Jeep Wrangler TJ. Manual - part 263

INSTALLATION). Connect the radiator hoses. Refill
the cooling system with the correct antifreeze/water
mixture (Refer to 7 - COOLING - STANDARD PRO-
CEDURE).

SPECIFICATIONS

TORQUE

DESCRIPTION

N·m

Ft.

Lbs.

In.

Lbs.

Automatic Belt Tensioner to
Mounting Bracket - 2.4L

Bolt, Automatic Belt Tensioner
Pulley - 2.4L

Bolt, Block Heater - 2.4L

Bolts, Condenser to Radiator

Bolts, Coolant Overflow Bottle
to Plenum - 2.4L only

8.5

Electric Fan to Fan Shroud
bolts

5.5

Bolts, 3.7LFan Blade Assy. to
Viscous Drive

210

Bolts, Fan Shroud to Radiator
Mounting

Bolts, Radiator Upper Isolator
to Crossmember

9.5

Bolts, Thermostat Housing -
2.4L

250

Bolts, Water Pump

2.4L

105

4.0l

200

SPECIAL TOOLS

COOLING

Pliers 6094

Adapter Pins 8346

Spanner Wrench 6958 with 8346 adapter pins

Pressure Tester 7700–A

Coolant Refractometer 8286

COOLING

7 - 13

COOLING (Continued)

ACCESSORY DRIVE

TABLE OF CONTENTS

page

ACCESSORY DRIVE

SPECIFICATIONS

BELT TENSION

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

BELT TENSIONERS

DESCRIPTION

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

REMOVAL

REMOVAL - 2.4L ENGINE

. . . . . . . . . . . . . . . 15

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . 15

INSTALLATION

INSTALLATION - 2.4L ENGINE

. . . . . . . . . . . 15

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . 16

DRIVE BELTS - 2.4L

DIAGNOSIS AND TESTING - ACCESSORY

DRIVE BELT

. . . . . . . . . . . . . . . . . . . . . . . . . 16

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . 19

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . 19

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . 19

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . 21

ACCESSORY DRIVE

SPECIFICATIONS

BELT TENSION

Belt tension can not be adjusted. Refer to the fol-

lowing Belt Tension chart for specifications.

DESCRIPTION

N·m

Lbs. ft.

New Serpentine Belt*

800-900

180-200

Used Serpentine Belt

623-712

140-160

* Belt is considered new if it has been used 15

minutes or less.

BELT TENSIONERS

DESCRIPTION

The automatic belt tensioner (Fig. 1) is a spring

loaded arm and pulley assembly. The tensioner
assembly is designed to apply constant pressure on
the accessory drive belt to maintain proper belt ten-
sion. There are three marks on the tensioner body,
these marks are there to indicate belt wear and belt
tension.

NOTE: On 4.0L engines, the tensioner arm has
three marks. Upon installation of a new belt, the
double line marks close to each other should be
very close to the mark on the base. The belt should
be replaced if the single line mark lines up with the
mark on the base.

Fig. 1 Accessory Drive Belt Wear Indicator - 4.0L

Engine

1 - INDICATOR MARK
2 - MINIMUM TENSION MARK
3 - MAXIMUM TENSION MARK

7 - 14

ACCESSORY DRIVE

REMOVAL

REMOVAL - 2.4L ENGINE

NOTE: The belt routing schematics are published
from the latest information available at the time of
publication. If anything differs between these sche-
matics and the Belt Routing Label, use the sche-
matics on Belt Routing Label. This label is located
in the engine compartment.

CAUTION: DO NOT LET TENSIONER ARM SNAP
BACK TO THE FREEARM POSITION, SEVERE DAM-
AGE MAY OCCUR TO THE TENSIONER.

Belt tension is not adjustable. Belt adjustment is

maintained by an automatic (spring load) belt ten-
sioner.

(1) Disconnect negative battery cable from battery.
(2) Rotate belt tensioner until it contacts its stop.

Remove belt, then slowly rotate the tensioner into
the freearm position.

REMOVAL

On 4.0L engines, the tensioner arm has three

marks. Upon installation of a new belt, the dou-
ble line marks close to each other should be
very close to the mark on the base. The belt
should be replaced if the single line mark lines
up with the mark on the base.

If the above specification cannot be met, check for:
• The wrong belt being installed (incorrect length/

width)

• Worn bearings on an engine accessory (A/C com-

pressor, power steering pump, water pump, idler pul-
ley or generator)

• A pulley on an engine accessory being loose

• Misalignment of an engine accessory

• Belt incorrectly routed.

NOTE: A used belt should be replaced if tensioner
indexing arrow has moved to the minimum travel
indicator. Tensioner travel stops at this point.

(1) Remove accessory drive belt (Refer to 7 -

COOLING/ACCESSORY

DRIVE/DRIVE

BELTS

REMOVAL).

(2) Remove tensioner assembly from mounting

bracket (Fig. 2).

WARNING: BECAUSE OF HIGH SPRING TENSION,
DO NOT ATTEMPT TO DISASSEMBLE AUTOMATIC
TENSIONER. UNIT IS SERVICED AS AN ASSEMBLY.

INSTALLATION

INSTALLATION - 2.4L ENGINE

Belt tension is not adjustable. Belt adjustment is

maintained by an automatic (spring load) belt tensioner.

(1) Check condition of all pulleys.

CAUTION: When installing the serpentine accessory
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to the water pump
rotating in the wrong direction.

(2) Install new belt (Fig. 3) or (Fig. 4). Route the

belt around all pulleys except the idler pulley. Rotate
the tensioner arm until it contacts its stop position.
Route the belt around the idler and slowly let the
tensioner rotate into the belt. Make sure the belt is
seated onto all pulleys.

(3) With the drive belt installed, inspect the belt

wear indicator. On 2.4L Engines the gap between the
tang and the housing stop (measurement A) must not
exceed 24 mm (.94 inches).

Fig. 2 Automatic Belt Tensioner - 4.0L Engine

1 - IDLER PULLEY TIGHTEN TO 47 N·m (35 FT. LBS.)
2 - AUTOMATIC BELT TENSIONER
3 - GENERATOR MOUNTING BRACKET

ACCESSORY DRIVE

7 - 15

BELT TENSIONERS (Continued)

INSTALLATION

(1) Install

tensioner

assembly

mounting

bracket, align the two dowels on the tensioner with
the mounting bracket and hand start the bolt.
Tighten bolt to 28 N·m (250 in. lbs.).

(2) Install accessory drive belt (Refer to 7 - COOL-

ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).

(3) Check belt indexing marks.

DRIVE BELTS - 2.4L

DIAGNOSIS AND TESTING - ACCESSORY
DRIVE BELT

VISUAL DIAGNOSIS

When diagnosing serpentine accessory drive belts,

small cracks that run across the ribbed surface of the
belt from rib to rib (Fig. 5), are considered normal.
These are not a reason to replace the belt. However,
cracks running along a rib (not across) are not nor-
mal. Any belt with cracks running along a rib must
be replaced (Fig. 5). Also replace the belt if it has
excessive wear, frayed cords or severe glazing.

Refer to the ACCESSORY DRIVE BELT DIAGNO-

SIS CHART for further belt diagnosis.

Fig. 3 Belt Routing 2.4L With A/C

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

Fig. 4 Belt Routing 2.4L Without A/C

1 - IDLER PULLEY
2 - GENERATOR PULLEY
3 - IDLER PULLEY
4 - POWER STEERING PUMP PULLEY
5 -CRANKSHAFT PULLEY
6 - TENSIONER
7 - NON A/C IDLER PULLEY
8 - ACCESSORY DRIVE BELT

Fig. 5 Belt Wear Patterns

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

7 - 16

ACCESSORY DRIVE

BELT TENSIONERS (Continued)

Content .. 261 262 263 264 ..