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 Post subject: How-To Install New Belt Tensioner/Serpentine Belt Removal
PostPosted: Tue Oct 07, 2014 9:11 pm 
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This is a How-To to change out a Belt Tensioner on the 3.7L. With it the serpentine belt will be removed and this can be a how-to at the same time by ignoring and skipping steps for the belt tensioner. I am writing this based off my experience and am not saying this is the proper way as I am not a professsionl. I AM NOT LIABLE FOR DAMAGES TO YOUR JEEP OR YOURSSELF...moving on haha:

Here is the 3.7L Belt Drive Pattern and which pulley goes to what
Image

Tools Needed:

Flat Head Screwdriver
T20 Torx Screwdriver
3/8" & 1/4" Drive Ratchet
2" 1/4" Extension
5/8" Socket
13mm Socket
10mm Socket
8mm Socket
About 2-3 hours of time

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1) Open Hood

Image

2) Remove Negative Battery Cable

Image

3) Move Hood Release Cable out of the way to remove the grille

Image

4) Remove the Grille

Remove plastic fasteners and lift top over the hood bump stops, undo clips from atop headlight housing and use flat head screwdriver to the hidden clip off the side of the headlight housing, pull towards you and set aside.

Tricky Clip
Image

Image

5) Remove Headlight Housing

Using the T20 torx screwdriver remove the 3 screws mounting the housing, then unplug headlights/fog light via quarter-turn counter-clockwise.

Image

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(Love the guard as it creates a chair for me haha)

6) Remove the Coolant/Wiper Fluid Tank

Using the T20 torx screwdriver remove the four screws mounting the tank, unscrew the radiator cap a quarter-turn and remove hose, unplug wiper pump connector via using the torx screwdriver to poke the hole and pulling up on the connector and remove hoses (90degree hose can be removed after tank is outside the engine bay, wiper fluid will slowly drain after removal of 90degree hose).

Top two screws
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Wiper Connector
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Driver's Side Bottom Screw
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Passenger's Side Bottom Screw
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7) Remove Fan Shroud

Using a 8mm socket remove the three screws mounting the fan shroud, after screws are removed lift shroud enough to unplug the fan's connector (use the flathead to pry the clip and pull out), then using the 10mm socket remove the bolt securing the wire harness connector and remove wire from shroud, set aside shroud.

Driver's Side Screw
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Passenger's Side Screw
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Bottom Screw (AC Lines are secured here)
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Fan's Connector (put flathead's tip where red dash is)
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Wire Harness Connector's Bolt
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8) Remove Serpentine Belt

Using a 5/8" socket (and a pipe extension) "tighten" the ribbed pulley (left pulley) on the belt tensioner (this goes against the torsion spring in the tensioner and releases pressure off the belt) and remove belt off of a pulley, work belt out of the engine bay.

Image

9) Remove Belt Tensioner

Using a 5/8" socket removed the ribbed pulley's bolt from the belt tensioner (this opens up the space needed to access the bolt mounting the belt tensioner), using a 13mm socket (and pipe extension) remove the bolt securing the old belt tensioner(it may be very tight, mine needed my breaker bar pipe extension).

Belt Tensioner Mounting Bolt
Image

Belt Tensioner Removed (leave circled alone, it's the alignment and bracing bolt for the tensioner)
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9) Install New Belt Tensioner

I bought an AC Delco Belt Tensioner, which has a different size tensioner bolt size (from 5/8" to 13mm).

Image

10) Re-install the Serpentine belt

Re-wrap the serpentine belt around the pulleys as shown in the belt drive pattern diagram leaving one pulley unwrapped until tensioner is "tightened", using the required bolt size, "tighten" the ribbed pulley to allow enough room to wrap the belt around the final pulley (I liked using the alternator pulley as it was small on the top). Ensuring nothing is in the fan's path, re-install the negative battery cable and test run the new pulley and/or belt. If everything checks out, remove negative battery cable again.

3.7L Belt Drive Pattern Diagram
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Re-installed Serpentine Belt
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11) Re-install the Fan Shroud and Connectors

12) Re-install the Coolant/Wiper Fluid Tank, Hoses, and Wiper Pump Connector

13) Re-install the Headlight Housings

14) Re-install the Grille

15) Re-install the Negative Battery Cable

16) Test run

Continue enjoying the KK for many more miles!

Please let me know if there should be any additions or changes to this how-to. Thank you for taking the time to read this!

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 Post subject: Re: How-To Install New Belt Tensioner/Serpentine Belt Remova
PostPosted: Tue Oct 07, 2014 10:02 pm 
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Awesome post, NAMoulton1! :BANANA: Thank you!
I linked to this thread in the KK How-To's Index, in the Under the Hood section.

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M116A3 Trailer build thread: viewtopic.php?f=72&t=77997


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 Post subject: Re: How-To Install New Belt Tensioner/Serpentine Belt Remova
PostPosted: Tue Oct 07, 2014 10:39 pm 
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I didn't realize how much effort it was to write these haha...spent more time doing the write up than the work! Hahaha

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 Post subject: Re: How-To Install New Belt Tensioner/Serpentine Belt Remova
PostPosted: Wed Oct 08, 2014 1:31 pm 
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Great write up!
They do take a very long time to do, and this is very well done!

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 Post subject: Re: How-To Install New Belt Tensioner/Serpentine Belt Remova
PostPosted: Tue Sep 05, 2017 3:18 pm 
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any ideas why I do not see any pictures? Tried with iPhone and PC chrome browser :?


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 Post subject: Re: How-To Install New Belt Tensioner/Serpentine Belt Remova
PostPosted: Tue Sep 05, 2017 3:24 pm 
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Aurum wrote:
any ideas why I do not see any pictures? Tried with iPhone and PC chrome browser :?

The IMG links in the original post point to pics that have been moved or deleted. You could PM NAMoulton1 and see if he'd be willing to fix the broken links for you.

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2008 Liberty Sport 4x4 Automatic
Image
Jeepin By Al 4" Lift Kit
BFG KO2’s 245/75R16
Full MOPAR skid plates
Rock Lizard Skink Super Sliders
AtTheHelm Front Recovery System & Roof Rack

M116A3 Trailer build thread: viewtopic.php?f=72&t=77997


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