Alternator Overdrive Pulley Install
*WARNING* remove your positive battery terminal. If you do not do this step you WILL get shocked.

It would be best to do this at the time of your UDP install(refer to UDP right up for how to remove belt and splash guard)

TOOLS NEEDED
extensions for ratchet
10mm socket
13mm socket
14mm wrench or socket
15/16" socket and impact gun
(if needed) dremel or other form of grinding tool
Patience if it does not work the first time

You will want to remove your belt and coolant reservoir for this. The coolant reservoir is 2 10mm bolts. One is kind of hidden and takes an extension to get to.

There are 3 13mm bolts holding the Alt. onto the engine. 1 on top and 2 on the bottom. The 1 on the top is cake to get off. The other 2 are a little on the difficult side. More awkward than difficult. I found it best to go at them from the bottom, but it may vary depending on the size of your tools and hands. After that there are 3 connections on the back of the alt. 2 Plugs and 1 Screwed on connection. The screwed on connection is the one that will knock you on your a$$ if you do not remove the terminal. It is a 10mm nut that hold the connection down. You now have to manuveur the alt. out of the hole it is in. Which can prove to be quite frustrating.

Once the alt. is out of the car you will need to remove the nut holding the pulley on. I used an impact gun and do not know another way to get it off. The nut is 15/16" in size.

Now for the fun part. The ZXtuner alt ODP rubbed and did not rotate freely. It rubbed on the outter edge on the inside of the new pulley. I pulled the the ODP off and grinded down the lip ON THE ALTERNATOR a little bit. I only took the lip down about 1/16 of an inch if that and rounded the edges again. I put the ODP back on and torqued the nut back on. It then spun freely without any problems. I would suggest when you go to install it you check your clearances before bolting it into the car.

Bolt the pulley up. Then try to rotate it. If it spins freely with no problems then you are done. If it is rubbing give it a few good twists and pull it off. Check the inside and see where it was rubbing. If it is rubbing like mine was grind the lip down on the ALT. DO NOT GRIND THE PULLEY. It will throw off rotational weight and be a bad thing.

Replace your connections on the alt. Replace your 3 bolts. Then replace your belt. Make sure all the ribs in the belt are alligned properly. Put your terminal back on and start the car. Enjoy

If you are doing this and your UDP was previously installed then you will need to remove your passenger wheel and your lower splashguard. Just like you did when you installed the pulley. You will need a 14mm wrench or socket to rotate the tensioner to remove the belt. Splashguard bolts are 10mm.

-CJW