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FWIW i changed the alternator pulley by using a impact with a 15/16" socket. Leave the belt on the alternator and take off the accessory belt then remove the stock 2 3/8" pulley.
Next put on the new 1 3/4 alternator pulley finger tighten the nut, put the new accessory belt (77") on then tighten down to 28ft lbs. start at 20 ftlbs finish at 28.
well i got the new starter put on last night and with the Kooks Lt's it a PITA!!! i had to take the right side header all the way off to get the starter loose and install the new one. The good news is that the car now reads 13.7-13.9 volts (with UD pulley and Overdrive Alternator Pulley) with the high beams on, flashers running, traction control on, and AC fan on high!!
For anyone wondering the bolts on the starter (solenoid) work like a T-bolt but you must have 2 NUTs on each brass bolt!! the first secures the brass bolt on the solenoid from wiggling and the second holds your wires into place. That is why my first starter had loose bolts and it appears that in had been that way for long enough to melt the plastic on top of the solenoid cap!!
I recently had a similar problem. Everything has been fine but today the AC and radio lights were flickering bad, and voltage at the dic was all over the place. 11.3 to 15. I read this thread and went out and tightened the battery connections, now all is fine. 13.7 at idle with everything on.
My 02 was doing fine but then I got a charging system failure immediately after start up but then goes away as soon as the alternator kicks in. I'm running about 13.9 to 14.3 after start up. I purchased a new battery and now no more system failures.
I got the same thing after changing plugs the day i go my tune. I had recently installed the headers as well, but had no issue at that point. I did have three loose plugs wires but didn't know if that had any effect. Could this be a starter issue as well? I haven't been able to work on the car due being out of state for a month and have thought it was the alternator. This does provide some good insight into the issue.