BHase
10-26-2004, 07:25 AM
Well, guys, it seems that almost every DIY I've done has become an adventure onto itself. Yesterday I tackled the 3-piece pulley set from Unorthodox Racing (alternator, power steering, crankshaft).
First, let me just say that my car ended up inoperable and is currently sitting parked across two parking spaces (diagonally) in the parking lot. I'm posting this thread mainly as a warning (to be reiterated at a later time...as in, when I give my overall impressions) to would-be pulley installers.
1. Make sure you get a replacement accessory drive belt tensioner. On mine, the fixture onto which you place the breaker bar + socket to detension the belt had broken off. To remove the belt, I was forced to actually remove a pulley and remove tension on the belt that way. If you don't get one, you may find yourself unable to replace it for days (and then with overnight shipping at far greater cost).
2. Make sure you get the 6-ribbed, 72" (1830 mm) accessory drive belt. I didn't realize that the crankshaft pulley is not only lightened but also signicantly smaller in diameter. I had ordered an OEM belt for $25 from ECS Tuning, which is 6-ribbed and 1882 mm. The 52 mm slack makes it impossible to install. I spent another $39 at Advance Auto Parts for an 1830 mm belt. The difference in size is only apparent once you do the install (unless you've read it or just happen to guess it); Unorthodox doesn't mention it even directly in their instructions (they do tell you the correct sized belt is 1830 mm/72").
3. The alternator pulley is in a design where the nut that holds it on sits upon a threaded rod which turns with the pulley. Therefore, a more special tool (i.e. a chain wrench or large capacity locking wrench or the like) is required to hold the pulley, while the nut is loosened with a large diameter socket. It is also not at all accessible. There is metal tubing which runs right in front of the pulley; in the end, the radiator panel's service position isn't sufficient. Take the front end off and save yourself a ton of frustration.
4. Once you get everything on, please, please, please do yourself the favor of making sure everything is perfectly tensioned. And also that the bolts on the pulleys are on right (the only one you'll still be able to access once everything is on is the top pulley (power steering).
Step 4 is where my problem occurred. The car drove great for about 30 minutes, including city and highway driving. I think it even felt great. Then, I pulled into the parking lot and my brake light came on, my steering didn't work at all (not even with great effort), and it was obvious that the accessory drive belt had come off of the pulleys. Upon further investigation, I found that the power steering pulley was no longer secured (three small torx screws hold it in). It was already dark and I had no light, and therefore this has been relegated to this afternoon (but now it is rainy). Hopefully I will fix it.
When it is fixed, I will post a more detailed installation instruction set. None of the instructions I had (manual and UR letter) really prepared me for everything I was to encounter. Unfortunately, I don't own a camera (digital or otherwise), so it'll be text only.
Ben
First, let me just say that my car ended up inoperable and is currently sitting parked across two parking spaces (diagonally) in the parking lot. I'm posting this thread mainly as a warning (to be reiterated at a later time...as in, when I give my overall impressions) to would-be pulley installers.
1. Make sure you get a replacement accessory drive belt tensioner. On mine, the fixture onto which you place the breaker bar + socket to detension the belt had broken off. To remove the belt, I was forced to actually remove a pulley and remove tension on the belt that way. If you don't get one, you may find yourself unable to replace it for days (and then with overnight shipping at far greater cost).
2. Make sure you get the 6-ribbed, 72" (1830 mm) accessory drive belt. I didn't realize that the crankshaft pulley is not only lightened but also signicantly smaller in diameter. I had ordered an OEM belt for $25 from ECS Tuning, which is 6-ribbed and 1882 mm. The 52 mm slack makes it impossible to install. I spent another $39 at Advance Auto Parts for an 1830 mm belt. The difference in size is only apparent once you do the install (unless you've read it or just happen to guess it); Unorthodox doesn't mention it even directly in their instructions (they do tell you the correct sized belt is 1830 mm/72").
3. The alternator pulley is in a design where the nut that holds it on sits upon a threaded rod which turns with the pulley. Therefore, a more special tool (i.e. a chain wrench or large capacity locking wrench or the like) is required to hold the pulley, while the nut is loosened with a large diameter socket. It is also not at all accessible. There is metal tubing which runs right in front of the pulley; in the end, the radiator panel's service position isn't sufficient. Take the front end off and save yourself a ton of frustration.
4. Once you get everything on, please, please, please do yourself the favor of making sure everything is perfectly tensioned. And also that the bolts on the pulleys are on right (the only one you'll still be able to access once everything is on is the top pulley (power steering).
Step 4 is where my problem occurred. The car drove great for about 30 minutes, including city and highway driving. I think it even felt great. Then, I pulled into the parking lot and my brake light came on, my steering didn't work at all (not even with great effort), and it was obvious that the accessory drive belt had come off of the pulleys. Upon further investigation, I found that the power steering pulley was no longer secured (three small torx screws hold it in). It was already dark and I had no light, and therefore this has been relegated to this afternoon (but now it is rainy). Hopefully I will fix it.
When it is fixed, I will post a more detailed installation instruction set. None of the instructions I had (manual and UR letter) really prepared me for everything I was to encounter. Unfortunately, I don't own a camera (digital or otherwise), so it'll be text only.
Ben