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:



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.



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]

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...

Update July 2017: Ordered an alternator R111799B at O'reilly in-store, and it arrived with the appropriate pulley.

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.

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

1. Disconnect negative battery cable [5/16 wrench or quick disconnect]
2. Remove intake duct, airhorn [8mm Nut Driver, T-25 Torx]
3. Remove oil pressure sender [oil pressure socket...$8 at O'reilly]
4. 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]
5. Remove upper passenger side alternator bolt and fan guard [13mm socket]
6. Loosen lower passenger side alternator bolt [13mm socket]
7. Remove driver side alternator bracketry and bolt [13mm x1, 10mm x3]
8. Remove rear alternator bolt [10mm ratcheting box wrench]
9. Loosen rear bolt to IH [10mm socket]
10. Disconnect alternator electrical connections (battery cable (+), wiring harness) [10mm, fingers]
11. Remove alternator from vehicle

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

[QB93Z]

Originally Posted by KPW

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.

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

1. Disconnect negative battery cable [5/16 wrench or quick disconnect]
2. Remove intake duct, airhorn [8mm Nut Driver, T-25 Torx]
3. Remove oil pressure sender [oil pressure socket...$8 at O'reilly]
4. 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]
5. Remove upper passenger side alternator bolt and fan guard [13mm socket]
6. Loosen lower passenger side alternator bolt [13mm socket]
7. Remove driver side alternator bracketry and bolt [13mm x1, 10mm x3]
8. Remove rear alternator bolt [10mm ratcheting box wrench]
9. Loosen rear bolt to IH [10mm socket]
10. Disconnect alternator electrical connections (battery cable (+), wiring harness) [10mm, fingers]
11. 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]

Originally Posted by KPW

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

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

[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]

Originally Posted by 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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Like This??

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

See All Aluminum Alternator Pulley

[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.