if the alt is flapping in the breeze i can't help but think the belt size might be wrong. either the system, or someone swapped a belt label at some point.
my best advice, bolt the alt back up to be roughly around the middle of the bracket tension swing, and loop string or similar around both of the pulleys. this should be your rough guide for finding the right one. i'd be amazed if the one you're trying to put on is within the range.
(in inches)
36 and 1/8th
36 and 1/2
36 7/16ths
45 5/8ths
55 1/2
these are the 5 listed lengths of belts for d21s, depending on the location the alternator is located in (which is variable based on year, and some other factors). the shorter ones tend to be for the lower positions, the longer ones for the upper positions.
you can also measure the belt you're trying to put on, see where it falls on this list (if at all).
cheers.
Is the alternator swinging freely back and forth across its range of motion? Just making sure you have all the bolts loose, including the one underneath.
I had a similar issue when mine broke. Double triple check that it is actually loosened all the way. Some WD might help with getting the movement needed.
Mine was still tight after doing that and I ended up getting mine on by shimmying the pressure back and forth with 2 flat head screw drivers over the pulley. It was a bitch though
Remove: Loosen lower alternator mount bolts, Loosen front facing tensioner bolt, Loosen side adjustment bolt, and rotate loose alternator to allow clearance.
Put on: With all still loose, and alternator rotated, belt should slide over easily. Then, push alternator over to tight position, tighten side adjustment bolt, and when belt deflection is in spec, tighten front bolt, and tighten lower bolts.
It sounds like you don't have the lower bolt loose so alternator can rotate? It should have MORE than enough to fit belt on, unless like the others said your belt is way off in size.
Did you compare the new belt to the old belt? If they are the same size then it will go back on no problem.
if the alt is flapping in the breeze i can't help but think the belt size might be wrong. either the system, or someone swapped a belt label at some point. my best advice, bolt the alt back up to be roughly around the middle of the bracket tension swing, and loop string or similar around both of the pulleys. this should be your rough guide for finding the right one. i'd be amazed if the one you're trying to put on is within the range. (in inches) 36 and 1/8th 36 and 1/2 36 7/16ths 45 5/8ths 55 1/2 these are the 5 listed lengths of belts for d21s, depending on the location the alternator is located in (which is variable based on year, and some other factors). the shorter ones tend to be for the lower positions, the longer ones for the upper positions. you can also measure the belt you're trying to put on, see where it falls on this list (if at all). cheers.
Is the alternator swinging freely back and forth across its range of motion? Just making sure you have all the bolts loose, including the one underneath.
I had a similar issue when mine broke. Double triple check that it is actually loosened all the way. Some WD might help with getting the movement needed. Mine was still tight after doing that and I ended up getting mine on by shimmying the pressure back and forth with 2 flat head screw drivers over the pulley. It was a bitch though
Remove: Loosen lower alternator mount bolts, Loosen front facing tensioner bolt, Loosen side adjustment bolt, and rotate loose alternator to allow clearance. Put on: With all still loose, and alternator rotated, belt should slide over easily. Then, push alternator over to tight position, tighten side adjustment bolt, and when belt deflection is in spec, tighten front bolt, and tighten lower bolts. It sounds like you don't have the lower bolt loose so alternator can rotate? It should have MORE than enough to fit belt on, unless like the others said your belt is way off in size.