New idler pulley installed but canít get a new (or the old!) drive belt to go on. - North American Motoring

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New idler pulley installed but canít get a new (or the old!) drive belt to go on.

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New idler pulley installed but canít get a new (or the old!) drive belt to go on.

  #1  
Old 03-15-2019, 11:40 AM
Huge Fun
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New idler pulley installed but canít get a new (or the old!) drive belt to go on.

Background: I have a 15% supercharger pulley on a 2005 R53 at 125k miles. Belt tensioner was replaced at 112k miles at WayMotorWorks when I had some other work done there so itís good to go.

Recently the idler pulley has been screeching. The drive belt popped off while I was stopped at an intersection. Dash lit up and started to overheat slightly. Shut it off and had it towed home.

Ordered new idler pulley and 15% drive belt from Way. Neighbor has a well-equipped garage and does a lot of wrenching. We followed Mod Mini videos to remove the front wheel, peel back the wheel liner, use the belt tool to insert the pin in the second hole to release pressure on the tensioner, and removed the old belt.

The old belt had not broken but the idler pulley had come loose and was out. Old idler pulley bearings were shot and scrunched together. Hand tightened the new idler pulley and then tightened further to 25 pounds with a torque wrench.

Routed the new belt in the correct order per the videos. Started at the supercharger pulley around to the ATI damper across to the AC compressor up to the alternator and down to the idler pulley. The new belt simply wonít go on to the idler pulley. Seems to be too short.

Two sets of eyes and hands have triple-checked that this is the correct belt size and that the new belt is properly seated in the grooves on each pulley. New belt does seem slightly thicker because of the old being somewhat worn, but that shouldnít be enough to cause this difficulty.

Hereís the catch: called my local mechanic to describe this. He said to reinstall the old belt and make sure it will go back on. It doesnít! It also appears too small now.

Suggestions most welcome. Thanks in advance.
 
  #2  
Old 03-15-2019, 12:26 PM
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Is the new idler pulley the same diameter as the old one?
 
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Old 03-16-2019, 11:18 AM
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Done! Didn't see the other hole for the idler pulley at first from my line of sight at the level the car was raised. Got whine again!
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Old 03-16-2019, 06:15 PM
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Other hole?
 
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Old 03-17-2019, 07:12 PM
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Originally Posted by Tgriffithjr View Post
Other hole?
Yup... Look here; Idler pulley goes in the top hole.


 

Last edited by AoxoMoxoA; 03-18-2019 at 07:05 AM. Reason: Clarification; added photo
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  #6  
Old 03-18-2019, 07:04 AM
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Originally Posted by AoxoMoxoA View Post


Yup... Look here.
I see. I thought he was talking about another hole in the pulley.
 
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Old 03-18-2019, 08:12 AM
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How did you manage to put it in the wrong hole? Wasn't there a bolt there already?

Related yt link:
 
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Old Yesterday, 10:21 AM
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There was no bolt in the hole after the old pulley literally came loose and out after the bearings seized and the drive belt came off while stopped at a traffic signal.

The bolt is part of the new idler pulley I was installing. Didn't see the other hole for the new idler pulley at first from my line of sight at the level the car was raised.
 
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