Changing the Accessory Belts

Last Updated - October 10th, 2004

Belts squeaking, popping off, or simply broken?  Here's how to replace them.


Difficulty:    

Time Investment:  Under 1 Hour


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Go to Instructions

Go to Tools & Supplies

Go to Notes


Pictures:

Click on a picture to enlarge it

Top view looking down at serpentine belt.
This is a shot of the belt being put on.  Note that the belt is to the inside of the tensioner pulley.
Lookup up at the power steering pulley from below.
Looking up and pulleys from below.
Offset wrench used to put belt on.  Note how the belt is pre-set on the inside of the tensioner pulley.
This is the A/C belt.  The tensioner pulley is raised and lowered by the top bolt head.
Here's a shot of the tensioner pulley.
Here's a shot of the A/C belt pulleys from below.


This Cell Intentionally Left Blank
This is a diagram of all of the belt driven accessories taken from the 1992 Chrysler FSM.
This is a diagram of the belt routing taken from the 1992 Chrysler FSM.
This is the A/C belt diagram taken from the 1992 Chrysler FSM.



Instructions:

A/C Belt Removal/Installation

1.  To remove the A/C belt, first loosen the bolt that goes through the center of the tensioner pulley.

2.  Once the pulley is loose, rotate the tensioner bolt (facing upward behind tensioner pulley) counter-clockwise to lower the pulley until you can get the belt off. If you attempt this without first loosening the pulley, it won't work.  Also, this is a great place to use an air ratchet with a long extension.

3.  If you are also replacing the serpentine belt, do that now.   Otherwise continue and put the new belt on.

4.  Put the new belt on where the old one was.

5.  Turn the tensioner screw clockwise until the belt is reasonably firm.  He-Man tight is not required here.

6.  Tighten the bolt that goes through the tensioner pulley.

7.  Start the car, drive it around, and try the A/C.  If the belt squeals, you need to adjust the tension.  Otherwise, it's fine.


Serpentine Belt Removal/Installation

1.  Remove the A/C Belt (via procedure above).

2.  Using a belt tensioner tool or a 15mm offset box end wrench, rotate the tensioner pulley forward and slip the belt off.
An offset box end wrench works fine but is difficult to get in there.  It's also difficult to get back out.  You'll need to play with it a little to figure out how to maneuver it, but it does work.  The belt can be slipped off to the inside of the tensioner pulley and also off the idler once you pull the wrench forward.

3.  Remove the belt and wrench completely.

4.  Put a new belt on according to the routing diagram.
There are a number of ways that it looks like this belt could go but only two known ways that you may think were successful.  To save yourself some frustration, look at the diagram.  Mike once discovered that you can put the belt over the idler pulley as opposed to under it...  It looks like it would work but screeches like crazy.

The best way to put the belt on is to lower it first so that you can get it around the power steering pulley.  Bring it up over the alternator, and down under the crank pulley.  With one hand taking up the slack, reach through and pull up the belt between the crank and the power steering pulley.  Pull it over the tensioner and let it rest inside the pulley.  Get your wrench in place pull forward, and then fix the way the belt sits on the idler and tensioner pulleys.  Piece of cake.

The crank and power steering pulleys are more difficult to slip a tight belt over because they have a big outer lip.  That's why you want to put the belt over those two first.

5.  Put the A/C belt back on.

 

Tools & Supplies:

  • 15mm offset box end wrench or serpentine belt tool
  • 3/8" or 1/2" drive ratchet with extensions 
  • Air ratchet - optional
  • New Belts

 Notes:

  • You do not need to use any kind of belt dressing on these belts and the FSM specifically says not to.
  • If you've taken the A/C tensioner bracket & pulley all the way off, there is a very thick washer that sits behind the tensioner pulley.  If that waser is lost, the pulley will not turn and you'll burn up your A/C belt shortly after starting the engine.  You'll see smoke and smell it burning very quickly.
  • The belt numbers for underdrive pulleys are as follows: