KJ CRD Alternator Pulley

[Billwill]

Hi, My 2002 2.5L CRD is currently out of action due to a snapped Serpentine Belt!

I have ordered a new belt but cannot get the Idler Pulleys and Tensioner locally...will have to order them from Overseas!

My main concern is the original Alternator pulley....cannot get this locally but have to buy the complete Alternator....not going to happen!

Years ago I was involved in some long discussions with the Experts on how to remove the existing pulley and replace it with a Litens pulley....I cannot find those posts at the moment!

Can someone please direct me to the relevant posts as regards the procedure to replace the Alternator Pulley!

Also how do I test the existing pulley without removing it?

The top left Idler Pulley had seized solid so that probably caused the belt to snap and I intend ordering new Idler Pulleys, Tensioner Assembly etc. but if I can test the existing Alternator Pulley while it is still fitted in place..it would help me greatly!

[Wantsawillys]

Hi Billwill,

I've had a 2.5, and currently a 2.8.
I've just replaced most everything on my 2.8 and from memory all the relevant bits on the 2.5 are the same.
If you're still looking for the pulley's and tensioner, Dayco produce them, and i was surprised how cheap and available they were here.
One of the local auto parts places (Bursons for us australians) even had them on the shelf.
I also just replaced my alternator pulley.
Now this is where it gets interesting, because there might be 2 different ways the pulley's are attached to the alternator if i'm going by the US site.
I'll tell you how i did mine, and you can see if yours is similar.
If you pry off the dust cap on the pulley, and clean out the rust dust from the inside, you should see the end of the alternator shaft inside. You are supposed to put a specialist 10mm socket on that, and a hex ring on the pulley and twist it off.
I didn't do that...
I went down to the local hardware store and grabbed an M10 coupler.
Just do a google image search for that one.
The one I bought fit perfectly in the end of the pulley, but others may need to be filed down a little.
With that in the end of the pulley I put my impact wrench on the coupler and gave about 5 quick hits and it spun right off.
(I removed the alternator, 3 bolts and it made it easier)
Installation was a reversal of this process, but to stop the alternator spinning I used a small pry bar and put it against the fins just inside the casing.

That is the easiest way to do it. If you have the other style pulley/alternator, I believe it requires an allen key to hold it in place.

The dayco catalogue shows the same pulley for 02-07 2.5 and 2.8 crds, and I never replaced the one on my 2.5 so I can't recall if there is a difference.

If you need any other info send me a pm and i'll respond as soon as I can

[Billwill]

Thanks for the reply....I have found a local CRD Owner who has found a place that could supply him with the correct Pulley....I will try them in the New Year as everything is pretty much closed down now!