Has any one had any experience with what to do with the belt run on a zetec after you ditch the power steering pump?

Also thinking about changing the altenator for a smaller one as the stock one ways more than a caterham R500 on its own!

Had a few problems here myself. The first thing that you need to look at is, what type of water pump you have. If it is an old escort one the pulley will be ribbed as it runs on the inside of the belt, if it is a mondeo or focus one is will probably be smooth, this will determine your belt configuration. Altough an escort water pump will not cost much.

I mounted my alternator out the front of the engine, it rotates the wrong way but still give me the right voltage and allowed me to have more space round the engine.

Any altenator will do, the smaller the better, all you are really powering is your ignition and lights if you are using it at night, and to recharge after starting of course.

See the picture below for the way I did it.
Rescued attachment alternator.jpg

Based my set up on Siert's info:

http://home.tiscali.nl/~svos/alternator.html

daihatsu charade alternator
custom made pulley by local engineering folks



fabricated own bracket to sierts instructions:

back plate 130 x 91 mm and 5 mm thick..the lugs were 10 mm thick and sized 30 x35mm. But look out as there are different types!! the way they fit to the plate differs...my alternator was with a single broad piece.

drive belt 6 rib 870mm, Falcon Automotive part 6FR870

fabricated bracket to tension belt via two end inlet manifold studs.

and 1.8 16v escort water pump and pulley

water pump pulley from Ford, pump from motorfactor, I asked for stuff for a 1.8 16v "P" reg.

hope this helps

[Edited on 3/11/03 by givemethebighammer]

Some pics
Pic 1
Pic 2
Pic 3

I fitted a kit from Spyder cars, bolts onto off side of the block just above the filter. Allows standard Ford alternator to be used. Nice and easy but cost £80.