Hi there! Did you find the problem at the end? Well I have the same problem mine has an alternator solid pulley as yours, I?think the early ones were like this, my picasso is now at 187k!! Yes not an issue,apart form servicing it. Bought it in uk and moved it to Uruguay, this place is a car hell dusty,hot full of nassive pot holes!, but she still going!!.
The flapping belt problem is been there from the 110k replacing belts time to time tensioners,Idler,crank pulley, at the end the alternator pulley which was alloy was worn out,and the belt was slipping always at idle a lot, today foud a new similar pulley from a 206 wich I had to shim up to align with the belt! (Cant!get just the pulley over here!) Right stopped slipping but the flapping returned with!the horrible tensioner rumbling, worse when cold!.
So I am a car mechanic I have a workshop, once I modified an old automatic tensioner, to make it fixed, and using a shorter belt than the stock 6pk1740, managed to get it tight using the manual tensioner at the bottom, fine for 2 days then the belt started falling apart!!.
So bought a new original tensioner still the same, again it gets worse when cold under and under more electrical load,alternator charges at 14.something spins with no play no drag,bearings are ok, so still as yours just the alternator to try, and!the batery.
for some reason this batery has 8 years!! Still starting at the flick of the key, it might take more power to charge it and that could be the problem? Is a euro ac delco, over here Im fitting the brazil ac delco ones to my customers and only last 3 years!
Any help will be apreciated thanks!!!
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