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Discussion Starter · #1 ·
Ok I did this before and the belt was very hard to put on but it finally went on. 2 years later the alternator stopped working again and when I took it off the motor bearings are worn out. I am thinking because the belt was on too tight.

I bought a new Bosch Alternator at Napa along with a belt (25-060854)

The serpentine belt will not go on this time period. Could the pulley on the alternator be the wrong size?

I have a 2000 ZX2 2.0L DOHC Zetec Engine 16 Valve with Air. Automatic.

I am putting the belt on the correct way I think. Put it on all the pulleys and put it on the belt tensioner last?

Last time I had to pry it on the drive pulley almost lost a finger in it.

Any sugestions other than going to a professional?
 

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Did they come together as a kit, or did you buy them seperately? I would recommend just getting a longer belt. I have seen other posts discussinf belts not fitting after replacing parts and the belts that run them, many times it is because the parts store system lists the wrong belt or they are different from one manufacturer to another. In the end it is just a belt, find the one that fits your application and write the number down in your repair manual for future reference.
 

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I just did my belt a week ago, I bought the new one then after removal of the old compared them to make sure it was the right size before trying to put it on. The same would apply to the alternator, you can match them up on the counter in the store to make sure the pulley is the right size. It is supposed to be pretty tight, but should go on easily when you pull the tensioner down with a 3/8 drive wrench. The routing is tricky, but a lot easier with the wheel and inner fender removed.
 

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I have bought rebuilt alternators that arrived with the wrong size pulley, both on my Escort and on other cars, even my motorhome. I just saved the old pulleys and put it on instead. Its only easy to do this if you have an impact wrench.

The belt could be the wrong size of course. But being too tight isnt likely. If its too small you wouldnt be able to get it on; if you are able to put it on at all, its probably going to have the correct tension on it.
Being snug enough to "almost loose a finger" is a good description of a normal new belt going on. They get easier to put on once they have a few hundred miles to limber them up.

If I didnt remove the splash shields, I dont think I could ever replace the serpentine belt on my 2nd gen Escorts. I wouldnt be able to guide the belt under/around the crank pulley, etc.
 

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Discussion Starter · #5 ·
Not a kit never seen a kit. I didn't save the original pulley when I first changed the alternator the first time. I didn't know that was something I was suppose to do. You would think it would come with the correct size pulley and I wouldn't get the wrong one 2 different times.

I ordered a new pulley from ford maybe it will work.

After I have the belt on and to the belt tensioner there isn't enough slack to put a wrench on the nut.

:(
 

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Discussion Starter · #6 ·
Bought a serpentine belt tool. It is real thin just what I needed to get the bolt. And with another set of hands to pull up on the top belt a bit it slipped on. :)

Now gonna see it I can make it to 200,000 miles.

:wink:
 

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200k?

my friends got 360k on his 99 - original engine and tranny!
 

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Discussion Starter · #8 ·
pextor said:
200k?

my friends got 360k on his 99 - original engine and tranny!
Yeah. I have 151,370 now. 200K would be nice 300k would be outstanding. 360K? Now that sounds better. :)

Now that I have the alternator and belt fixed. Anyone know where I can get a replacement License plate lamp socket? Both mine in the rear are out.
 

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I havent asked in any auto parts stores yet, I probably should; to begin creating a 'demand'. I got my extra license lamp housings & lenses from pick-n-pull junkyards, where you may find some usable ones, along with the cracked ones or the ones whose screws are so rusted you cant undo them.
Also the Collision Repair Parts businesses, who sell fenders and such to the body shops might have a source for them.
The ones for the sedans are slightly different from the ones on the wagons too - just enough that they wont interchange.
 

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Discussion Starter · #10 ·
denisond3 said:
I havent asked in any auto parts stores yet, I probably should; to begin creating a 'demand'. I got my extra license lamp housings & lenses from pick-n-pull junkyards, where you may find some usable ones, along with the cracked ones or the ones whose screws are so rusted you cant undo them.
Also the Collision Repair Parts businesses, who sell fenders and such to the body shops might have a source for them.
The ones for the sedans are slightly different from the ones on the wagons too - just enough that they wont interchange.
The dealer had one. $8.05 each. I installed it today. :) All done till something else happens.
 
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