help please with problem refitting alternator

[drunknmunky]

So I'm rejuvenating the mr2 after being parked up for 18 months, alternator had seized so got it out and had it reconditioned. The problem refitting is I can't get the bottom section of the casing into the bracket.
It took some 'gentle persuasion' to get it out, but it appears as if the bracket is about 3mm to narrow. Anybody else had this, or is it common and just takes some more persuasion to refit??
Thanks in advance all.

[mr2garageswindon]

Where the bottom bolt goes through there is a movable bush type thing which probably needs a tap with a hammer to make it fit. When doing it back up it moves to take up the clearance to the bracket.

[drunknmunky]

Thankyou so much, I've been swearing at it for it feels like forever!!

[aussieGT]

Where the bottom bolt goes through there is a movable bush type thing which probably needs a tap with a hammer to make it fit.

I had to take my bracket out and use Thors' hammer to 'tap' mine.

They get a build up corrosion behind the lip, thats what pushes them out making alternators &*%$ to get out and close to impossible to get a new one in.

Drift the xxxxxx out, buy a new bush/collar thing and re-install.

[drunknmunky]

Ok, so having some problems, please help. As soon as I turn the key, the alternator seizes up. I've had it reconditioned so in theory is as good as new.
I install the bracket (3 bolts 2 nuts) then the alternator (2 bolts and tension and plug and earth) so is there something I'm missing. This is getting ridiculous, it's not rocket science but I'm at a complete loss.
Is there anyone local to Nuneaton that wouldn't mind coming to look, maybe try a spare unit in place, that way I would know if the recon is no good.
Please somebody help, I'm ready to throw my spanners away!!

[MartinF]

Did you check it all rotated freely before you fitted it ?

Also when you look down from above are all the pulleys lined up, i.e. the belt is running true. ?

[drunknmunky]

Yep, everything spun free and lined up perfectly, just as soon as I turned it over it locks up.

[MartinF]

Weird.

Are you able to provide a picture looking down from above showing the belt and how it is fitting in the pulley between the alternator and crank ?

[drunknmunky]

I don't know how to add images on here to be honest.

[aussieGT]

Could you have over tightened the belt in a massive way? That could stop it moving. Maybe.

[drunknmunky]

Don't think so, was able to easily put a full half twist into the belt with just a finger and thumb, at the middle point between the two pulleys. Tis what I was always told that would make tension about right.

[drunknmunky]

So finally, it lives again turns out, there was a small crack in the bottom bolt section of the casing, and when tightening the bolt, it was distorting the housing slightly, just enough to stop it spinning. Of course, as soon as it was undone it would spin again which is why it was so hard to find!
Many thanks to all that tried to help, I'm sure. I'll need more before everything is sorted :-S

[MartinF]

Well done on finding it, was a bit unusual !!