Pulley alignment

[2.3 belt]

Hi
I have a 2001 2.3 galaxy Ghia. Which has has a squealing belt since I bought it. Was told it was the tensioner pulley but upon investigation it was the tensioner itself.
I have replaced the tensioner and the pulley plus the idler pulley and fitted a new belt and the noise disappeared for a few hundred miles then returned as a 'chirp' then a squeal at higher revs.
     I have now came to the conclusion that one of the pulleys is misaligned. I have checked all the pulleys and there is no significant play in any of them (very slight in water pump pulley) also the belt is wearing on the outside and running very close to the edge of the idler pulley.
     As the next component after the idler is the water pump would it be wise to assume that this is the misaligned pulley? Pulling the belt to the edge of the idler and thus causing the 'chirp'?
Or could it possibly be the aircon compressor clutch??
Any help would be greatly received don't wanna start changing components for the sake of it.

[insanitybeard]

Did you use genuine or aftermarket replacement parts? Unfortunately auxiliary belt/tensioner issues are by all accounts fairly common with the 2.3 petrol engine, do all the other pulleys (e.g, power steering pump, alternator, a/c compressor) spin ok by hand with the belt removed? If for example the air con compressor was starting to bind or was in the early stages of seizing then that could cause issues, though you wouldn't necessarily be able to detect that just by spinning the compressor by hand. Does the noise get worse if the air con is on or the steering is hard over on full lock for example?

[2.3 belt]

Thanks
Yes all gen ford parts used.
All pulleys turn freely by hand. Noise no worse with steering lock on.
Only reason for suspecting air con was that the air con does not work (needs Regas) and the clutch still engages now and then which could explain the noise. Can the pulley/clutch be adjusted or is it a one for one change? Can the belt be changed and re routed to by pass the air con compressor??

[insanitybeard]

You may be able to adjust the compressor clutch by means of different thickness shim washers but for most intents and purposes it's not really a repairable/ adjustable unit. Compressor and clutch problems aren't unusual on the Galaxy either. You could potentially bypass the compressor but this depends on you being able to find a shorter belt exactly the right length to pass round all the other pulleys (assuming you can route a belt satisfactorily whilst bypassing the compressor) and still be able to be adequately tensioned by the tensioner.

[2.3 belt]

Thanks again
Think it is the compressor causing the probs as when clutch egaged noise changes.
I will look tonight and see if it has moved in its mounts and is pulling the belt drive system out of line!

[2.3 belt]

Update!
So I removed the compressor and stripped it down clutch plate non existent so have removed it and replaced the compressor. Result grindinding noise gone (no surprise) but annoying chirpy squeak still present.
Next I removed the belt and compared to the old belt! New belt was slight bigger although both say 1570mm do I refitted the old belt and reversed it. RESULT!! Noise completely gone. Genius? no after driving 100 miles noise is back. Which to me suggests one of the pulleys is out of line or is it that the belt supplied is to small and the idler pulley is now damaged again?? All the components seem fine and look in line but without a laser u can't tell if the out of line!
Any ideas?
Anyone had this prob before?

[insanitybeard]

Can you determine which one of the pulleys is responsible for the making the chirping noise? Normally most of the components driven by the auxiliary drive belt (A/C compressor, alternator etc) are located onto the engine block or brackets with dowels or bushes so they are rigid when bolted up and can't move on their mountings, meaning that if something is out of line it's either because of a manufacturing fault or a design flaw (or wear of a component). Like I say, I'm sure I've heard several tales of this kind of issue on the 2.3 petrol Galaxy so it's not uncommon.