I have a 1993 SH 2.4 Express 4WD and have had a lot of trouble getting the right length fan belt (which also goes round the alternator). The standard length is 1005mm but that is a fraction too long - I can't tighten it as much as is recommended, so it is on the verge of slipping. I tried the next shorter belt (Bosch) of 990mm, and it won't go on, it seems there isn't enough movement in the alternator to get it on. When I was buying the shorter belt, I asked the local spare parts guy if there was a size between those two, in case the short one wouldn't go on. He said there isn't, but he's been doing this for 19 years and no-one has ever got caught needing an in-between size that doesn't exist and "you won't be the first" (i.e. there will always be enough adjustment). You can guess what happened when I took it home! It wasn't even close to going on. These two belts were 13mm wide. There was an old random spare belt at home that by luck fit nicely and it was only 965mm - it seems it fitted because it's only 11mm wide so it sits deeper in the pulley, thus decreasing the length needed. Yet even at 11 inches (rather than the standard 13mm) it seems a fraction too wide for the pulley.

This belt sits behind two other belts (power steering, and air con) and has been frustrating and time consuming. Can anyone enlighten me as to what's going on? And yes I do use the belt adjusting bolt, not just the alternator mounting bolt!
Thanks.

Put the belt on the alternator pulley 1st mate. Then start the belt on the crank pulley. (it probably won't go on but try to get the belt started at the top). Then rotate the crank (19mm socket clockwise) and it'll pull the belt on. You might have to hand feed it on at the start but it will go. Oh yeh make sure you're in neutral and the keys OFF before trying this.

A belt will always go onto a bigger pulley easier than a smaller one. This is accompanied with the "V" groove on the alternator is why it won't go.

Hope this helps.