Chrysler Full-Size Vans 1989-1998 Repair Guide

Belts

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Two types of drive belt assemblies are used on these vehicles. Early model vehicles use multiple V-type drive belts. Each belt or pair of matched belts is adjusted separately.

Late model vehicles use a serpentine drive belt with an automatic tensioner. A single belt drives all accessories and is automatically adjusted.

V-belts should be inspected and the tension adjusted at 7,000 mile (24,000 km) intervals.

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

REMOVAL & INSTALLATION



When installing the serpentine accessory drive belt, the belt must be routed correctly. Engine overheating may occur due to water pump rotating in the wrong direction if the belt is not routed properly.

V-Belts

See Figures 6 and 7



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Fig. Fig. 6: Belt routing and tensioning guide for vehicles without air conditioning



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Fig. Fig. 7: Belt routing and tensioning guide for vehicles with air conditioning

Some vehicles use matched V-belt sets. These matched sets can be identified by looking for two belts of equal length and routing. When replacing matched V-belts, it is important to replace both belts simultaneously with a correct matched set.

It may be necessary to remove more than one belt in order to access the desired belt. Always note belt routing for reference upon installation.

  1. Loosen the belt tension, as illustrated.
  2.  
  3. Remove belt from engine.
  4.  
  5. Inspect pulleys for damage or wear and replace as necessary.
  6.  
  7. Install belt, routing as illustrated.
  8.  
  9. Ensure that the belt is properly positioned on all pulleys.
  10.  
  11. Adjust belt tension to the proper specification (as measured on a belt tension gauge):

    Adjust new belts to 60 lbs.
     
    Adjust used belts to 80 lbs.
     

  12.  

Any belt that has been operating for a minimum of 10 minutes is considered a used belt. In the first 10 minutes, the belt should stretch to its maximum extent. After 10 minutes, stop the engine and recheck the belt tension.

  1. If a belt tension gauge is not available, tension may be set by using the following procedure:
    1. Position a ruler perpendicular to the drive belt at its longest straight run.
    2.  
    3. Test the tightness of the belt by pressing it firmly with your thumb. The deflection should not exceed 1 / 4 in.
    4.  
    5. If the deflection exceeds 1 / 4 in., loosen the mounting bolts and tighten the adjustment.
    6.  
    7. When the belt is properly tensioned, tighten the mounting bolts to specification.
    8.  

  2.  

Serpentine Belts

See Figures 8 and 9

Serpentine belts use an automatic belt tensioner assembly. Periodic belt tension adjustments are not necessary.

  1. Using an appropriately sized wrench, rotate the belt tensioner clockwise to release the tension.
  2.  
  3. Remove the drive belt from the pulleys.
  4.  
  5. When installing the new drive belt, ensure that it is routed correctly and that it is properly installed on each pulley.
  6.  



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Fig. Fig. 8: Serpentine belt routing schematic



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Fig. Fig. 9: Rotate the tensioner to release the pressure on the belt for removal

 
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