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I've installed a 3" pulley, it isn't too small. I also have a 3.1" on my car, that dosen't make noise either... it could be that there is anti-sieze on the belt, nothing he wrote indicated that it's the tensioner, and only the tensioner. That is another thing to check though... There's othe Cobalts running around with a 3" pulley...
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'05 Stage 2 Redline -One of the few Red REDlines
Sp00n's HP Tuned GM Stage 2, K&N CAI, SFPH 2.8" Pulley, GMPP Exhaust Manifold, B&M Shifter, Eibach Drop, GMPP Rotors, JBP Brake Lines, URC-Subframe, TqForward Strut Bars.
260whp 225wtq
1/4 - 14.0 @ 103.7
Red Red Line Club #001
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