Chrysler Front Wheel Drive Cars 4-CYL 1981-1995 Repair Information

Accessory Drive Belts

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INSPECTION



See Figures 1, 2, 3, 4 and 5

Except Serpentine Belt


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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

Check the drive belts every 15,000 miles (24,000 km) or 12 months (whichever occurs first). Determine the belt tension at a point half-way between the pulleys by pressing on the belt with moderate thumb pressure. The belt should deflect about 1 / 4 - 1 / 2 in. (6-13mm) at this point. Note that "deflection'' is not play, but the ability of the belt, under actual tension, to stretch slightly and give.

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.

Although it is generally easier on the component to have the belt too loose than too tight, a very loose belt may place a high impact load on a bearing due to the whipping or snapping action of the belt. A belt that is slightly loose may slip, especially when component loads are high. This slippage may be hard to identify. For example, the generator belt may run okay during the day, and then slip at night when headlights are turned on. Slipping belts wear quickly not only due to the direct effect of slippage but also because of the heat the slippage generates. Extreme slippage may even cause a belt to burn. A very smooth, glazed appearance on the belt's sides, as opposed to the obvious pattern of a fabric cover, indicates that the belt has been slipping.

Serpentine Belt

The 1989-93 2.2L Turbo III and 1988-89 2.5L Premier engines are equipped with serpentine belts. Check the drive belts every 15,000 miles (24,000 km) or 12 months (whichever occurs first). 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.

ADJUSTMENT




WARNING
Be careful not to overtighten the drive belts, as this will damage the driven components' bearings.

1981-88 Models

Determine the belt tension at a point half-way between the pulleys by pressing on the belt with moderate thumb pressure. The belt should deflect a certain amount (depending on the particular belt-refer to the accompanying chart) at this point. Note that "deflection'' is not play, but the ability of the belt, under actual tension, to stretch slightly and give.

EXCEPT ALTERNATOR/WATER PUMP DRIVE BELT
  1. Loosen the accessory's slotted adjusting bracket bolt. If the hinge bolt is excessively tight, it too will have to be loosened.
  2.  
  3. Use a strong, wooden prytool to lever the accessory either closer to, or farther away from, the engine to provide the correct tension. Do not use a metal prybar, which may damage the component. Refer to the accompanying charts for the proper deflection of the drive belt.
  4.  
  5. When the belt tension is correct, tighten the adjusting bracket bolts. Check the adjustment, in case the component moved slightly while tightening the bolts.
  6.  

ALTERNATOR/WATER PUMP DRIVE BELT

On most of the 1981-88 model year engines covered in this information, the alternator/water pump drive belt is tensioned by a screw type tensioner, which makes precise tension adjustment easy.

  1. On 1981-87 models, loosen the locknut, located on the locking screw or lockbolt-located in a slotted portion of the outboard alternator mounting bracket.
  2.  
  3. On 1988 models, loosen the T-bolt, located in the center of the disc shaped portion of the outboard alternator bracket.
  4.  
  5. Tighten or loosen the drive belt tensioning bolt. This bolt is tightened to increase belt tension and loosened to decrease it.
  6.  
  7. When the belt tension is correct, tighten the lockbolt.
  8.  

1989-95 Models-Except Turbo III and Premier Engines

See Figure 6

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Fig. Fig. 6: Accessory drive belt routing-2.2L and 2.5L engines

Determine the belt tension either by using a belt tensioning tool, such as Special Tool Kit C-4162, or by using a torque wrench in the adjusting openings in the component brackets (refer to the belt routing diagrams for exact locations). The actual tension is different for each belt.

A/C COMPRESSOR BELT
  1. Loosen the idler bracket pivot bolt (A) and locking bolts (B).
  2.  
  3. Adjust belt tension by applying 35 ft. lbs. (47 Nm) for a new belt, or 20 ft. lbs. (27 Nm) of force (with a torque wrench) to the square hole (C) on the idler bracket.
  4.  
  5. While holding the tension on the belt with the torque wrench, tighten the locking bolts, then the pivot bolt to 40 ft. lbs. (55 Nm).
  6.  

POWER STEERING PUMP BELT-ZF AND TC TYPES



  1. Loosen locking nut, locking bolt (G) and pivot nut (H).
  2.  
  3. Loosen the adjusting nut (J) to release belt tension.
  4.  
  5. Tighten the adjusting nut (J) to adjust belt tension to 105 lbs. (467 N) for a new belt, or to 80 lbs. (358 N) for a used belt. To accurately measure the belt tension a special tension tool will be needed, such as Chrysler Special Tool Kit C-4162.
  6.  
  7. Tighten the locking nut and bolt (G) to 40 ft. lbs. (55 Nm).
  8.  
  9. Tighten the pivot nut (H) to 20 ft. lbs. (27 Nm).
  10.  

POWER STEERING PUMP BELT-S TYPE
  1. From the top of the vehicle, loosen the locking bolt (G).
  2.  
  3. From under the vehicle, loosen the pivot bolt and pivot nut (H).
  4.  
  5. Adjust the belt tension with a torque wrench installed in the adjusting bracket. Tighten the belt until the torque wrench registers 43 ft. lbs. (58 Nm) for a new belt, or 32 ft. lbs. (43 Nm) for a used belt.
  6.  
  7. While holding the correct amount of tension on the belt, tighten the locking bolt (G) to 40 ft. lbs. (55 Nm). Tighten the pivot bolt and nut (H) to 40 ft. lbs. (55 Nm).
  8.  

ALTERNATOR BELT
  1. Loosen the T-bolt locking nut (E) and adjusting bolt (F).
  2.  
  3. Tighten the adjusting bolt (F) to adjust the belt tension. To measure the belt tension, a belt tension tool will be needed, such as Chrysler Special Tool Kit C-4162. A new belt requires 135 lbs. (600 N) and a used belt will need 80 lbs. (358 N).
  4.  
  5. Tighten the T-bolt locking nut (E) to 40 ft. lbs. (55 Nm).
  6.  

2.2L Turbo III and Premier 2.5L Engines

See Figure 7

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Fig. Fig. 7: Accessory serpentine drive belt routing-2.2L Turbo III engines

The serpentine belts found on the 2.2L Turbo III engine and the Eagle Premier 2.5L engine are adjusted automatically by an idler pulley/tensioner assembly. No belt tensioning is possible or necessary.

REMOVAL & INSTALLATION




WARNING
Be careful not to overtighten the drive belts, as this will damage the driven components' bearings.

1981-88 Models

If a belt must be replaced, the driven unit must be loosened and moved to its extreme loosest position, generally by moving it toward the center of the motor. After removing the old belt, check the pulleys for dirt or built-up material which could affect belt contact. Carefully install the new belt, remembering that it is new and unused-it may appear to be just a little too small to fit over the pulley flanges. Fit the belt over the largest pulley (usually the crankshaft pulley at the bottom center of the motor) first, then work on the smaller one(s). Gentle pressure in the direction of rotation is helpful. Some belts run around a third or idler pulley, which acts as an additional pivot in the belt's path. It may be possible to loosen the idler pulley as well as the main component, making your job much easier. Depending on which belt(s) you are changing, it may be necessary to loosen or remove other interfering belts to get at the one(s) you want.

When buying replacement belts, remember that the fit is critical according to the length of the belt ("diameter''), the width of the belt, the depth of the belt and the angle or profile of the V shape or the ribs. The belt shape should exactly match the shape of the pulley; belts that are not an exact match can cause noise, slippage and premature failure.

After the new belt is installed, draw tension on it by moving the driven unit away from the motor and tighten its mounting bolts. This is sometimes a three or four-handed job; you may find an assistant helpful. Make sure that all the bolts you loosened get retightened and that any other loosened belts also have the correct tension. A new belt can be expected to stretch a bit after installation so be prepared to re-adjust your new belt, if needed, within the first two hundred miles of use.

EXCEPT ALTERNATOR/WATER PUMP DRIVE BELT

See Figure 8

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Fig. Fig. 8: Once the A/C compressor bolts are loosened, the belt can be removed from the pulley

  1. Loosen the accessory's slotted adjusting bracket bolt. If the hinge bolt is excessively tight, it too will have to be loosened.
  2.  
  3. Push the component toward the engine to provide enough slack in the belt so that it will slide over one of the accessory drive pulleys. Remove the drive belt from the accessory drive pulleys and from the vehicle.
  4.  

To install:
  1. Position the new drive belt over the component pulleys. Make sure that it is routed correctly.
  2.  
  3. Adjust the tension of the belt, as described earlier in this section.
  4.  

ALTERNATOR/WATER PUMP DRIVE BELT

See Figures 9 and 10

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Fig. Fig. 9: After loosening the lockbolt, loosen the adjusting bolt to relieve the belt's tension



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Fig. Fig. 10: Once the belt is adequately loosened, remove the belt from the drive pulley

  1. On 1981-87 models, loosen the locknut, located on the locking screw or lockbolt-located in a slotted portion of the outboard alternator mounting bracket.
  2.  
  3. On 1988 models, loosen the T-bolt, located in the center of the disc shaped portion of the outboard alternator bracket.
  4.  
  5. Loosen the drive belt tensioning bolt until the most possible slack is gained from the component.
  6.  
  7. Slip the belt off of the alternator pulley, then remove it from the other pulleys. Remove the belt from the vehicle.
  8.  

To install:
  1. Route the new belt on the component pulleys. Make certain that it is routed correctly-incorrect routing could cause a components to spin backward, possibly damaging it.
  2.  
  3. Once the belt is correctly positioned on all of the pulleys, adjust the tension as described earlier in this section.
  4.  

1989-95 Models-Except Turbo III and Premier Engines

See Figure 6

A/C COMPRESSOR BELT
  1. Loosen the idler bracket pivot bolt (A) and locking bolts (B).
  2.  
  3. Move the idler pulley until the most amount of slack is gained.
  4.  
  5. Remove the drive belt from the A/C compressor pulley, then from the other applicable pulleys.
  6.  

To install:
  1. Position the new belt over the crankshaft pulley, the idler pulley and the A/C compressor pulley. Make certain that it is correctly routed, otherwise it could cause the A/C compressor to be rotated backwards. This could cause damage to the compressor.
  2.  
  3. Adjust the belt tension, as described earlier in this section.
  4.  
  5. While holding the tension on the belt with the torque wrench, tighten the locking bolts, then the pivot bolt to 40 ft. lbs. (55 Nm).
  6.  

POWER STEERING PUMP BELT-ZF AND TC TYPES



  1. Loosen locking nut, locking bolt (G) and pivot nut (H).
  2.  
  3. Loosen the adjusting nut (J) to release belt tension until the maximum amount of slack in the drive belt is gained.
  4.  
  5. Remove the drive belt from the applicable pulleys.
  6.  

To install:
  1. Route the new belt onto the component pulleys. Make certain that it is correctly routed, otherwise damage may occur to the power steering pump.
  2.  
  3. Adjust belt tension, as described earlier in this section. To accurately measure the belt tension a special tension tool will be needed, such as Chrysler Special Tool Kit C-4162.
  4.  
  5. Tighten the locking nut and bolt (G) to 40 ft. lbs. (55 Nm).
  6.  
  7. Tighten the pivot nut (H) to 20 ft. lbs. (27 Nm).
  8.  

POWER STEERING PUMP BELT-S TYPE
  1. From the top of the vehicle, loosen the locking bolt (G).
  2.  
  3. From under the vehicle, loosen the pivot bolt and pivot nut (H).
  4.  
  5. Push the power steering pump toward the engine until the maximum amount of slack in the belt is gained.
  6.  
  7. Remove the drive belt from the components' pulleys.
  8.  

To install:
  1. Position the drive belt onto the accessories pulleys. Make sure that the new belt is correctly routed.
  2.  
  3. Adjust the belt tension, as described earlier in this section.
  4.  
  5. While holding the correct amount of tension on the belt, tighten the locking bolt (G) to 40 ft. lbs. (55 Nm). Tighten the pivot bolt and nut (H) to 40 ft. lbs. (55 Nm).
  6.  

ALTERNATOR BELT
  1. Loosen the T-bolt locking nut (E) and adjusting bolt (F).
  2.  
  3. Tighten the adjusting bolt (F) to loosen the belt tension. Loosen the drive belt until the maximum amount of slack is gained.
  4.  
  5. Remove the drive belt from the applicable drive pulleys.
  6.  

To install:
  1. Install the drive belt onto the applicable pulleys.
  2.  
  3. Adjust the drive belt tension, as described earlier in this section.
  4.  
  5. Tighten the T-bolt locking nut (E) to 40 ft. lbs. (55 Nm).
  6.  

2.2L Turbo III and Premier 2.5L Engines

See Figure 7

The serpentine drive belt is provided with a dynamic tensioner to maintain proper belt tension. To remove or install this belt:

  1. Raise the front of the vehicle and safely support on jackstands.
  2.  
  3. Remove the right front splash shield.
  4.  
  5. Release tension of the belt by rotating the tensioner assembly clockwise.
  6.  
  7. While holding the tensioner in the rotated position, remove the belt from the various pulleys-make sure to note the route that the belt takes before removal.
  8.  

To install:
  1. Route the belt on the various pulleys except for the tensioner pulley. Once the belt is satisfactorily mounted on the pulleys, rotate the tensioner clockwise and slide the belt onto the tensioner pulley. Make certain that the belt is mounted so that the grooves in the belt are correctly aligned with the grooves in the pulleys.
  2.  
  3. Install the right front splash shield to the underside of the vehicle.
  4.  
  5. Lower the vehicle back to the ground.
  6.  
  7. Start the engine and allow to idle for a few minutes. Shut the engine off and double check the placement of the belt on the pulleys.
  8.  

 
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