Long story, but I'll try to keep it short. 2008 Mini Cooper (base) with 57k miles. Multiple issues in last 8 months of ownership. Latest is bad alternator (over voltage) which also toasted the battery. I replaced both, which fixed the voltage problem. While in there, I noticed the belt was starting to crack so I replace it as well. For the alternator, I went with a Pure Energy re-manufactured unit (they claim it is a Valeo 120 amp). For the belt, I went with a Gates belt (had good luck in past on other cars). I cleaned the pulleys and checked the tensioners (seem OK to me).

It frayed the belt in less than 10 miles. I confirmed the belt was installed correctly on the pulleys. I got a replacement belt, confirmed correct installation, and it has shredded in less than 20 miles. The ribs on the new belt are the correct spacing, but not quite as tall. The alignment of the pulleys looks OK visually (crank and air conditioner were not removed), but not sure how to confirm.

Not sure where to go from here. Any advice will be appreciated.

Update: While waiting for yet another belt (Continental this time), I tried to check the alignment of the pulleys, and the re-manufactured alternator didn't look right. Out of frustration and a need to get the car repaired, I bought a brand-new Valeo alternator. When it arrived, I compared the 2 units. The re-manufactured unit had a slightly different pulley, and it wasn't pushed onto the shaft as far. Both of these caused the grooved to be off by full groove. The difference was easy to miss until I measured them. I installed the new alternator and belt, and the car has been running fine since. As stated above, the re-manufactured unit was a "Valeo" unit by Pure Energy. Regardless of what unit you buy, check the pulley alignment very carefully to save yourself a lot of extra work and frustration.

 

Try to hand crank the engine (clockwise) to see if the belt is actually spinning and nothing is stuck..

 

Thank-you for the reply. With both belts, I started the engine with the wheel well still out. All pulleys (including water pump) were spinning freely. Everything was OK, even with a/c on.

 

Is there a difference in the pulleys on different brands of alternators? If so, how can I tell if the one I got is correct?
(I already returned the original alternator for the core charge.)

 

if they were for mini coopers, then no. the only visual test you can do it laying the belt on the pulley to see if all of the rips match exactly. I just replaced my alternator with a used one from ebay for $45 and i got to keep the old one. It might be a good idea to buy a good used one and return the one you got? what brand is it, by the way?

 

It is a remanufactured Valeo unit (so they claim), by Pure Energy.

 

all the belts you used were the same? did you try another brand like continental?

 

So far, I have used 2 belts from Gates. Trying another brand will be easier than replacing the alternator (again).
Thank-you.