51 captured repliesDiscussion pagination complete · Source accounts, not a confirmed diagnosis
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Discussion summary
YOUR RESEARCHserpentine belt question
Leading reported evidence
Install than the boxster water pump
Performed · outcome unconfirmed
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0
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1
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Discussions that performed work without a confirmed outcome
1
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Performed · outcome unconfirmed
The Turbo water pump has a much smaller pulley fitted than the Boxster water pump.
Leading evidence: 'Install than the boxster water pump' (no explicit attributable resolution; this is a reported action or suggestion). Across 1 matching discussions, the most frequently mentioned possible cause is 'alternator pulley' (1 discussions; 0 report identifying it and 1 suggest it). The most frequently discussed action is 'Check belt part numbers and the routing' (1 discussions). For that action, 0 discussions report a resolution and 0 report an unsuccessful attempt. No action has an explicit, attributable resolution report under the current rules. These are forum reports and suggestions, not a confirmed diagnosis.
Source reports, not a diagnosis or a success probability. Counts refer to discussions and can overlap.
Replace belt about 5 minutes ago and it worked fine
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Performed · outcome unconfirmed
I just changed my belt about 5 minutes ago and it worked fine.
Outcome qualification: Negation, uncertainty or missing explicit repair resolution overrides the raw extraction signal.
Replace only thing
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Performed · outcome unconfirmed · Original poster
The only thing that was changed pulley wise before install was the water pump.
Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.
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0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
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Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.
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0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
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Suggestion
BTW, and I know this is going to read wise after the fact, but a habit of mine is whenever changing a belt to compare the old one and the new one to verify the width and length are the same.
Counts describe captured discussions, not unique people or a diagnosis. Author identities are not reliably stored. Exact duplicate evidence is counted once across matching discussions; one discussion counts at most once per action/state. Multiple repairs reported together remain a combination. Suggestions and failed attempts do not establish a fix. Matches cover whole discussions and can include related faults, model variants and incomplete threads.
51 eligible posts · 0 unverified posts · 1 discussions match the subject in their title or opening post.
Rennlist: 1 discussions
0 evidence records excluded for query context · 0 excluded by outcome qualification · 1 adjusted by outcome qualification.
1 acknowledgements have no verified action link; they do not establish a repair result.
Outcome without a verified action link
There was just a thread where the 997 water pump did NOT work.
Got a motor for my project and will installing it soon but when I put the new belt on even with the tensioner all the way pushed down, I had to use a pry bar to stretch the belt to get around the last pulley and by looking at the picture, you can see hat the two pulleys are only a few millimeters apart. Any ideas on what is going on? I double checked the belt part numbers and the routing but I'm obviously missing something? Or is this normal??
Are you sure the belt is seated correctly into the grooves on all the pulleys? Looks like its not at the lower right of the crank pulley...or it's just the angke of the photo...
^^ yes. If you look at the picture, the tensioner is in the pulled down position now. I've been doing research, but there is only one belt size regardless of its its a Tip or manual, and its a stock 03 3.6 motor. The only thing that was changed pulley wise before install was the water pump. And I just read a thread on 6speed who had the same issue with no 'correction'.
That's not right. I've never known a belt replacement to require any use of any real force to get the belt on. 3 hands sometimes. But no force. By wrenching the tensioner in the proper direction the belt can be slipped over the last pulley and all seating checked and if ok then the tensioner released and the belt is installed.
Either the routing is wrong or perhaps the water pump is the wrong pump, and has the wrong sized pulley for the car.
I note the casting part number of the water pump for my 02 Boxster and my 03 Turbo is the same but the biggest difference is the water pump pulley size. The Turbo water pump has a much smaller pulley fitted than the Boxster water pump.
BTW, if you had to use a pry bar to slip the belt on a pulley the belt has been compromised and should be replaced. It will likely fail catastrophically in service. Never ever use a pry bar or a screwdriver anything to get one of these belts on. With the tensioner turned in the right direction to remove any tension from the belt and to provide enough slack in the belt the belt should be removed or installed by hand with no real force required.
Your routing is correct and the water pump is the number one suspect. What is its part number? If it starts with 997, it's the wrong pump and there's a recent thread about it.
Dammit... yes it has a brand new, from Porsche mind you, 997 pump.. So i assume the pulleys are different but mine spun freely with the newer pump unlike that other thread. Of course I just finished tightening the last bolt on the engine install which will now make the pump install much harder.. lol..
yeah, but looking at the pictures, the pulleys look exactly the same size, so i doubt it will fix my original problem. i will measure them when i get them together.
Yea i know. However, all your other pulleys also look like they are of the right sizes in your photo. I guess like you said, you just have measure and compare the 996 and 997 pumps.
Looking at you photo again. I also suspect your alternator pulley but it's hard to tell. My alt pulley is definitely smaller than the idle pulley right next to it but yours seem to be not the case.
There was just a thread where the 997 water pump did NOT work. Change out pumps and I bet your lucky might change. Maybe, maybe not but look at that pump and make sure the blade fins aren't going to score your block.
Definitely something amiss...
OP- you may need to document what works with what going forward.
I had a similar issue on an engine upgrade on one of my older BMW's. The belts/pulley's/serpentine system can be unique to the donor.
You'll figure it out, just write it down going forward...lol
ok, so far:
Crank pulley - 996.102.115.63
Alt pulley - 996.603.152.50
PS Pulley - 996.147.223.60
AC pulley - 996.573.926.00
are all correct.
All of my deflection/idler pulleys have the same part number - 996.102.120.55 but that doesn't pull up in PET, so I am going to the call the dealer and find out the correct idlers for my VIN. I'm also going to pull a 996 and 997 water pump off the shelf and compare the pulley diameters.
And one last thing, I just ran across this:
http://986forum.com/forums/general-d...too-tight.html
which basically says some belts was mislabeled from the factory and are 1 1/2 inches too short. I really hope that is the issue, and I will check that in the morning!!
That would actually make the most sense!!
Yeah, I noticed that they have different part numbers in PET also, but if you go to order one, they all go to the same number..
I'm just hoping its the belt itself!!
UPDATE..
Even though the three pulleys, (deflection, idler and tensioner) all have different part numbers, they all have the same casting number stamped on the pulley itself which made me curious. I went by the dealer today and compared them all. All of the pulleys diameters are identical as they all have the same number stamped on them.
So even though the parts catalog calls for these three metal pulleys:
996.102.117.57, 996.102.118.56 and 996.102.119.58, you can also use the newer plastic updated ones which are: 997.102.117.00, 997.102.118.00 and 997.102.119.00, but either way, all of the pulley sizes are the same. The have different part numbers because of the center type of bearing and lug positions and the tensioner is hollow.
I then went and pulled a 996 and a 997 water pump and those pulleys are identical as well.
So at this point all of my pulleys are correct. Time to measure the belt. In looking at all the reputable suppliers, it showed the belt to be 83.25 inches, or 2115mm. Mine measured out at 83" even. I stopped by on the way home and picked up another new belt (after measuring it of course) It was exactly 83.25. Brought it home and while it was still a tight fit, it slipped over the last pulley with just my hand.
ALL OF THIS OVER .@25 OF AN INCH!
Yeah it does sound easy, but it is a new replacement engine to me and it had a 997 pump on it so of course I overlook the obvious and assume that all of my pulleys are wrong. Lol. If it would have been just a replacement belt that didn't fit, that would have been the first thing I looked at! Ha! Well I hope this helps someone else down the road.
Well, sorry for the runaround on the pulleys. I assumed the belt was known to be proper size.
At least you got it figured out, but I would have a conversation with whoever you got that short belt from.
Just a belt. Bad enough but it could have been much worse. Glad to read you got it sorted.
BTW, and I know this is going to read wise after the fact, but a habit of mine is whenever changing a belt to compare the old one and the new one to verify the width and length are the same.
Trust me, I feel like a doofus, but the odds were against me. Remember, I just got the engine so no telling who did what to it before I got it and there was no belt on it to compare it to, so when I bought a new belt, I
assumed
it was good and there must be a problem somewhere else. When I noticed it had the 997 water pump on it, it sent me down the rabbit hole of pulley land.. Lol. Oh well, I certainly learned a lot!
Thanks for sharing that with us though as I certainly myself wouldn't have expected an OEM belt to be out of spec too. This might save others some headaches down the road as I don't recall another thread like this about shortened OEM belts.
At first the pulleys were just about touching each other and the tensioner felt like it didn't release from the pushed down position and now, funny as it sounds, they are about 1/4' apart but i felt the tensioner release if that makes sense.
I think that may be ok even though I still think something is not right. The pulleys should be more than just 1/4" apart
See all the photos in this ad
http://www.ebay.com/itm/03-Porsche-9...-/281248090380
Here's what happened to mine...
https://rennlist.com/forums/996-foru...al-solved.html
The idler mounting bolt broke off. Not sure you have the same problem, but my issue wasn't obvious at first
I looked at 2 other 996s in the shop and several pictures online and mine seem to be the normal distance apartIn my research though, I called many parts houses and found that the belt length ranged from 83" up until 88"!! So just depends on what brand belt you get I suppose. I got it running last night and it's fine.
This is a source reference. Confirm exact model applicability in the original material.
