1993 capri non turbo. alternator pulley gets so hot that belt will burn after a few minutes of running. the dash indicator shows it is losing charge. alternator passes bench test. seems like alternator is trying to charge but resistance somewhere in system. starter connections are clean and tight.
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Disconnect the Red battery terminal first and then loosen the serpentine belt by moving the tensioner pulley with the correct socket to permit slack enough to dislodge the serpentine belt from any pulley such as the idler pulley or other pulley. Pay close attention of how the belt is routed prior to removing. Remove electrical connections to the alternator. Remove all alternator mounting bolts to remove the alternator. I would recommend a Haynes manual from the parts store on your vehicle. I will help you now and well into the future with all problems that may occur. Be sure you have a fully charged battery at all times as a low battery will cause the internal voltage regulator to over heat and burn up due to the need for more amperage than the alternator can generate.
Most after market replacement alternators have the wrong pulley installed...the shafts are different sizes, so you cannot even use your old pulley. Best is to have the original alternator rebuilt. Alternative is to use a heavy duty industrial belt, like a Gates...not a perfect solution, but it will help...good luck...Chris
Could be the belt or tensioner(if so equipped) was too tight and then it may have warped the pulley or ruined the alternator. The belt smoking could definately be overtensioned or the bearings are shot in the alternator and creating the friction in your belt. Check the tension specs for most vehicles is usually between 1-1/2 to 2 inches of play. Thats how far your belt can be moved up and down by hand after tensioned. Too tight and you risk burning up bearings in other places or too loose and you hear squeeking and the vehicle may not charge properly or even overheat from water pump not turning well enough.
If the car was running great and then all of a sudden it started this problem and you did not change the timing belt. Then I would say its not your timing belt. Once a timing belt is on its stays timed until it breaks, unless it looses a tooth on the belt and at that point it would run really ruff all the time or not at all. If it cranks well and idles with a small skip but when you add gas it get worse. I would look at your fuel injectors and spark plugs and wires. start simple and work towards the big stuff. most of the time its simple like plugs and wires or gummed up injectors. Run some good injector cleaner as well. Hope this helps