Just put a timing belt and water pump on my 1995 dodge intrepid es 3.5 changed the tensioner pulley and new hydraulic tensioner, have had 4 new tensioners collapse can anyone tell me why they are doin

The water pump is located in the front of the engine & is driven by the timing belt. So if you go in there you might as well replace the belt and tensioners if needed.
Drain the cooling system (turn the radiator drain 1 full turn only)

1. Remove the upper radiator hose
2. Remove the top radiator support
3. Remove the two 10mm head bolts from either side of the radiator and gently pull the top of the radiator forward to gain a little more room
4. Remove the four 10mm head bolts holding the cooling fan module to the radiator . Remove the four clip nuts and the cooling fan electrical connector and lift the fan module out of the vehicle
5. Loosen and remove the drive belts and remove the three 13mm head bolts holding the alternator belt tensioner pulley to the timing cover
6. Remove the three piece timing belt cover (the lowest piece can be accessed through the crankshaft pulley by turning the pulley and removing the bolts)
7. turn the crankshaft pulley and line up the timing marks on top dead center
8. Remove the timing belt tensioner two 13mm bolts and remove the tensioner (If the tensioner pulley wheel is made of plastic you will want to purchase a revised steel tensioner pulley) . Put the tensioner in a suitable vise to compress it and install a small allen wrench from the front to hold it in place (close the vise slowly to compress the tensioner)
9. (If need be) Remove the plastic tensioner pulley (the 15mm head attaching bolt can be removed without removing the crankshaft pulley)
10. The timing belt can easily be slipped under/around the crankshaft pulley by slightly bending it to the outside of the timing belt housing on the drivers side and working it with your hand through the crankshaft pulley . No excessive force is needed to do this and be sure to clean the area well prior to installing the new belt
11. With the belt removed , remove and replace the water pump . Coat the gasket with a little RTV silicone and clean the gasket mating surface well
12. Install the timing belt in the opposite direction as removed . Make sure that all the timing marks are lined up .
13. Reinstall the timing belt tensioner
    
    Note: There are several different length bolts used, so pay attention to where they are removed from, they must be installed in the same placement.
    
    I hope this information was helpful.

Make sure your timing marks are lined up and start putting your belt on the rear cam first that would be 1,3,5 cam. Then route it under the water pump and up around the front cam 2,4,6 cam being careful the rear cam don't jump off it's mark. Keep tension on the belt while routing it. Continue routing it over the idler pulley keeping tension on it route it down and around the crank sprocket. Now set your tension pulley and replace the tension pin. Once the belt is set hand crank the engine 2 to 3 complete cycles then recheck your marks. This is for a 2.5 engine. Good luck hope this helps.

Thank you for the inquiry.




Disconnect the negative (black) cable from the battery.

Remove all accessories that are in the way of the timing belt cover. The Intrepid's 3.5 liter engine and small engine bay make for very cramped working conditions; it is thus necessary to remove all engine accessories so that you can properly work on the timing belt. Begin by loosening the tension bolt on the alternator with a belt tensioner, then use a socket wrench to remove the bolts on the water pump, air condition compressor and power steering pump.

Remove the four bolts on the top timing belt cover, using a socket wrench, then remove the cover.

Use a jack to lift the front end of the Intrepid and place the front end securely on two jack stands. Get underneath the engine.

Remove the three bolts on the bottom timing belt cover, using a socket wrench, then remove the cover.

Use the belt tensioner to put some slack into the timing belt, then remove the belt from the pulleys with your hands.

Line up the pulleys, so that the engine is at the top dead center and the two marks on the camshaft are lined up with the marks on the cams.

Place the new timing belt over the pulleys, making sure not to move any of the pulleys in either direction.

Use the tensioner to tighten the belt.

Reattach the top and bottom timing belt covers and secure them in place, using the bolts you had removed earlier.

Reattach all of the accessories you have removed (in any order), using a socket wrench. When done, place the belts over the pulleys and return tension to them by using the belt tensioner to tighten the tension bolt on the alternator.

Attach the negative (black) battery cable to the battery.

Belt Installation, Aerostar 4.0L Engine





Item Part Number Description 1 8620 Drive Belt 2 N606068 Bolt 3 10300 Generator 4 10153 Generator Mounting Bracket 5 8509 Water Pump Pulley 6 6B209 Drive Belt Tensioner 7 N800199 Screw 8 8678 Belt Idler Pulley 9 N802096 Screw 10 19703 A/C Compressor 11 2882 A/C Compressor Mounting Bracket 12 3C718 Brace 13 N806020 Bolt 14 3A674 Power Steering Pump 15 3A733 Power Steering Pump Pulley 16 N800199 Screw 17 N606572 Bolt 18 N620481 Nut 19 8501 Water Pump 20 6312 Crankshaft Pulley A - Belt Tension Check (See Specifications) B - Tighten to 40-55 Nm
(30-41 Lb-Ft) C - Tighten to 24-30 Nm
(18-23 Lb-Ft) D - Tighten to 21-29 Nm
(15-21 Lb-Ft) E - Tighten to 40-50 Nm
(30-37 Lb-Ft)

Belt Installation, Ranger and Explorer 4.0L Engine





Item Part Number Description 1 8620 Drive Belt 2 10300 Generator 3 8678 Belt Idler Pulley 4 19703 A/C Compressor 5 3A733 Power Steering Pump Pulley 6 8501 Water Pump 7 6312 Crankshaft Pulley 8 6B209 Drive Belt Tensioner 9 N806020 Bolt 10 2882 A/C Compressor Mounting Bracket 11 3A674 Power Steering Pump 12 N606572-S2 Bolt 13 N800199-S8M Bolt 14 N620481-S2 Nut 15 3C718 Brace 16 N606068 Bolt 17 10153 Generator Mounting Bracket 18 8509 Water Pump Pulley 19 N605805-S2 Bolt A - Belt Tension Check (See Specifications) B - Tighten to 21-29 Nm
(15-21 Lb-Ft) C - Tighten to 40-55 Nm
(30-41 Lb-Ft)

Belt Installation, Ranger 2.3L Engine





Item Part Number Description 1 8678 Belt Idler Pulley 2 10300 Generator 3 8509 Water Pump Pulley 4 3A733 Power Steering Pump Pulley 5 2E884 A/C Clutch Pulley 6 6312 Crankshaft Pulley

Belt Installation, Aerostar 3.0L Engine





Item Part Number Description 1 10300 Generator 2 3F671 Belt Idler Pulley 3 3A733 Power Steering Pump Pulley 4 6B209 Drive Belt Tensioner 5 6312 Crankshaft Pulley 6 8509 Water Pump Pulley 7 19703 A/C Compressor

what engine? Please rate if this helps. Took a lot of time to dig out.

here's 2002 3.0L 2 valve



Item Part Number Description 1 10346 Generator pulley 2 8678 Belt idler pulley 3 3A733 Power steering pump pulley 4 8620 Drive belt 5 2E884 A/C clutch pulley 6 6B209 Drive belt tensioner pulley 7 6312 Crankshaft pulley 8 8509 Water pump pulley


4 valve



Item Part Number Description 1 3A733 Power steering pump pulley 2 8620 Drive belt 3 2E884 A/C clutch pulley 4 6316 Crankshaft pulley 5 6B209 Drive belt tensioner pulley 6 10344 Generator pulley

water pump 4 valve



Item Part Number Description 1 6A359 Camshaft drive pulley 2 8K543 Drive belt 3 8509 Water pump pulley 4 8W508 Drive belt tensioner pulley

A/C Compressor Belt

1. Remove the alternator/power steering and water pump drive belt to gain access to the air conditioning belt.
   

2. Loosen the tensioner pulley locknut, then turn the adjusting screw to raise or lower the tensioner pulley assembly. Remove the belt.
   

To install:

1. Install the belt.
   

2. To adjust the belt, loosen the tensioner pulley nut and adjust the belt tension by tightening the adjusting screw. Tighten the pulley nut to 40 ft. lbs. (54 Nm) after adjustment.
   

3. Install the alternator/power steering and water pump drive belt and adjust.
   

4. Start the engine and check for proper belt alignment and any abnormal noise.
   

Hi.

Here the belt routing for 2005 Dodge Sprinter 2005, whch was sold only with the 2.7 engine mounted:






Fig. Accessory Belt Routing-A/C Compressor (1), Power Steering Pump (2), Tensioner (3), Crankshaft Pulley (4), Water Pump (5), Alternator (6), Idler Pulley (7)-All Engines

Here a different view:



Here also the fan belt routing;



Fig. Fan belt routing-Fan pulley (1), Fan belt (2), Crankshaft pulley (3)-3.0L engine shown

PROCEDURE Removal & Installation


2.7L Engine

1. Loosen the tension adjust and remove the A/C compressor drive belt.
2. Attach a 3 / 8 inch drive ratchet to the automatic belt tensioner.
3. Rotate the belt tensioner counterclockwise to release the belt tension.
4. Remove the accessory drive belt, starting with the water pump pulley.



To install:

1. Position the accessory drive belt around every pulley except the water pump pulley.
2. Rotate the drive belt tensioner clockwise, install the accessory drive belt and release the tensioner.
3. Position the A/C Compressor drive belt over the crankshaft pulley and A/C compressor pulley.
4. Tighten the drive belt tensioner.
5. Ensure the belt is seated properly on all of the pulleys.

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All the best.

Ginko.

a timing belt. the water pump uses it to turn it and you got to take it off to change the pump anyway so you might as well get a new one.also the hydralic timing belt tensioner should be replaced at the same time just to be sure.you will need anti freeze of course as well

This is not an easy task and you will find it takes about 6-8 hours if you have all the needed parts ready to install if you need them. Don't expect to just go to the local parts place and obtain some of these parts. There are several dealer only parts.

Before you start this job:
1. Inspect the upper and lower torque struts that hold the motor on the passenger side. Order them ahead of time if you see they are damaged. Make sure the local parts store has them in stock if you are not sure of their integrity. You can tell if they are bad when you remove them; they just fall apart or you can see the split neoprene.
2. Inspect your accessory belts and the serpentine tensioner pulley prior to beginning the work. Order the belts (If you have over 75,000 miles on the vehicle, you will need the new accessory belts.) or know where you can purchase them locally.
3. Make sure you can get a new timing belt tensioner unit locally at your Mopar Dealer. If you have a mechanical timing belt tensioner, you are warned by a Dodge technical bulletin to replace it with a hydraulic unit.
4. Order a water pump and replace it while replacing the timing belt.
5. Of course, purchase a timing belt, lol...


First, it was necessary to remove the passenger side tire and the splash guard behind the tire in the wheel well. The next items to remove were the accessories belts (ac, alternator, etc.) which included the serpentine belt. The crankshaft damper had to be removed with a three-arm puller tool and a small insert that protects the crankshaft threads. Remove the power steering pump by just setting it off to the side after removing the bolts. You don't have to undo the hoses; just lay it over to the side.

Using a floor jack, you hold the engine in place while you remove the lower torque arms. Inspect the upper and lower torque arms carefully. I would at least inspect these torque arms carefully for broken neoprene prior to beginning the timing belt change.


Next, you must remove the serpentine tensioner plate which has three bolts. This was a totally unexpected cost for my timing belt replacement when I tried to purchase only the plastic tensioner pulley and was informed that the item was not a replacement part; you had to go to Dodge and purchase an entire plate (with a redesigned "hydraulic" tensioner for the serpentine belt tensioner). go to a local salvage yard and obtained a fairly new tensioner pulley for about $5.00; the old plastic pulley will be completely worn away. A new serpentine tensioner plate with the integral tensioner is $429 at Dodge.


You can now remove the front timing cover. Make sure to align the camshaft and crankshaft timing marks before removing the timing belt. The camshaft pulley has a mark that needs to align with the mark on the head above the pulley. The crankshaft sprocket should line up at the same time with its mark at the top of the oil pump assembly. If you accidentally move the camshaft in some manner, after you remove the timing belt, you can damage the pistons or valves.

Next, to loosen the old timing belt, you need to look at the tensioner. Insert an 8 mm Allen wrench into the hexagon opening located on the front of the belt tensioner pulley. Rotate the pulley counterclockwise until it contacts the stop. While holding tensioner pulley against stop, insert a 1/8" or 3 mm diameter pin or Allen wrench through the hole located to the left of the hex opening. While pushing pin into hole, allow the tensioner pulley to rotate back. Almost immediately, the pin should engage the locking hole to prevent further movement of the pulley. I was totally surprised by what happened when I tried to purchase a new timing belt tensioner pulley as my pulley was worn quite badly. I received the wrong part to replace the tensioner pulley three times at three different parts stores. It took about an hour to discover that there was a problem with the old "mechanical" timing belt tensioners. It is not just recommended that you change the tensioner; you must replace the timing belt tensioner plate and all if you have the older mechanical tensioner. This is a technical bulletin from Mopar that says there have been several "explosions" of the mechanical units with engine replacements needed; the tensioner actually blew a hole in the engine block. Of course, this is not a "free replacement" due to a manufacturing problem; you must purchase this item. Some of the latter models of the 2000 Neon have had the hydraulic units installed and all you need to purchase is the tensioner pulley which costs about $30. You can tell if you have the mechanical one when you actually get into and remove the timing belt; the mechanical unit has four pronounced legs, while the hydraulic unit is more of a plate (even though the holes align for both units). You must replace the back timing belt cover with a new tensioner installation (and it comes with the kit). In the earlier neon model required a complete plate, hydraulic unit and tensioner pulley replacement. And, of course, it a dealer item only with a cost of $469.

Before you begin your job of timing belt replacement, find out if you own an earlier 2000 and also locate a dealer with the unit in stock. You honestly should install the hydraulic unit as the technical bulletin explains the damage from an "explosion".


While you are in there, you should replace the water pump. If you read all the bulletins and people's posts about this item going bad just after they finished the timing belt, you really should just purchase the water pump and make sure it has the seal in the kit (some did not include the water pump seal.). The water pump was only $40. If you have to replace it, you see all the trouble you must go through again to get it out of the timing belt area. The water pump is driven by the timing belt.
The oil pump is also driven by the timing belt; however, there are not many failures of the oil pumps.

Now you may start to put the timing belt into place. If you have gotten the timing just a tiny bit off, you can follow the procedure as below. It is hard to explain in words only without pictures; however, I will try to do so.


Set crankshaft sprocket to TDC by aligning the sprocket with the arrow on the oil pump housing, then back off to 3 notches before TDC, that is clockwise three teeth.

Use a large wrench and the crankshaft nut to carefully adjust the timing. This is to allow for belt installation later.


Set camshaft to TDC by aligning mark on sprocket with the arrow on the rear of timing belt cover. Move crankshaft to 1/2 mark before TDC for belt installation.


Install timing belt.
Starting at the crankshaft, go around the water pump sprocket and then around the camshaft sprocket.
Move crankshaft sprocket to TDC to take up belt slack.
Remove the pin or 1/8" or 3 mm Allen wrench from belt tensioner.
Rotate crankshaft 2 revolutions and check the alignment of the timing marks.


Install front timing belt cover. Install engine mount bracket. Install right engine mount to engine mount bracket through bolt. Remove jack from under engine. Install upper torque strut. Install power steering pump assembly. Raise vehicle and install lower torque strut. Install crankshaft damper using M12-1.75 x 150 mm bolt, washer, thrust bearing and nut from Special Tool 6792. Install crankshaft damper bolt and tighten to 142 Nm (100 ft. lbs.). Install accessory drive belts. Install right inner splash shield.
Lower vehicle and perform camshaft and crankshaft timing relearn procedure as follows: Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of instrument panel; near the steering column. Turn the ignition switch on and access the "miscellaneous" screen. Select "re-learn cam/crank" option and follow directions on DRB screen.
It is not a fun job unless you enjoy some very hard work and have a few specialized tools. The scan tool was purchased at Sears (I hope I can say a specific name. You can purchase the scan tool at a parts store or off the web as well.). The special tool is a three-arm puller. The other special tool is to protect the crankshaft threads. Hope this helps!!! and thank you for using FIxya

5.9L DIESEL
The 5.9L diesel engine accessory drive system (with a/c) consists of :

1. Generator Pulley (1)
2. Water Pump Pulley (2)
3. Idler Pulley (3)
4. Power Steering Pump Pulley (4)
5. Radiator Fan Pulley (5)
6. Crankshaft Pulley (6)
7. Automatic Tensioner (7)
8. A/C Compressor Pump Pulley (8)

CAUTION: When installing the accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. Refer to or for correct engine belt routing. The correct belt with correct length must be used.
1. Position drive belt over all pulleys except water pump pulley. 2. Attach a 1/2 inch ratchet to tensioner.


The 5.9L diesel engine accessory drive system (without a/c) consists of :

1. Generator Pulley (1)
2. Water Pump Pulley (2)
3. Idler Pulley (3)
4. Power Steering Pump Pulley (4)
5. Radiator Fan Pulley (5)
6. Crankshaft Pulley (6)
7. Automatic Tensioner (7)

3. Rotate ratchet and belt tensioner clockwise. Place belt over water pump pulley. Let tensioner rotate back into place. Remove ratchet. Be sure belt is properly seated on all pulleys.