Chrysler Caravan/Voyager/Town and Country 1996-1999

Belts

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INSPECTION



See Figures 1, 2, 3, 4 and 5

Inspect the belts for signs of glazing or cracking. A glazed belt will be perfectly smooth from slippage, while a good belt will have a slight texture of fabric visible. Cracks will usually start at the inner edge of the belt and run outward. All worn or damaged drive belts should be replaced immediately. It is best to replace all drive belts at one time, as a preventive maintenance measure, during this service operation.



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Fig. Fig. 1: There are typically 3 types of accessory drive belts found on vehicles today



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Fig. Fig. 2: An example of a healthy drive belt



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Fig. Fig. 3: Deep cracks in this belt will cause flex, building up heat that will eventually lead to belt failure



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Fig. Fig. 4: The cover of this belt is worn, exposing the critical reinforcing cords to excessive wear



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Fig. Fig. 5: Installing too wide a belt can result in serious belt wear and/or breakage

ADJUSTMENT



2.4L Engine
A/C COMPRESSOR AND ALTERNATOR DRIVE BELT

See Figure 6

  1. Disconnect the negative battery cable.
  2.  
  3. Loosen the locknut at the top and pivot bolt at the bottom of the alternator.
  4.  
  5. Adjust the belt by rotating the adjusting bolt until the correct tension is reached. A new belt should be adjusted to 130-150 lbs. tension. A used belt should be adjusted to 80-90 lbs. tension.
  6.  
  7. After the belt is properly adjusted, tighten the pivot bolt and locknut to 40 ft. lbs. (54 Nm).
  8.  
  9. Connect the negative battery cable.
  10.  



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Fig. Fig. 6: A/C compressor and alternator belt adjustment on the 2.4L engine

POWER STEERING PUMP DRIVE BELT
  1. Disconnect the negative battery cable.
  2.  
  3. From above the vehicle, loosen the locking nuts at the top of the power steering pump.
  4.  
  5. Raise and safely support the front of the vehicle securely on jackstands.
  6.  
  7. From underneath the vehicle, loosen the pivot bolt at the bottom of the power steering pump.
  8.  
  9. Rotate the adjusting bolt above the power steering pump to adjust the belt tension. A new belt should be adjusted to 130-150 lbs. tension. A used belt should be adjusted to 80-90 lbs. tension.
  10.  
  11. After the belt is adjusted properly, tighten the pivot bolt to 40 ft. lbs. (54 Nm).
  12.  
  13. Lower the vehicle.
  14.  
  15. Tighten the locking nuts to 40 ft. lbs. (54 Nm).
  16.  
  17. Connect the negative battery cable.
  18.  

3.0L Engines
AIR CONDITIONING COMPRESSOR BELT

See Figure 7



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Fig. Fig. 7: Air conditioning compressor belt locknut (A) and adjuster bolt (B) location

  1. Disconnect the negative battery cable.
  2.  
  3. Loosen the locknut on the idler pulley.
  4.  
  5. Loosen the adjuster bolt on the idler pulley.
  6.  
  7. Adjust to specification by tightening the adjusting screw.
  8.  
  9. Tighten the idler pulley locknut to 40 ft. lbs. (55 Nm).
  10.  
  11. Connect the negative battery cable.
  12.  

ALTERNATOR/POWER STEERING PUMP BELT

The alternator/power steering pump belt is provided with a dynamic tensioner to maintain proper belt tension.

3.3L and 3.8L Engines

All of the belt driven accessories on the 3.3L and 3.8L engines are driven by a single serpentine belt. The belt tension is maintained by am automatic tensioner.

REMOVAL & INSTALLATION



2.4L Engine
A/C COMPRESSOR AND ALTERNATOR DRIVE BELT

See Figure 8



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Fig. Fig. 8: Accessory drive belt routing for the 2.4L engine

  1. Disconnect the negative battery cable.
  2.  
  3. Loosen the locknut at the top and pivot bolt at the bottom of the alternator.
  4.  
  5. Rotate the adjuster screw , on top of the alternator, to decrease the belt tension.
  6.  
  7. Take note of the exact routing of the belt prior to removal. Lift the drive belt from the pulleys and remove it from the engine compartment.
  8.  

To install:
  1. Position the replacement belt around the pulleys, making sure the belt routing is correct.
  2.  
  3. Adjust the belt by rotating the adjusting bolt until the correct tension is reached. Refer to the procedure earlier in this section for belt adjustment.
  4.  
  5. After the belt is installed and/or properly adjusted, tighten the pivot bolt and locknut to 40 ft. lbs. (54 Nm).
  6.  
  7. Connect the negative battery cable.
  8.  

POWER STEERING PUMP DRIVE BELT

See Figure 8

  1. Disconnect the negative battery cable.
  2.  
  3. From above the vehicle, loosen the locking nuts at the top of the power steering pump.
  4.  
  5. Raise and safely support the front of the vehicle securely on jackstands.
  6.  
  7. From underneath the vehicle, loosen the pivot bolt at the bottom of the power steering pump.
  8.  
  9. Loosen the adjusting bolt above the power steering pump. With the tension released, remove the drive belt.
  10.  

To install:
  1. Install the drive belt around the crankshaft and power steering pump pulleys.
  2.  
  3. Rotate the adjusting bolt clockwise to adjust the belt tension. Refer to the procedure earlier in this section for belt adjustment.
  4.  
  5. After the belt is installed and/or adjusted properly, tighten the pivot bolt to 40 ft. lbs. (54 Nm).
  6.  
  7. Lower the vehicle.
  8.  
  9. Tighten the locking nuts to 40 ft. lbs. (54 Nm).
  10.  
  11. Connect the negative battery cable.
  12.  

3.0L Engines
AIR CONDITIONING COMPRESSOR BELT

See Figures 9 and 7



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Fig. Fig. 9: Accessory drive belt routing for the 3.0L engine. The roting diagram can be found in the engine compartment

  1. Disconnect the negative battery cable.
  2.  
  3. Loosen the locknut on the idler pulley.
  4.  
  5. Loosen the adjuster bolt on the idler pulley.
  6.  
  7. Remove the belt and install a replacement.
  8.  
  9. Adjust to specification by tightening the adjusting screw.
  10.  
  11. Tighten the idler pulley locknut to 40 ft. lbs. (55 Nm).
  12.  
  13. Connect the negative battery cable.
  14.  

ALTERNATOR/POWER STEERING PUMP BELT

See Figures 9 and 10



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Fig. Fig. 10: Alternator/power steering pump belt tensioner bolt location

The alternator/power steering pump belt is provided with a dynamic tensioner to maintain proper belt tension.

  1. Disconnect the negative battery cable.
  2.  
  3. Raise the front of the vehicle and safely support it with jackstands.
  4.  
  5. Remove the right front splash shield.
  6.  
  7. Release tension by rotating the tensioner clockwise.
  8.  
  9. Remove the belt and install a replacement.
  10.  
  11. Proper belt tension is maintain by the dynamic tension.
  12.  
  13. Install the right front splash shield. Lower the front of the vehicle.
  14.  
  15. Connect the negative battery cable.
  16.  

3.3L and 3.8L Engines
ACCESSORY DRIVE BELT

See Figure 11



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Fig. Fig. 11: Accessory drive belt adjustment-3.3L and 3.8L engines

All of the belt driven accessories on the 3.3L and 3.8L engines are driven by a single serpentine belt. The belt tension is maintained by am automatic tensioner.

  1. Disconnect the negative battery cable.
  2.  
  3. Raise the front of the vehicle and safely support it with jackstands.
  4.  
  5. Remove the right front splash shield.
  6.  
  7. Release tension by rotating the tensioner clockwise.
  8.  
  9. Remove the belt and install a replacement.
  10.  
  11. Proper belt tension is maintain by the dynamic tension.
  12.  
  13. Install the right front splash shield. Lower the front of the vehicle.
  14.  
  15. Connect the negative battery cable.
  16.  

 
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