323 BJ 1999-model alternator belts keep breaking
 

Hi!

I have a Mazda 323 BJ 1999-model with automatic gear that eats alternator belts for breakfast. I first busted one alternator belt after it had howled for a long time. After a few months the alternator broke and this was replaced, but only a week later another alternator belt broke. This time a new mechanic tok a look at the car and found out that the alternator wheel was 1.5 mm off, and reckoned that this would solve the problem but now the alternator belt howls again and will break if I continue driving the car. Does anyone have any ideas or experiences which this issue? I have checked my battery but the indicator says its fine and all the belt wheels are good as well.

Could you tell us in which way the alternator belt is breaking? Is it tearing through, or are the ridges ripped off?
It should be rather simple to get this fixed. But you need a mechanic who looks into every detail:
Every bearing must be checked. The pulleys must be checked for damages or foreign bodies stuck in the grooves. If the belt squeals the sides of the grooves may need a little bit of sanding to improve friction with the belt. Make sure there is no oil or other fluid leaking on the belt or pulleys. The pulleys must be properly aligned, the tension must be set according to the book. You need to mount a top quality belt such as Gates or an original Mazda belt. Make sure the alternator sits perfectly perpendicular to the belt line and is bolted down so it does not move under load.

It would be wrong to overtension the belt in order to eliminate a squeal. The tension is either set with a spring laded tensioner pulley (consider replacing the whole tensioner including the spring) or it is set with an adjusting bolt.

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I am sorry, I don't have the exact amount of deflection handy. Your mechanic should look it up.
I cannot think of anything else that could cause early belt failure.

the pulley was off by 1.5 mm. did he fix that? how? if the fix was to put on a narrow belt to keep it from rubbing on the edges, that wont work. the grooves will still be off and the belt will break. check that you dont have a washer missing or something. or you might be able to get it back in alignment by using a washer behind the pulley