Content .. 66 67 68 69 ..

Chrysler Town, Dodge Caravan. Manual - part 68

INSTALLATION

GENERATOR AND AIR CONDITIONING BELT

(1) Install belt onto all pulleys except for the

crankshaft (Fig. 5).

(2) Rotate belt tensioner clockwise until belt can

be installed onto the crankshaft pulley (Fig. 2).
Slowly release belt tensioner.

(3) Verify belt is properly routed and engaged on

all pulleys (Fig. 5).

(4) Install drive belt shield (Fig. 7) and lower vehi-

cle.

POWER STEERING PUMP

(1) Install belt over crankshaft and power steering

pump pulleys (Fig. 5).

(2) Apply an initial snug torque to pivot bolt (3)

and front locking nut (2) (Fig. 3).

(3) Tighten adjusting bolt (4) until proper belt ten-

sion is obtained (Fig. 3). For belt tension check pro-
cedure, (Refer to 7 - COOLING/ACCESSORY DRIVE/
DRIVE

BELTS

STANDARD

PROCEDURE

CHECKING POWER STEERING BELT TENSION).

(4) Tighten pivot bolt (3) and front locking nut (2)

to 54 N·m (40 ft. lbs.) (Fig. 3).

(5) Tighten rear locking nut (1) to 54 N·m (40 ft.

lbs.) (Fig. 3).

ADJUSTMENTS

Satisfactory performance of the belt driven accesso-

ries depends on proper belt tension. Belt tensioning
should be performed with the aid of Special Tool
7198. Because of space limitations in the engine com-
partment, the use of this gauge may be restricted.
Raise the vehicle on a hoist and the remove the
splash shield to gain access to the drive belts, if nec-
essary. Adjust belt tension for either a New or Used
belt. For specifications, (Refer to 7 - COOLING/AC-
CESSORY DRIVE - SPECIFICATIONS).

BELT TENSIONER - 2.4L

REMOVAL

(1) Raise vehicle on hoist.
(2) Remove the drive belt shield.
(3) Remove the generator/A/C drive belt. (Refer to

7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)

(4) Remove the belt tensioner (Fig. 6).

INSTALLATION

(1) Install belt tensioner and bolt (Fig. 6). Tighten

bolt to 54 N·m (40 ft. lbs.).

(2) Install generator/A/C compressor drive belt.

(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE
BELTS - INSTALLATION)

(3) Install splash shield.
(4) Lower the vehicle.

Fig. 5 Accessory Drive Belts - 2.4L

1 - POWER STEERING PUMP PULLEY
2 - BELT TENSIONER
3 - GENERATOR PULLEY
4 - BELT - A/C AND GENERATOR
5 - A/C COMPRESSOR PULLEY
6 - CRANKSHAFT PULLEY
7 - BELT - POWER STEERING

Fig. 6 Belt Tensioner - 2.4L

1 - BELT TENSIONER
2 - GENERATOR BRACKET
3 - BOLT

7 - 10

ACCESSORY DRIVE

DRIVE BELTS - 2.4L (Continued)

DRIVE BELTS - 3.3/3.8L

REMOVAL

(1) Raise vehicle on hoist.
(2) Remove the drive belt shield (Fig. 7).

WARNING: DO NOT ALLOW DRIVE BELT TEN-
SIONER TO SNAP BACK, AS DAMAGE TO TEN-
SIONER

AND/OR

PERSONAL

INJURY

COULD

RESULT.

(3) Position a wrench on the belt tensioner lug

(Fig. 8).

(4) Release belt tension by rotating the tensioner

counterclockwise (Fig. 8).

(5) Remove the drive belt (Fig. 10).
(6) Carefully return tensioner to its relaxed posi-

tion.

CLEANING

Clean all foreign debris from belt pulley grooves.

The belt pulleys must be free of oil, grease, and cool-
ants before installing the drive belt.

INSPECTION

Belt replacement under any or all of the following

conditions is required:

• Excessive wear

• Frayed cords

• Severe glazing
Poly-V Belt system may develop minor cracks

across the ribbed side (due to reverse bending). These
minor cracks are considered normal and acceptable.
Parallel cracks are not (Fig. 9).

NOTE: Do not use any type of belt dressing or
restorer on Poly-V Belts.

Fig. 7 Accessory Drive Belt Shield

1 - ATTACHING SCREW
2 - ATTACHING SCREWS
3 - SPLASH SHIELD

Fig. 8 DRIVE BELT TENSION RELEASE

1 - BELT TENSIONER LUG
2 - WRENCH

Fig. 9 Drive Belt Wear Pattern

1 - NORMAL CRACKS - BELT OK
2 - NOT NORMAL CRACKS - REPLACE BELT

ACCESSORY DRIVE

7 - 11

INSTALLATION

(1) Route and position the drive belt onto all pul-

leys, except for the crankshaft (Fig. 10).

(2) Rotate belt tensioner counterclockwise until

belt can be installed onto the crankshaft pulley (Fig.
8). Slowly release belt tensioner.

(3) Verify belt is properly routed and engaged on

all pulleys.

(4) Install drive belt shield (Fig. 7) and lower vehi-

cle.

BELT TENSIONER - 3.3/3.8L

REMOVAL

(1) Raise vehicle on hoist.
(2) Remove the drive belt shield.
(3) Remove the drive belt. (Refer to 7 - COOLING/

ACCESSORY DRIVE/DRIVE BELTS - REMOVAL)

(4) Remove the belt tensioner (Fig. 11).

INSTALLATION

(1) Install the belt tensioner and bolt (Fig. 11).

Tighten bolt to 28 N·m (250 in. lbs.).

(2) Install the drive belt. (Refer to 7 - COOLING/

ACCESSORY DRIVE/DRIVE BELTS - INSTALLA-
TION)

(3) Install the drive belt shield.
(4) Lower the vehicle.

Fig. 10 ACCESSORY DRIVE BELT

1 - DRIVE BELT
2 - POWER STEERING PUMP PULLEY
3 - BELT TENIONER PULLEY
4 - IDLER PULLEY
5 - GENERATOR PULLEY
6 - AIR CONDITIONING COMPRESSOR PULLEY
7 - CRANKSHAFT PULLEY
8 - WATER PUMP PULLEY

Fig. 11 BELT TENSIONER - 3.3/3.8L

1 - BELT TENSIONER
2 - BOLT

7 - 12

ACCESSORY DRIVE

DRIVE BELTS - 3.3/3.8L (Continued)

ENGINE

TABLE OF CONTENTS

page

ENGINE

DIAGNOSIS AND TESTING - ENGINE

COOLING SYSTEM

. . . . . . . . . . . . . . . . . . . . 14