Intercooler Install - Extremely Tight Supercharger Belt

**BadDecisions** · 04-11-2020

Hey guys,

I bought a full stack intercooler off one of the guys on the forum last year (big thanks btw) and I'm finally getting around to installing it thanks to this quarantine. The install of the intercooler core has gone pretty smooth so far. Now I'm running into 2 small issues.

#1 - The supercharger has a 3.4" pulley on it right now and I believe I have the correct belt (6K685). The issue lays in the fact that the tensioner seems completely bottomed up and the belt was a STRUGGLE to get on. There seems to be no play whatsoever in the belt or tensioner now.

#2 - Relates to #1 - The belt rubs on the underside of the coil pack mount. Obviously I know this has to be corrected. I have read that adding some washers to raise the coil pack plate and grinding away some of the mount will do the trick. In machinegunsquids write up he also mentions that you can relocate the coil packs but I cannot find the write up. I'm following his install process pretty closely.

If anyone can give me any pointers it would be EXTREMELY appreciated.

Thanks guys!

Matt

**Scottydoggs** · 04-11-2020

spacers under the icm, and get a longer belt.

**BillBoost37** · 04-12-2020

Or You can grind part of the coil pack bracket after removing them (about 1/4") and move them over. I proved it out and took pics. They should be somewhere on here in the how to section.

**BillBoost37** · 04-12-2020

How to clearance your stock cast bracket for an intercooler and belt BillBoost way

**Scottydoggs** · 04-12-2020

i did the billboost cut and grind method too.

https://oi1097.photobucket.com/album...=1586733132667

**BadDecisions** · 04-12-2020

I got the coil pack issue sorted. Trimmed the mount and added spacers underneath.

Belt is still super tight. On the ZZP website they recommend the 6K685 (which is what I have) for 3.3"+ pulleys. I was hoping to run a 3.5" first to see if I had any KR before I drop to the 3.4"...but theres ZERO chance of that belt fitting.

Obviously I'm going to go grab a large belt, I was more curious if anyone else ran into this issue. I cant see what ZZP would recommend it if i really doesnt work.

Of course I may have misread something but it just seems odd.

**Scottydoggs** · 04-12-2020

i just go to the parts store and ask for a few belts and go test fit em, buy what works.

**BadDecisions** · 04-13-2020

That's the plan. This COVID bs really throws a wrench in it though

**Scottydoggs** · 04-13-2020

it sure is. all my parts stores are open here in NJ still. found a open one yesterday of all days.

**BadDecisions** · 04-13-2020

Parts stores are "open" here too (Niagara Falls, Canada) but for curbside pick up only...which makes guessing at things a little more difficult.

FORTUNATELY I was able to guess right on the usable belt size. So for anyone wondering or in a similar spot, grab either

AC Delco 6K695
Dayco 5060695

Fits like a glove