Power steering DODGE RAM 1500 1998 2.G User Guide

PEDAL
DESCRIPTION
NOTE: The brake pedal is serviced as a complete
assembly including accelerator pedal and the
bracket.
A suspended-type brake pedal is used. The pedal is
attached to the pedal support bracket with a pivot
shaft pin and bushings. If the bushings become dry a
spray lubricant can be used to eliminate noises. The
booster push rod is attached to the pedal with a clip.
The pedal, bushings, pivot pin and support bracket
are not serviceable components (Fig. 50).
OPERATION
The brake pedal is attached to the booster push
rod. When the pedal is depressed, the primary
booster push rod is depressed which moves the
booster secondary rod. The booster secondary rod
depress the master cylinder piston.
REMOVAL
NOTE: The brake pedal is serviced as a complete
assembly including accelerator pedal and the
bracket.
(1) Disconnect the negative battery cable.
(2) Remove the steering column opening cover(Re-
fer to 23 - BODY/INSTRUMENT PANEL/STEERING
COLUMN OPENING COVER - REMOVAL).(3) Remove the brake lamp switch and discard(Re-
fer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTE-
RIOR/BRAKE LAMP SWITCH - REMOVAL).
(4)On vehicles equipped with adjustable ped-
als.Disconnect the adjuster cable to the pedal (Fig.
51).
(5) Remove the steering column (Refer to 19 -
STEERING/COLUMN - REMOVAL).
(6) Remove the brake booster (Fig. 52)(Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/POWER
BRAKE BOOSTER - REMOVAL).
(7) Disconnect the electrical connectors.
(8) Remove the module mounting bolts.
(9) Disconnect the accelerator pedal cable.
(10) Remove the pedal assembly mounting nuts/
fasteners (Fig. 52).
INSTALLATION
(1) Install the pedal assembly to the vehicle (Fig.
52).
(2) Install the mounting bolts (Fig. 52) and tighten
to 28 N´m (21 ft. lbs.).
(3) Reconnect the accelerator cable to the pedal.
(4) Install the module mounting bolts and tighten
to 38 N´m (28 ft. lbs.).
(5) Reconnect the electrical connectors.
(6) Install the brake booster (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/POWER BRAKE
BOOSTER - INSTALLATION).
(7) Install the steering column (Refer to 19 -
STEERING/COLUMN - INSTALLATION).
(8) Install a new brake lamp switch. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - REMOVAL).
Fig. 50 BRAKE PEDAL
1 - CLIP
2 - BUSHINGS
3 - PIVOT SHAFT PIN
4 - PEDAL ASSEMBLY
ADJUSTABLE PEDAL SHOWN
NON ADJUSTABLE PEDAL IS SIMILIAR
5-PAD
Fig. 51 PEDAL/CABLE
1 - CABLE
2 - BRAKE PEDAL ASSEMBLY
5 - 28 BRAKES - BASEDR

(9)On vehicles equipped with adjustable
brake pedal.Reconnect the electrical connector to
the motor and the adjuster cable at the pedal.
(10) Install the steering column opening cover
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN OPENING COVER - INSTALLA-
TION).
(11) Reconnect the negative battery cable.
POWER BRAKE BOOSTER
DESCRIPTION
All models use a tandem diaphragm, power brake
booster.
NOTE: The power brake booster is not a repairable
component. The booster must be replaced as an
assembly if diagnosis indicates a malfunction has
occurred.
OPERATION
The booster unit consists of a single housing
divided into two by a tandem diaphragm. The outer
edge of the diaphragm is secured to the housing. The
booster push rod, which connects the booster to the
brake pedal and master cylinder, is attached to the
center of the diaphragm. A check valve is used in the
booster outlet connected to the engine intake mani-
fold. Power assist is generated by utilizing a combi-
nation of vacuum and atmospheric pressure to boost
brake assist.
REMOVAL
(1) Remove master cylinder. (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/MASTER CYLINDER -
REMOVAL).
(2) Disconnect vacuum line at booster.
(3) Remove clip securing booster push rod to brake
pedal (Refer to 5 - BRAKES/HYDRAULIC/MECHAN-
ICAL/PEDAL - REMOVAL). (Fig. 53).
(4) Remove the nuts from the booster mounting
studs (Fig. 53).
(5) Remove the booster and gasket from front cowl
panel.
INSTALLATION
(1) Guide the booster studs into the cowl panel
holes and seat the booster on the panel (Fig. 53).
(2) Install and tighten new booster attaching nuts
to 28 N´m (250 in. lbs.).
(3) Install the booster push rod on brake pedal and
install clip (Fig. 53).
(4) Install the booster check valve if removed and
connect the vacuum hose to the check valve.
(5) Install the master cylinder. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/MASTER
CYLINDER - INSTALLATION).
(6) Fill and bleed the brake system. (Refer to 5 -
BRAKES - STANDARD PROCEDURE).
Fig. 52 PEDAL ASSEMBLY (ADJUSTABLE PEDALS
SHOWN)
1 - ADJUSTABLE PEDAL MOTOR
2 - PEDAL ASSEMBLY BRACKET
3 - MOUNTING NUT
4 - BRAKE & ACCELERATOR PEDAL
5 - BRAKE BOOSTER MOUNTING STUDS
Fig. 53 POWER BRAKE BOOSTER
1 - MOUNTING NUT
2 - POWER BRAKE BOOSTER
DRBRAKES - BASE 5 - 29
PEDAL (Continued)

HYDRO-BOOST BRAKE
BOOSTER
DIAGNOSIS AND TESTING - HYDRAULIC
BOOSTER
The hydraulic booster uses hydraulic pressure from
the power steering pump. Before diagnosing a
booster problem, first verify the power steering pump
is operating properly. Perform the following checks.
²Check the power steering fluid level.
²Check the brake fluid level.
²Check all power steering hoses and lines for
leaks and restrictions.
²Check power steering pump pressure.
NOISES
The hydraulic booster unit will produce certain
characteristic booster noises. The noises may occur
when the brake pedal is used in a manner not asso-
ciated with normal braking or driving habits.
HISSING
A hissing noise may be noticed when above normal
brake pedal pressure is applied, 40 lbs. or above. The
noise will be more noticeable if the vehicle is not
moving. The noise will increase with the brake pedal
pressure and an increase of system operating temper-
ature.
CLUNK-CHATTER-CLICKING
A clunk-chatter-clicking may be noticed when the
brake pedal is released quickly, after above normal
brake pedal pressure is applied 50-100 lbs..
BOOSTER FUNCTION TEST
With the engine off depress the brake pedal several
times to discharge the accumulator. Then depress the
brake pedal using 40 lbs. of force and start the
engine. The brake pedal should fall and then push
back against your foot. This indicates the booster is
operating properly.
ACCUMULATOR LEAKDOWN
(1) Start the engine, apply the brakes and turn the
steering wheel from lock to lock. This will ensure the
accumulator is charged. Turn off the engine and let
the vehicle sit for one hour. After one hour thereshould be at least two power assisted brake applica-
tion with the engine off. If the system does not retain
a charge the booster must be replaced.
(2) With the engine off depress the brake pedal
several times to discharge the accumulator. Grasp
the accumulator and see if it wobbles or turns. If it
does the accumulator has lost a gas charge and the
booster must be replaced.
SEAL LEAKAGE
If the booster leaks from any of the seals the
booster assembly must be replaced (Fig. 54).
²INPUT ROD SEAL:Fluid leakage from rear
end of the booster.
²PISTON SEAL:Fluid leakage from vent at
front of booster.
²HOUSING SEAL:Fluid leakage between hous-
ing and housing cover.
²SPOOL VALVE SEAL:Fluid leakage near
spool plug.
²RETURN PORT FITTING SEAL:Fluid leak-
age from port fitting.
Fig. 54 Hydraulic Booster Seals
1 - PUMP
2 - GEAR
3 - INPUT SEAL
4 - HOUSING SEAL
5 - ACCUMULATOR SEAL
6 - PISTON SEAL
7 - SPOOL PLUG SEAL
8 - RETURN
5 - 30 BRAKES - BASEDR

HYDRAULIC BOOSTER DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
Slow Brake Pedal Return 1. Excessive seal friction in booster. 1. Replace booster.
2. Faulty spool valve action. 2. Replace booster.
3. Restriction in booster return hose. 3. Replace hose.
4. Damaged input rod. 4. Replace booster.
Excessive Brake Pedal
Effort.1. Internal or external seal leakage. 1. Replace booster.
2. Faulty steering pump. 2. Replace pump.
Brakes Self Apply 1. Dump valve faulty. 1. Replace booster.
2. Contamination in hydraulic
system.2. Flush hydraulic system and replace
booster.
3. Restriction in booster return hose. 3. Replace hose.
Booster Chatter, Pedal
Vibration1. Slipping pump belt. 1. Replace power steering belt.
2. Low pump fluid level. 2. Fill pump and check for leaks.
Grabbing Brakes 1. Low pump flow. 1. Test and repair/replace pump.
2. Faulty spool valve action. 2. Replace booster.
STANDARD PROCEDURE - BLEEDING
The hydraulic booster is generally self-bleeding,
this procedure will normally bleed the air from the
booster. Normal driving and operation of the unit will
remove any remaining trapped air.
(1) Fill power steering pump reservoir.
(2) Disconnect fuel shutdown relay and crank the
engine for several seconds, Refer to Fuel System for
relay location and WARNING.
(3) Check fluid level and add if necessary.
(4) Connect fuel shutdown relay and start the
engine.
(5) Turn the steering wheel slowly from lock to
lock twice.
(6) Stop the engine and discharge the accumulator
by depressing the brake pedal 5 times.
(7) Start the engine and turn the steering wheel
slowly from lock to lock twice.
(8) Turn off the engine and check fluid level and
add if necessary.
NOTE: If fluid foaming occurs, wait for foam to dis-
sipate and repeat steps 7 and 8.
REMOVAL
NOTE: If the booster is being replaced because the
power steering fluid is contaminated, flush the
power steering system before replacing the booster.
(1) With engine off depress the brake pedal 5
times to discharge the accumulator.
(2) Remove brake lines from master cylinder.
(3) Remove mounting nuts from the master cylin-
der.
(4) Remove the bracket from the hydraulic booster
lines and master cylinder mounting studs.
(5) Remove the master cylinder.
(6) Remove the return hose and the two pressure
lines from the hydraulic booster (Fig. 55).
(7) Remove the booster push rod clip, washer and
rod remove from the brake pedal.
(8) Remove the mounting nuts from the hydraulic
booster and remove the booster.
DRBRAKES - BASE 5 - 31
HYDRO-BOOST BRAKE BOOSTER (Continued)

INSTALLATION
(1) Install the hydraulic booster and tighten the
mounting nuts to 28 N´m (21 ft. lbs.).
(2) Install the booster push rod, washer and clip
onto the brake pedal.
(3) Install the master cylinder on the mounting
studs. and tighten the mounting nuts to 23 N´m (17
ft. lbs.).
(4) Install the brake lines to the master cylinder
and tighten to 19-200 N´m (170-200 in. lbs.).
(5) Install the hydraulic booster line bracket onto
the master cylinder mounting studs.
(6) Install the master cylinder mounting nuts and
tighten to 23 N´m (17 ft. lbs.).
(7) Install the hydraulic booster pressure lines to
the bracket and booster.
(8) Tighten the pressure lines to 41 N´m (30 ft.
lbs.).
NOTE: Inspect o-rings on the pressure line fittings
to insure they are in good condition before installa-
tion. Replace o-rings if necessary.
(9) Install the return hose to the booster.
(10) Bleed base brake system, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL - STAN-
DARD PROCEDURE).
(11) Fill the power steering pump with fluid,
(Refer to 19 - STEERING/PUMP - STANDARD PRO-
CEDURE).
CAUTION: MOPAR (MS-9602) ATF+4 is to be used in
the power steering system. No other power steering
or automatic transmission fluid is to be used in thesystem. Damage may result to the power steering
pump and system if any other fluid is used, and do
not overfill.
(12) Bleed the hydraulic booster (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/POWER
BRAKE BOOSTER - STANDARD PROCEDURE).
ROTORS
DIAGNOSIS AND TESTING
DISC BRAKE ROTOR
The rotor braking surfaces should not be refinished
unless necessary.
Light surface rust and scale can be removed with a
lathe equipped with dual sanding discs. The rotor
surfaces can be restored by machining with a disc
brake lathe if surface scoring and wear are light.
Replace the rotor for the following conditions:
²Severely Scored
²Tapered
²Hard Spots
²Cracked
²Below Minimum Thickness
ROTOR MINIMUM THICKNESS
Measure rotor thickness at the center of the brake
shoe contact surface. Replace the rotor if below min-
imum thickness, or if machining would reduce thick-
ness below the allowable minimum.
Rotor minimum thickness is usually specified on
the rotor hub. The specification is either stamped or
cast into the hub surface.
ROTOR RUNOUT
Check rotor lateral runout with dial indicator
C-3339 (Fig. 56). Excessive lateral runout will cause
brake pedal pulsation and rapid, uneven wear of the
brake shoes. Position the dial indicator plunger
approximately 25.4 mm (1 in.) inward from the rotor
edge.
NOTE: Be sure wheel bearing has zero end play
before checking rotor runout.
Maximum allowable rotor runout is 0.127 mm
(0.005 in.).
ROTOR THICKNESS VARIATION
Variations in rotor thickness will cause pedal pul-
sation, noise and shudder.
Measure rotor thickness at 6 to 12 points around
the rotor face (Fig. 57).
Fig. 55 HYDRO-BOOST UNIT
1 - INLET HOSE
2 - HYDRO-BOOST UNIT
3 - MASTER CYLINDER UNIT
4 - RETURN HOSE
5 - OUTLET HOSE
5 - 32 BRAKES - BASEDR
HYDRO-BOOST BRAKE BOOSTER (Continued)

BRAKES - ABS
TABLE OF CONTENTS
page page
BRAKES - ABS
DESCRIPTION.........................45
OPERATION...........................45
STANDARD PROCEDURE - ABS BRAKE
BLEEDING...........................46
SPECIFICATIONS
TORQUE CHART......................46
FRONT WHEEL SPEED SENSOR
DESCRIPTION.........................47
OPERATION...........................47
REMOVAL.............................48
INSTALLATION.........................48
REAR WHEEL SPEED SENSOR
DIAGNOSIS AND TESTING - REAR WHEEL
ANTILOCK...........................48
REMOVAL.............................48
INSTALLATION.........................48TONE WHEEL
DIAGNOSIS AND TESTING - REAR WHEEL
SPEED SENSOR......................49
HYDRAULIC/MECHANICAL
DESCRIPTION - ELECTRONIC VARIABLE
BRAKE PROPORTIONING...............49
OPERATION - ELECTRONIC VARIABLE
BRAKE PROPORTIONING...............49
HCU (HYDRAULIC CONTROL UNIT)
DESCRIPTION.........................49
OPERATION...........................49
REMOVAL.............................50
INSTALLATION.........................50
R WA L VA LV E
DESCRIPTION.........................50
OPERATION...........................50
REMOVAL.............................51
INSTALLATION.........................51
BRAKES - ABS
DESCRIPTION
The antilock brake system (ABS) is an electroni-
cally operated, three channel brake control system.
The vehicle has Electronic Variable Brake Propor-
tioning (EVBP) designed into the system which elim-
inates the combination/proportioning valve.
The system is designed to prevent wheel lockup
and maintain steering control during braking. Pre-
venting lockup is accomplished by modulating fluid
pressure to the wheel brake units.
The hydraulic system is a three channel design.
The front wheel brakes are controlled individually
and the rear wheel brakes in tandem. The ABS elec-
trical system is separate from other electrical circuits
in the vehicle. A specially programmed controller
antilock brake unit operates the system components.
ABS system major components include:
²Controller Antilock Brakes (CAB)
²Hydraulic Control Unit (HCU)
²Wheel Speed Sensors (WSS)
²ABS Warning Light
OPERATION
Battery voltage is supplied to the CAB. The CAB
performs a system initialization procedure at start
up. A check of the ABS motor is performed at 15miles per hour. Initialization consists of a static and
dynamic self check of system electrical components.
The static and dynamic checks occurs at ignition
start up. During the dynamic check, the CAB briefly
cycles solenoids to verify operation. An audible noise
may be heard during this self check. This noise
should be considered normal. The ABS motor and
pump are then checked at a speed of 15 mile per
hour.
If an ABS component exhibits a fault during ini-
tialization, the CAB illuminates the amber warning
light and registers a fault code in the microprocessor
memory.
The CAB monitors wheel speed sensor inputs con-
tinuously while the vehicle is in motion. However,
the CAB will not activate any ABS components as
long as sensor inputs indicate normal braking.
During normal braking, the master cylinder, power
booster and wheel brake units all function as they
would in a vehicle without ABS. The HCU compo-
nents are not activated.
The purpose of the antilock system is to prevent
wheel lockup. Preventing lockup helps maintain vehi-
cle braking action and steering control.
The antilock CAB activates the system whenever
sensor signals indicate periods of wheel slip.
The antilock system prevents lockup during a
wheel slip condition by modulating fluid apply pres-
sure to the wheel brake units.
DRBRAKES - ABS 5 - 45

STANDARD PROCEDURE - REFILLING
COOLING SYSTEM 5.9L DIESEL ENGINE
Clean cooling system prior to refilling (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(1) Close radiator drain plug.
CAUTION: Due to the use of the one-way check
valve, the engine must not be operating when refill-
ing the cooling system.
NOTE: The diesel engine is equipped with two one-
way check valves (jiggle pins). The check valves
are used as a servicing feature and will vent air
when the system is being filled. Water pressure (or
flow) will hold the valves closed.
(2) Fill the cooling system with a 50/50 mixture of
water and antifreeze.
(3) Fill coolant reserve/overflow tank to the FULL
mark.
(4) Start and operate engine until thermostat
opens. Upper radiator hose should be warm to touch.
(5) If necessary, add 50/50 water and antifreeze
mixture to the coolant reserve/overflow tank to main-
tain coolant level. This level should be between the
ADD and FULL marks. The level in the reserve/over-
flow tank may drop below the ADD mark after three
or four warm-up and cool-down cycles.
STANDARD PROCEDURE - ADDING
ADDITIONAL COOLANT
The use of aluminum cylinder blocks, cylinder
heads and water pumps requires special corrosion
protection. Only MopartAntifreeze/Coolant, 5
Year/100,000 Mile Formula (glycol base coolant with
corrosion inhibitors called HOAT, for Hybrid Organic
Additive Technology) is recommended. This coolant
offers the best engine cooling without corrosion when
mixed with 50% distilled water to obtain a freeze
point of -37ÉC (-35ÉF). If it loses color or becomes con-
taminated, drain, flush, and replace with fresh prop-
erly mixed coolant solution.
CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.
Do not remove the radiator cap to add coolant to
the system. When adding coolant to maintain the cor-
rect level, do so only at the reserve/overflow bottle.
Remove the radiator cap only for testing or when
refilling the system after service. Removing the cap
unnecessarily can cause loss of coolant and allow air
to enter the system, which produces corrosion.
WARNING: DO NOT REMOVE OR LOOSEN THE
RADIATOR CAP WITH THE COOLING SYSTEM HOTAND UNDER PRESSURE. SERIOUS BURNS FROM
THE COOLANT OR HIGH PRESSURE STEAM CAN
OCCUR.
SPECIFICATIONS
TORQUE
DESCRIPTION N´m Ft.
Lbs.In.
Lbs.
Bolt - Automatic Belt
Tensioner to Block41 30 -
Bolt - Automatic Belt
Tensioner Pulley61 45 -
Bolt - Automatic Belt
Tensioner Pulley - Diesel43 32 -
Bolt - Block Heater 2 - 17
Bolts - Generator/
Compressor Mounting
Bracket
# 1 and 2 54 40 -
# 3 40 30 -
Bolts - Generator/
Compressor Mounting
Bracket - Diesel24 18 -
Bolts - Fan Shroud to
Radiator Mounting - All
Except 5.9L Diesel6-55
5.9L Diesel 11.8 - 105
Bolts - Radiator to Support 8.5 - 75
Bolts - Fan Blade to
Viscous Fan Drive24 18 -
Fan Drive - All Except
8.0L/5.9L Diesel50 37 -
8.0L/5.9L Diesel 115 85 -
Bolt - Idler Pulley 54 40 -
Bolt - Idler Pulley - Diesel 43 32 -
Bolts - Thermostat Housing
- All Except 5.9L13 - 112
Bolts - Thermostat Housing
5.9L23 16 -
Bolts - Thermostat Housing
- Diesel10 - 89
Bolts - Power Steering Oil
Cooler8.4 - 75
Bolts - Transmission
Auxiliary Oil Cooler6-55
DRCOOLING 7 - 19
COOLING (Continued)

ACCESSORY DRIVE
TABLE OF CONTENTS
page page
BELT TENSIONER - 3.7L / 4.7L
DESCRIPTION.........................21
OPERATION...........................21
REMOVAL.............................21
INSTALLATION.........................22
BELT TENSIONER-5.7L
DESCRIPTION.........................22
OPERATION...........................22
REMOVAL.............................22
INSTALLATION.........................23
BELT TENSIONER - 5.9L DIESEL
DESCRIPTION.........................23
OPERATION...........................23REMOVAL.............................23
INSTALLATION.........................24
DRIVE BELT - 3.7L / 4.7L
DIAGNOSIS AND TESTING - ACCESSORY
DRIVE BELT.........................24
REMOVAL.............................26
INSTALLATION.........................26
DRIVE BELT - 5.9L DIESEL
DIAGNOSIS AND TESTINGÐACCESSORY
DRIVE BELT.........................27
REMOVAL.............................29
INSTALLATION.........................29
BELT TENSIONER - 3.7L / 4.7L
DESCRIPTION
Correct drive belt tension is required to ensure
optimum performance of the belt driven engine acces-
sories. If specified tension is not maintained, belt
slippage may cause; engine overheating, lack of
power steering assist, loss of air conditioning capac-
ity, reduced generator output rate, and greatly
reduced belt life.
It is not necessary to adjust belt tension on the
3.7L or 4.7L engine. These engines are equipped with
an automatic belt tensioner (Fig. 1). The tensioner
maintains correct belt tension at all times. Due to
use of this belt tensioner, do not attempt to use a belt
tension gauge on 3.7L or 4.7L engines.
OPERATION
The automatic belt tensioner maintains belt ten-
sion by using internal spring pressure, a pivoting
arm and pulley to press against the drive belt.
REMOVAL
On 3.7L and 4.7L engines, the tensioner is
equipped with an indexing tang on back of ten-
sioner and an indexing stop on tensioner hous-
ing. If a new belt is being installed, tang must
be within approximately 24 mm (.94 inches) of
indexing stop. Belt is considered new if it has
been used 15 minutes or less.
If the above specification cannot be met, check for:²The wrong belt being installed (incorrect length/
width)
²Worn bearings on an engine accessory (A/C com-
pressor, power steering pump, water pump, idler pul-
ley or generator)
²A pulley on an engine accessory being loose
²Misalignment of an engine accessory
²Belt incorrectly routed.
NOTE: A used belt should be replaced if tensioner
indexing arrow has moved to the minimum tension
indicator. Tensioner travel stops at this point.
Fig. 1 AUTOMATIC BELT TENSIONER
1 - AUTOMATIC TENSIONER ASSEMBLY
DRACCESSORY DRIVE 7 - 21

(1) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(2) Remove tensioner assembly from mounting
bracket (Fig. 2).
WARNING: BECAUSE OF HIGH SPRING PRES-
SURE, DO NOT ATTEMPT TO DISASSEMBLE AUTO-
MATIC TENSIONER. UNIT IS SERVICED AS AN
ASSEMBLY EXCEPT FOR PULLEY ON TENSIONER.
(3) Remove pulley bolt. Remove pulley from ten-
sioner.
INSTALLATION
(1) Install pulley and pulley bolt to tensioner.
Tighten bolt to 61 N´m (45 ft. lbs.) torque.
(2) An indexing slot is located on back of tensioner.
Align this slot to the head of the bolt on the front
cover. Install the mounting bolt. Tighten bolt to 41
N´m (30 ft. lbs.).
(3) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(4) Check belt indexing marks (Fig. 1).
BELT TENSIONER-5.7L
DESCRIPTION
Correct drive belt tension is required to ensure
optimum performance of the belt driven engine acces-
sories. If specified tension is not maintained, belt
slippage may cause; engine overheating, lack of
power steering assist, loss of air conditioning capac-
ity, reduced generator output rate, and greatly
reduced belt life.
It is not necessary to adjust belt tension on the
5.7L engines. This engines is equipped with an auto-
matic belt tensioner. The tensioner maintains correct
belt tension at all times (Fig. 3). Due to the use of
this belt tensioner, do not attempt to use a belt ten-
sion gauge on 5.7L engine.
OPERATION
The automatic belt tensioner maintains belt ten-
sion by using internal spring pressure, a pivoting
arm and pulley to press against the drive belt.
REMOVAL
(1) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(2) Remove tensioner and mounting bracket.
(3) Remove the tensioner assembly from the
mounting bracket.
(4)
Fig. 2 AUTOMATIC BELT TENSIONER - 3.7L/4.7L
ENGINE
1 - TIMING CHAIN COVER
2 - BOLT TORQUE TO 41 N´m (30 FT LBS)
3 - AUTOMATIC BELT TENSIONER
Fig. 3 Automatic Belt Tensioner
1 - TENSIONER
2 - BOLT
7 - 22 ACCESSORY DRIVEDR
BELT TENSIONER - 3.7L / 4.7L (Continued)

INSTALLATION
(1) Install tensioner on to the mounting bracket.
Tighten bolt to 41 N´m (30 ft. lbs.).
(2) Install tensioner and bracket assembly
(3) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
BELT TENSIONER - 5.9L
DIESEL
DESCRIPTION
Drive belts on all engines are equipped with a
spring loaded automatic belt tensioner (Fig. 4). This
tensioner maintains constant belt tension at all times
and requires no maintenance or adjustment.
CAUTION: Do not attempt to check belt tension with
a belt tension gauge on vehicles equipped with an
automatic belt tensioner.
OPERATION
WARNING: THE AUTOMATIC BELT TENSIONER
ASSEMBLY IS SPRING LOADED. DO NOT ATTEMPT
TO DISASSEMBLE THE TENSIONER ASSEMBLY.
The automatic belt tensioner maintains correct belt
tension using a coiled spring within the tensioner
housing. The spring applies pressure to the tensioner
arm pressing the arm into the belt, tensioning the
belt.
REMOVAL
WARNING: BECAUSE OF HIGH SPRING PRES-
SURE, DO NOT ATTEMPT TO DISASSEMBLE AUTO-
MATIC TENSIONER. UNIT IS SERVICED AS AN
ASSEMBLY.
(1) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(2) Remove tensioner mounting bolt (Fig. 5) and
remove tensioner.
Fig. 4 Accessory Drive Belt - 5.9L Diesel
1 - GENERATOR
2 - WATER PUMP
3 - IDLER
4 - POWER STEERING PUMP
5 - RADIATOR FAN PULLEY
6 - CRANKSHAFT
7 - AUTOMATIC TENSIONER
8 - A/C COMPRESSOR
Fig. 5 AUTOMATIC BELT TENSIONER 5.9L DIESEL
ENGINE
1 - GENERATOR
2 - WATER PUMP
3 - IDLER
4 - POWER STEERING PUMP
5 - RADIATOR FAN PULLEY
6 - CRANKSHAFT
7 - AUTOMATIC TENSIONER
8 - A/C COMPRESSOR
DRACCESSORY DRIVE 7 - 23
BELT TENSIONER-5.7L (Continued)