Chrysler Caravan/Voyager/Town n Country 1984-1995

Drive Belts

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INSPECTION



See Figures 1, 2, 3, 4 and 5

Check the condition and tension of all drive belts every 12,000 miles, or at least once a year. Loose drive belts can lead to poor engine cooling and diminished alternator, power steering pump, air conditioning compressor, or emission air pump output. A belt that is too tight places a strain on the bearings in the driven component.



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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

Replace any drive belt that is glazed, worn, cracked, or stretched to the point where correct adjustment tension is impossible. If two belts are used to drive a component, always replace both belts when replacement is necessary. After installing a new belt, run the engine for ten minutes, shut OFF the engine and recheck the belt tension. Readjust if necessary.

ADJUSTMENT



See Figures 6, 7, 8, 9 and 10



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Fig. Fig. 6: Engine belt tension chart-2.2L engines



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Fig. Fig. 7: Engine belt tension chart-1987-89 2.5L engines



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Fig. Fig. 8: Engine belt tension chart-2.6L engines



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Fig. Fig. 9: Engine belt tension chart-1990-93 models



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Fig. Fig. 10: Engine belt tension chart-1994-95 models

Two popular methods of checking drive belt adjustment are; the Belt Tension Gauge Method and the Belt Deflection Method. The former requires a special gauge and the latter requires a straight edge and scale or just a good eye for measurement. The deflection method will be used in the following belt replacement instructions. A rule of thumb for checking belt tension by the deflection method is to determine the midpoint between two pulleys of the drive belt and press down at that point with moderate thumb pressure. The belt should deflect to the measurement indicated in the following installation procedures. Adjustment is necessary if the belt is either too loose or too tight.


WARNING
A belt adjustment which is either too loose or too tight will eventually damage the accessory that belt is driving. A too loose adjustment allows free-play in the belt which could transfer a whipping motion or shock to the accessory drive pulley. Similarly, a belt which is too tight will preload the accessory bearings, leading to early failure.

REMOVAL & INSTALLATION



See Figure 11

Raise the front of the vehicle, support on jackstands and remove the lower splash shield if access is hampered due to space limitations when changing drive belts.



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Fig. Fig. 11: Support the vehicle, then remove the lower right side splash shield for access to the drive belts

2.2L Engines
A/C COMPRESSOR DRIVE BELT

See Figures 12, 13 and 14



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Fig. Fig. 12: A/C compressor drive belt adjusting points-2.2L engines



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Fig. Fig. 13: Loosening the locking screws for A/C compressor drive belt removal



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Fig. Fig. 14: Removing the A/C compressor drive belt from under the vehicle

  1. Loosen the idler pulley bracket pivot screw and the locking screw.
  2.  
  3. Remove the belt and install a replacement.
  4.  
  5. Using a breaker bar and socket apply torque to the welded nut provided on the mounted bracket to obtain proper tension.
  6.  
  7. Tighten the locking screw first, followed by pivot screw. Tighten to 40 ft. lbs. (55 Nm).
  8.  

ALTERNATOR DRIVE BELT (CHRYSLER TYPE)

See Figures 15 and 16



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Fig. Fig. 15: Alternator belt adjustment-2.2L engine



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Fig. Fig. 16: Loosening the locking screw for alternator drive belt removal

If removal of the alternator belt is required, the A/C belt must first be removed.

  1. Loosen the pivot nut, locking screw, and the adjusting screw.
  2.  
  3. Remove the belt and install a replacement.
  4.  
  5. Adjust to specification by tightening the adjusting screw.
  6.  
  7. Tighten the locking screw to 25 ft. lbs. (34 Nm).
  8.  
  9. Tighten the pivot nut to 30 ft. lbs. (41 Nm).
  10.  

ALTERNATOR DRIVE BELT (BOSCH TYPE)

If removal of the alternator belt is required, the A/C belt must first be removed.

  1. Loosen the pivot nut, locking nut, and adjusting screw.
  2.  
  3. Remove the belt and install a replacement.
  4.  
  5. Adjust to specification by tightening the adjusting screw.
  6.  
  7. Tighten the locking nut to 25 ft. lbs. (34 Nm).
  8.  
  9. Tighten the pivot nut to 30 ft. lbs. (41 Nm).
  10.  

POWER STEERING BELT

If removal of the power steering belt is required, the A/C and alternator belts must first be removed.

  1. Loosen the locking screw, and pivot screw.
  2.  
  3. Remove the belt and install a replacement.
  4.  
  5. Install a 1 / 2 in. breaker bar into the pump bracket slot, apply pressure with the breaker bar and adjust the belt to specification.
  6.  
  7. Tighten the locking screw first, then the pivot screw. Tighten to 40 ft. lbs. (55 Nm).
  8.  

AIR PUMP DRIVE BELT

See Figure 17



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Fig. Fig. 17: Air pump belt adjustment-2.2L engines

When servicing the air pump, use the square holes provided in the pulley to prevent camshaft rotation.

  1. Remove the nuts and bolts retaining the drive pulley cover.
  2.  
  3. Remove the locking bolt and pivot bolt from the pump bracket, then remove the pump.
  4.  
  5. Remove the belt and install a replacement.
  6.  
  7. Position the pump, then install the locking bolt and pivot bolt finger-tight.
  8.  
  9. Install a 1 / 2 in. breaker bar into the bracket assembly (block the drive pulley to prevent camshaft rotation), and adjust the belt to specification.
  10.  
  11. Tighten locking bolt and pivot bolt to 25 ft. lbs. (35 Nm).
  12.  

2.5L Engines
AIR CONDITIONING COMPRESSOR

See Figure 18



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Fig. Fig. 18: Drive belt adjustment points-2.5L engines

  1. Loosen the idler bracket pivot screw and the locking screws to replace, or adjust belt.
  2.  
  3. Remove the belt and install a replacement.
  4.  
  5. Adjust the belt to specification by applying torque to weld nut on the idler bracket.
  6.  
  7. Tighten locking screw first, followed by the pivot screw. Tighten to 40 ft. lbs. (55 Nm).
  8.  

ALTERNATOR BELT

See Figure 18

If replacement of the alternator belt is required, the A/C drive belt must first be removed.

  1. Loosen the pivot nut, locking nut, and adjusting screw.
  2.  
  3. Remove the belt and install a replacement.
  4.  
  5. Adjust the belt to specification by tightening the adjusting screw.
  6.  
  7. Tighten the locking nut to 25 ft. lbs. (35 Nm).
  8.  
  9. Tighten the pivot nut to 30 ft. lbs. (40 Nm).
  10.  

POWER STEERING PUMP

See Figure 18

If replacement of the power steering belt is required, the A/C and alternator belts must first be remove.

  1. Loosen the locking screw and pivot screw to replace, or adjust the belt.
  2.  
  3. Remove the belt and install a replacement.
  4.  
  5. Using a 1 / 2 in. breaker bar positioned in adjusting bracket slot, adjust the belt to specification.
  6.  
  7. Tighten the locking screw followed by the pivot screw. Tighten to 40 ft. lbs. (55 Nm).
  8.  

2.6L Engines
ALTERNATOR/AIR CONDITIONING COMPRESSOR BELT

See Figure 19



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Fig. Fig. 19: Drive belt adjustment points-2.6L engines

  1. Loosen the locking screw, jam nut, and pivot nut.
  2.  
  3. Loosen the adjusting screw.
  4.  
  5. Remove the belt and install a replacement.
  6.  
  7. Adjust the belt to specification by tightening the adjusting screw.
  8.  
  9. Tighten the locking screw followed by the pivot nut. Tighten to 16 ft. lbs. (22 Nm).
  10.  
  11. Tighten the jam nut to 21 ft. lbs. (28 Nm).
  12.  

POWER STEERING PUMP BELT

See Figure 19

If replacement of the power steering belt is required, the alternator and A/C belt must first be remove.

  1. Loosen the pivot screw, and the locking screw.
  2.  
  3. Remove the timing pickup.
  4.  
  5. Remove the belt and install a replacement.
  6.  
  7. Install a 1 / 2 in. breaker bar in the adjusting bracket slot, torque to specification.
  8.  
  9. Tighten the locking screw, followed by the pivot screw. Tighten to 40 ft. lbs. (55 Nm).
  10.  
  11. Install the timing pick-up, and tighten to 160 inch lbs. (18 Nm).
  12.  

3.0L Engines
AIR CONDITIONING COMPRESSOR BELT

See Figures 20 and 21



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Fig. Fig. 20: Air conditioning compressor belt-1988-90 3.0L engines



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Fig. Fig. 21: Air conditioning compressor belt-1991-95 3.0L engines

  1. Loosen the locknut on the idler pulley.
  2.  
  3. Loosen the adjusting screw on the idler pulley.
  4.  
  5. Remove the belt and install a replacement.
  6.  
  7. Adjust to specification by tightening the adjusting screw.
  8.  
  9. Tighten the idler pulley locknut to 40 ft. lbs. (55 Nm).
  10.  

ALTERNATOR/POWER STEERING PUMP BELT-1988-90 MODELS

See Figure 22



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Fig. Fig. 22: Alternator/power steering pump belt adjustment-1988-90 3.0L engines

If replacement of the alternator/power steering drive belt is required, the air conditioner drive belt must first be removed.

  1. Install a 1 / 2 in. breaker bar into the tensioner slot, and rotate counterclockwise to release belt tension.
  2.  
  3. Remove the belt and install a replacement.
  4.  
  5. Proper belt tension is maintain by the dynamic tensioner.
  6.  

ALTERNATOR/POWER STEERING PUMP BELT-1991-95 MODELS

See Figure 23



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Fig. Fig. 23: Alternator/power steering pump belt adjustment-1991-95 3.0L engines

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

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

3.3L and 3.8L Engines
ACCESSORY DRIVE BELT

See Figure 24



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Fig. Fig. 24: 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. Raise the front of the vehicle and safely support it with jackstands.
  2.  
  3. Remove the right front splash shield.
  4.  
  5. Release tension by rotating the tensioner clockwise.
  6.  
  7. Remove the belt and install a replacement.
  8.  
  9. Proper belt tension is maintain by the dynamic tension.
  10.  
  11. Install the right front splash shield. Lower the front of the vehicle.
  12.  

 
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