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Correct drive belt tension is required to ensure optimum performance of the belt driven engine accessories. There are different types of adjustment gauges for checking either a serpentine or a V-type belt. Use the correct gauge when checking belt tension. Place gauge in the middle of the section of belt being tested (between two pulleys) to check tension. Do not allow the gauge (or gauge adapter) to contact anything but the belt. BELT SCHEMATICS The belt routing schematics are published from the latest information available at the tingle of publication. If anything differs between these schematics and the Belt Routing Label, use the schematics on Belt Routing Label. This label is located in the engine compartment. BELT REPLACEMENT OR ADJUSTMENT- LEFT HAND DRIVE Belt tension is adjusted at the power steering pump bracket and idler pulley assembly. 1. Disconnect negative battery cable from battery. 2. Loosen idler pulley bolt at the power steering bracket. 3. Loosen adjusting bolt until belt can be removed from pulleys. 4. Remove belt. INSTALLATION 1. Check condition of all pulleys. CAUTION: When installing the serpentine accessory drive belt, the belt MUST be routed correctly. If not, the engine may overheat due to the water pump rotating in the wrong direction. 2. Install new belt. 3. Using serpentine belt tension gauge, tighten adjusting bolt until belt reaches proper tension. Refer to Belt Tension at the rear of this section for proper belt tension. 4. After belt is tensioned correctly, tighten idler pulley bolt to 47 Nm (35 ft. lbs.) 5. After idler pulley has been tightened into position, recheck belt tension. Adjust if necessary. BELT REPLACEMENT OR ADJUSTMENT- RIGHT HAND DRIVE (4.0L) 1. Disconnect negative battery cable from battery. 2. Loosen lower alternator mounting bolt and nut. 3. Loosen upper alternator mounting nut. 4. Loosen adjusting bolt at upper alternator bracket until belt can be removed from pulleys. 5. Remove belt. INSTALLATION 1. Check condition of all pulleys.

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SERPENTINE BELT SLIPS OFF IDLER PULLEY Model(s): 1996-1999 Chrysler (NS) Town & Country 1996-1999 Dodge (NS) Caravan 1996-1999 Plymouth (NS) Voyager 1996-1999 Chrysler (GS) Voyager (International Market) SYMPTOM/CONDITION Loss of power steering assist and occurs when driving through deep snow or standing water. Snow or rain can enter the engine compartment from underneath the vehicle and force the serpentine belt off of the idler pulley. DIAGNOSIS Visually inspect the serpentine belt and idler pulley to determine if mis-alignment exists (If the serpentine belt is off the pulleys install the serpentine belt). Start the engine and let it run for one minute before checking alignment). The belt should be approximately 2mm (0.08 in.) from the inboard edge of the idler pulley (Fig. 1 ) when alignment is correct and this bulletin does not apply. If the belt and pulley appear as in Fig. 2 , perform the REPAIR PROCEDURE . REPAIR PROCEDURE This repair is compatible with DaimlerChrysler’s Mobile Service Program and does not require hoists or other full service facility special equipment. 1. Remove the serpentine belt from around the idler pulley by rotating the tensioner clockwise (Fig. 3 ). 2. Remove the purge duty cycle solenoid and wiring harness from the right side engine mount. 3. Remove the two right side engine mount insulator vertical fasteners and loosen the horizontal fastener. DO NOT remove the large nut in the center of the core of the insulator (Fig. 4 ). 4. Remove the load on the engine mount by carefully supporting the engine with a floor jack. 5. Remove the vertical and horizontal fasteners from the engine side bracket. Remove the engine mount assembly. 6. Remove the idler pulley from the engine mounting bracket. (Fig. 3 ). 7. Remove the engine mounting bracket. 8. Install a new engine mounting bracket. Torque the fasteners to 40-68 N.m (30-50 ft-lbs.). 9. Install the idler pulley to the engine mounting bracket. Torque the fastener to 40-68 N.m (30-50 ft-lbs.). 10. Properly route and position a serpentine belt onto all pulleys except the idler pulley (Use a new belt if there is any evidence of damage to the original one). 11. Rotate the belt tensioner clockwise until the belt can be installed onto the idler pulley. Slowly release the belt tensioner. 12. Install the engine mount; torque the assembly in the following order, engine mount to rail fasteners 68 N.m (50 ft-lbs.), vertical fastener 102 N.m (75 ft-lbs.), and horizontal fastener 150 N.m (111 ft-lbs.). 13. Install the purge duty cycle solenoid to the engine mount. 14. Start the vehicle and let it run for one minute then turn the engine off. 15. Verify the serpentine belt is properly aligned (Fig. 1 ).

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INSPECTION When inspecting serpentine drive belts, small cracks that run across the ribbed surface of the belt from rib to rib are considered normal. If the the cracks are running along the rib (rather across), this is not normal and the belt(s) must be replaced. ADJUSTMENT It is not necessary to adjust belt tension on the 5.2L or 5.9L engines and on the 2.5L and 4.0L engines (without power steering). These engines are equipped with an automatic tensioner. The tensioner maintains correct tension at all times. 2.5L and 4.0L Engines With Power Steering See Figures 1, 2, 3 and 4 If the vehicle is not equipped with power steering, it will be equipped with an idler pulley. If equipped with an idler pulley, refer to and follow the 5.2L/5.9L belt removal and installation procedure. 1. Loosen the pump upper pivot bolt, lower locknut and pump adjusting bolt using a ratchet and 13mm socket or a 13mm box wrench. 2. Use a belt tension gauge placed in the middle of the belt being tested. Proper tension for a new belt is 180-200 lbs. (800-900 N) and 140-160 lbs. (623-712 N) for a used belt. 3. Tighten the pump adjusting bolt to achieve proper tension and recheck the belt tension.

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Remove or Disconnect: 1. Disconnect negative battery cable 2. Remove serpentine belts from crankshaft pulley 3. Properly raise and support vehicle 4. Remove right front tire and wheel assembly 5. Remove right inner fender access cover 6. Using 28 mm socket, remove crankshaft harmonic balancer retaining bolt 7. Using special tool J38197, remove crankshaft harmonic balancer 8. Remove crankshaft position sensor shield 9. Disconnect sensor electrical connector 10. Remove sensor from block face Install or Connect: 1. Install crankshaft position sensor to block face 2. Tighten bolts Torque Value: 20-40 N-m (14-28 lb.ft.) 3. Install crankshaft position sensor shield 4. Connect electrical connector 5. Install balancer on crankshaft 6. Apply thread sealer GM #1052080 or equivalent to threads of crankshaft balancer bolt Torque Value: 150 N-m + 76° (110 lb.ft. + 76°) 7. Install inner fender shield 8. Install tire and wheel assembly Torque Value: 140 N-m (104 lb.ft.) 9. Lower vehicle 10. Install serpentine belt 11. Connect negative battery cable

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REMOVE OR DISCONNECT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Serpentine belt from the crankshaft pulley. Raise the vehicle on a hoist. Right front tire and wheel assembly. Right inner fender access cover. Using a 28 mm socket, remove the crankshaft harmonic balancer retaining bolt. Crankshaft harmonic balancer using tool J 38197 or equivalent. Sensor electrical connector. Foreign object deflector. (DO NOT use a pry bar.) Sensor and pedestal from block face. Sensor from pedestal. INSTALL OR CONNECT: Loosely install the crankshaft sensor on the pedestal. Position the sensor with pedestal attached on special Tool J 37089. Position the special tool on the crankshaft. Bolts to hold the pedestal to the block face, torque to 20-40 Nm (14-28 ft lbs). Torque the pedestal pinch bolt to 4-4.5 Nm (36-40 in lbs). Remove special tool J 37089. Foreign object deflector. Place the special tool 37089 on the harmonic balancer and turn. If any vane of the harmonic balancer touches the tool, replace the balancer assembly. 9. Balancer on the crankshaft. ^ Apply thread sealer (GM 1052080) or equivalent to the threads of the balancer bolt. 1. 2. 3. 4. 5. 6. 7. 8.