Chrysler Full-Size Trucks 1997-2000 Repair Guide

Belts

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WARNING
Belt routing schematics are based on the latest information available at the time of publication. The vehicle's Belt Routing Label, located in the engine compartment, should be consulted when replacing belt.



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Fig. Vehicle-specific belt routing is provided on a plate in the engine compartment

INSPECTION




CAUTION
If equipped, the electrically operated cooling fan may come on under certain circumstances, even though the ignition is OFF . Be sure to disconnect the negative battery cable before servicing your vehicle

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.

Check belt tension. For 2.5L engines, tension is checked with a belt tension gauge. For models with automatic tensioners, alignment marks are used to indicate proper position when belt replacement is required:

For 4.7L engines:

Check the belt if the distance between index marks exceeds 0.94 in. (24 mm).

For other engines

Check the belt if indexing arrow has moved to the tensioner travel limit as shown in the illustration. The arrow should be within 1 / 8 inch (3mm) of the indexing mark if a new belt is installed.

If wear indicators show that belt replacement is needed, check that belt wear is the cause. False readings can be caused by loose or worn pulleys, damaged bearings, loose or misaligned accessories or incorrectly fitted belts.



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Fig. There are typically three types of accessory drive belts found on vehicles today



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



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



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Fig. Typical wear patterns for a serpentine drive belt



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Fig. Accessory drive belt wear indicator-4.7L engine



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Fig. The belt wear limit occurs when the indexing arrow reaches the travel limit indicator (A)-typical

ADJUSTMENT



The 2.5L engine requires periodic adjustment. All other models are fitted with automatic belt tensioners. Be sure, however, to inspect/replace the belts at the proper intervals.

Belt Adjustment (2.5L)

Belt tension is adjusted at the power steering pump bracket and idler pulley assembly. This procedure requires the use of a belt tension gauge.

  1. Disconnect the battery negative cable.
  2.  
  3. Loosen the idler pulley center bolt.
  4.  
  5. Using the adjusting bolt, tension the belt to 140-160 lbs. for in-service belts. Tension for new belts (used 15 mins. or less) should be 180-200 lbs.)
  6.  
  7. Tighten the idler pulley center bolt to 42 ft. lbs. (57 Nm)
  8.  
  9. Recheck the belt tension.
  10.  



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Fig. Belt tension adjusting bolt (1) and idler pulley bolt (2)-2.5L engine

REMOVAL & INSTALLATION



2.5L Engine
  1. Loosen the idler pulley bolt, then the adjusting bolt to remove tension from the belt.
  2.  
  3. Remove the belt.
  4.  
  5. Check the pulleys for damage.
  6.  
  7. Install the belt per the appropriate diagram.
  8.  
  9. Adjust tension as described in the "Belt Adjustment (2.5L)" section, above.
  10.  



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Fig. Belt routing-2.5L engine with A/C



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Fig. Belt routing-2.5L engine without A/C

All Other Models

Use a socket, wrench or ratchet on the tensioner pulley to rotate the tensioner arm, loosen the belt and disengage it from one of the fixed pulleys. To install, place the belt over all pulleys but the tensioner pulley, then rotate the tensioner arm in the same manner and slip the belt over the pulley. When you release it, the spring-loaded tensioner will automatically apply the correct tension to the belt.



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Fig. Some tensioners may be rotated clockwise to remove tension . . .



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Fig. . . . while others must be rotated counterclockwise. Check before applying excessive force



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Fig. Diesel engines may use a square hole instead of a bolt or nut to rotate the tensioner arm. Use a ratchet without any socket for these vehicles


NOTE
Depending on model, engine and belt driven accessories, the tensioner arm may be rotated clockwise or counter clockwise to relieve tension. Be sure to check this by attempting to move the tensioner in either direction. Also, a wrench, a socket and ratchet, a plain ratchet, or a special belt tensioner tool may be used.


CAUTION
Be sure the tool used to rotate the tensioner is the proper size. Bodily harm may occur from tool slippage due to the pressure applied by the tensioner.



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Fig. Rotating tensioner and removing serpentine belt

  1. Disconnect the negative battery cable.
  2.  
  3. Attach the proper size socket, wrench, or ratchet to the automatic belt tensioner pulley bolt or square hole.
  4.  
  5. Rotate the tensioner arm until tension has been removed from the belt.
  6.  
  7. Remove the belt from the tensioner pulley, and then slowly allow the tensioner arm to rotate back until it stops.
  8.  
  9. Remove the belt from the remaining pulleys.
  10.  

To install:


WARNING
The drive belt must be installed exactly as the manufacturer states. Refer to the Belt Routing Label in the engine compartment to ensure proper installation. Unless the belt is correctly routed, engine or accessories may be damaged due components rotating in the wrong direction.

  1. Position the belt over all of the pulleys except the tensioner.
  2.  
  3. Attach the proper size socket, wrench, or ratchet to the automatic belt tensioner pulley bolt.
  4.  
  5. Rotate the tensioner until the stop is reached. Carefully position the belt over the tensioner pulley and release it slowly until it contacts the belt.
  6.  
  7. Check the tensioner indexing marks to make sure the proper new belt is installed and the tensioner is not worn beyond its limits.
  8.  
  9. Check to make sure the belt is seated properly on all the pulleys. Check for proper belt routing.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Start the engine and observe the belt to ensure proper operation.
  14.  


CAUTION
Do NOT attempt to disassemble the automatic belt tensioner. High spring pressure may cause flying parts and bodily injury.



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Fig. Verify serpentine belt alignment in the pulley



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Fig. Serpentine belt routing-3.9L,V6 5.2L/5.9L V-8 LDC-gas engines



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Fig. Serpentine belt routing-4.7L engine



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Fig. Serpentine belt routing-5.9L HDC-gas engines and 8.0L V-10 engines with A/C



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Fig. Serpentine belt routing-5.9L HDC-gas engines and 8.0L V-10 engines without A/C



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Fig. Serpentine belt routing-5.9L diesel engines without air conditioning



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Fig. Serpentine belt routing-5.9L diesel engines with air conditioning

 
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