Conversion to 8-rib serpentine system

[TooManyHobbies]

Well I took the remnants of the stock alternator decoupler pulley to the hardware store to find a matching nut so that I can install the new pulley that does not have a decoupler. An M16-2.0 bolt threaded on the remnants pretty well, but the threads looked finer. I came home with an M16-2.0 nut and an M16-1.5 fine nut. Neither one of them will thread onto the shaft. What the hell is this thing?

[Doug Hilliard]

I have no idea but maybe it's english? I just tried sockets over the nut on mine and both a 15/16" and a 24mm fit pretty well so that was no help. I also think I told you wrong on the machining of the pulley; I think you will have to take off 5mm on the boss that mates with the alternator shaft itself. The belt needs to run very close to the face of the alternator but since you pulley looks different than mine, you'll just have to try it and see. On the nut, I think I'd call an alternator repair shop and ask them.

[TooManyHobbies]

Been searching the interwebz and pretty sure it is an M17 1.5.

Next I need to figure out the thread on the inside of the PS shaft. My puller worked great to get the PS pulley off, but the threads do not match up to push the new pulley on.

[Doug Hilliard]

Been searching the interwebz and pretty sure it is an M17 1.5.

Next I need to figure out the thread on the inside of the PS shaft. My puller worked great to get the PS pulley off, but the threads do not match up to push the new pulley on.

I just rented a puller from AutoZone and it worked fine but I couldn't tell you what the threads are.

[-Ray-]

All the parts have arrived, so it is time to bug Doug again. For the lower idler (89102) there is a deep side and a shallow side. The 5 mm gets machined off which side? I assume the shallow side since you put a washer behind it. Also the extra belt width is to the front of the engine. Correct me if I am wrong.

If you don't have a caliper, go to HF and buy one.
Measure Dia. in both inch and metric. Metric Dia. you'll round up to the nearest Dia. Inch you will round up to nearest fractional size. Metric threads are pitch to pitch measurement. Inch threads are per inch. Since it looks like you'll only be able to measure length by 1/4", multiply by 4 to get inch pitch measurement.

[STL_G8GT]

If you don't have a caliper, go to HF and buy one.
Measure Dia. in both inch and metric. Metric Dia. you'll round up to the nearest Dia. Inch you will round up to nearest fractional size. Metric threads are pitch to pitch measurement. Inch threads are per inch. Since it looks like you'll only be able to measure length by 1/4", multiply by 4 to get inch pitch measurement.

Great info ... Never added a caliper to my tool chest, I need to!

[TooManyHobbies]

I got done pinning the crank and then put the PS pump back where it belonged. Only thing still holding the alternator on was the big wire in back so I disconnected that. I do need to grind the cast aluminum boss on the front. The pulley does rub. A lot easier to grind with it off since it was most of the way there anyway.

Also waiting for my alternator nut order to arrive. If anybody else is considering this I have 4 of these rare items on order, I will send you one if you pay postage!

[TooManyHobbies]

After searching on some Aussie forums I confirmed that the thread on the inside of the shaft is 3/8-16 even for a metric country. The PS puller/installer set I have will work. The threads on the inside are just all rusted up which seems to be pretty common. I ran a 3/8 tap down it and now the installer will thread on with no issue.

[TooManyHobbies]

I am going to add more details to the excellent information that Doug started.

I worked on the alternator tonight. I started out grabbing the Dremel with a grind stone then realized some serious metal removal was necessary. I got out the die grinder with NF bit I bought to port the lower Maggie manifold. That made quick work of it. I grabbed one on the youngest's red crayons and put a heavy dose of it on the pulley after I had ground down a bit. After I twisted the pulley around a bit it let me know where I had to remove more material. Here is a before and after:

[TooManyHobbies]

I can confirm the alternator pulley nut is 17mm X 1.5. It also takes a good thick lock washer. I almost thought I needed to use two. I have extras nuts and washers now if anybody wants one. Coming right along now. Damper hub seated and tightened down. If the PS pulley does not give me fits when I try to put it on I will be out of the woods.