolt [13mm x1, 10mm x3]
Remove rear alternator bolt [10mm ratcheting box wrench]
Loosen rear bolt to IH [10mm socket]
Disconnect alternator electrical connections (battery cable (+), wiring harness) [10mm, fingers]
Remove alternator from vehicle

Installation was basically reverse of removal. Had to get all the alternator bolts started in parallel more or less.

[QB93Z]

Alrighty then. I decided I'd be better off just replacing the alternator now while I've got the chance.

I ordered one from O'reilly (R111799B) ...which I see now is different than R111799A mentioned above. However, the website pointed me at the B version...

When I received the alternator the pulley was too small in diameter (56mm vs the needed 62mm). I went to my local O'reilly, and they helped me order a replacement. Same problem there, so I returned it and did some more research.

Based on some product pictures I was seeing, it looked like there was an AC Delco rebuild that had a promising looking pulley. I called around until I found a shop that had one, and had them measure the pulley for me. Bingo, 62mm. I ordered it, and just got done installing it, and my new belt is very glad for it.

So to make a long story short, the AC Delco 334-2318 is a proper fit off-the-shelf for the ZR-1, pulley and all.:cheers:

Also, I did this replacement without pulling the plenum or throttle body. [Tools used in square brackets]

Disconnect negative battery cable [5/16 wrench or quick disconnect]
Remove intake duct, airhorn [8mm Nut Driver, T-25 Torx]
Remove oil pressure sender [oil pressure socket...$8 at O'reilly (http://www.oreillyauto.com/site/c/detail/LIS0/13250/N1694.oap?ck=Search_oil+socket_N1694_1041297_3434&keyword=oil+socket&pt=N1694&ppt=C0195)]
Remove serpentine belt and belt tensioner (tensioner got in the way of the lower driver side alternator bracket) [1/2 Ratchet/Breaker Bar, 18mm ratcheting box wrench]
Remove upper passenger side alternator bolt and fan guard [13mm socket]
Loosen lower passenger side alternator bolt [13mm socket]
Remove driver side alternator bracketry and bolt [13mm x1, 10mm x3]
Remove rear alternator bolt [10mm ratcheting box wrench]
Loosen rear bolt to IH [10mm socket]
Disconnect alternator electrical connections (battery cable (+), wiring harness) [10mm, fingers]
Remove alternator from vehicle
Installation was basically reverse of removal. Had to get all the alternator bolts started in parallel more or less.

Thanks for posting your procedure for replacing the alternator without removing the Plenum or Throttle Body. I will try it next time I replace an alternator.

Jim

[Dynomite]

I ordered one from O'reilly (R111799B) ...which I see now is different than R111799A mentioned above. However, the website pointed me at the B version...

When I received the alternator the pulley was too small in diameter (56mm vs the needed 62mm). I went to my local O'reilly, and they helped me order a replacement. Same problem there, so I returned it and did some more research.



What is the outside diameter on the face of the correct pulley?
The Pulley on my rebuilt alternator was not the correct diameter so this is getting confusing. I think the correct outside diameter on the face of the pulley is 2.75 inches.

Like your write up on Alternator Replacement without pulling plenum :handshak:

In the mean time I am making a tool to quickly remove that Alternator Pulley such that no matter which pulley is on the rebuilt alternator I can just switch pulleys during the exchange :p

[KPW]

Dyno, you're right on the 2.75 inches. There was some serious pulley confusion on my end as well. Glad it's behind me for the moment!


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[Dynomite]

Dyno, you're right on the 2.75 inches. There was some serious pulley confusion on my end as well. Glad it's behind me for the moment!


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Like This?? :handshak:

Also...........Note the All Aluminum Belt Tensioner Pulley below the All Aluminum Alternator Pulley.

See All Aluminum Alternator Pulley (http://www.corvetteforum.com/forums/c4-zr-1-discussion/3005470-tech-info-lt5-modifications-rebuild-tricks-500-hp-13.html#post1592505495)

http://i287.photobucket.com/albums/ll142/dynomite007/Dynomite19/d8a219b2-f604-4653-9c28-360157f1027b.jpg

[garyhugo]

KPW just finished replacing an alternator using your method. It worked. Getting the extra deep socket for my oil pressure sensor and swapping pulleys took longer then the replacement.Thanks again.

[KPW]

KPW just finished replacing an alternator using your method. It worked. Getting the extra deep socket for my oil pressure sensor and swapping pulleys took longer then the replacement.Thanks again.



Awesome! Glad it worked out for you.


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