Replacing both serpentine belts and testing a new pulley

belt_hole

Is it bad if the belt has a hole?

pulleys

(On the left, original Toyota pulley. On the right, the one that fits BMW and now fits MR2 too)

I’m not the biggest fan of original toyota pulleys (they’re expensive and heavy) so I decided to check out if I could find an alternative. The toyota pulley is 90mm dia, around 20mm wide and has a 10mm hole.

I found a BMW tensioner pulley, which is 70mm dia, 25mm wide with 10mm hole. It is a Dayco 89046 and has a bmw part number 11 28 1 748 131. Fits at least E34 518/520/525.

pulley_installed

Seems to work pretty well. And now it fits AW11 too.

The Tein fits – pictures

rear_shock

The rear is almost perfect fit. SW20 type camber adjustment bolts are needed.

uppermounts

Rear upper mount differences. SW20 Type on the left is slightly bigger than my Toda on the right. I’ve drawn the area that needs to be cut away on the SW20 one.

topmount_upsidedown

SW20 type upper mount sitting upside down. The needed cut is perfect. 🙂

The Tein fits

Short update: the Tein fits with some modifications.

While I’m uploading the pictures, I’ll try to list the mods needed.

1. The rear shocks are almost perfect fit. I had to dial the rears down around 45mm to get the height right.

2. The rear upper mounts have thicker threads. AW11 has 3x M8 and SW20 has 3x M10. The pattern is almost identical, so I resorted to drilling.

3. The rear needs SW20 camber adjustment bolts.

4. The Tein rear upper mounts need to be slightly cut.

5. I can’t remember what I did with the sway bar links. I might have mixed and matched two from AW11 and two from the Tein kit.

6. Fronts needed Toda upper mounts + upper mount nuts.

7. One additional washed was taken from Toda set. This one should be hardware store stuff.

8. Front knuckle mount needs an adapter. Can’t remember the exact thickness just now.

9. AW11 front knuckle mount bolts are M12, while SW20 are M14. I did few washers to get the holes to align correctly. Front camber adjustment is a mess after this. I’ll try to build a better adapter for the front.

10. Front left and right shock need to be swapped.

11. I had to grind some paint off from the brake line supports.

12. It runs pretty good 😀

New balljoints

Got all new balljoints for the suspension. Old ones had punctured rubbers and other damages (I might have whacked one with a huge mallet to loosen it from suspension arm…) so the replacement was needed. Rear balljoints came from a japanese company called 555 and the front ones were genuine (and expensive) toyota originals.

balljoints

555_balljoint_one 555_balljoint_two

Test fit.

555_balljoint_three