belt DODGE RAM 2002 Service Owner's Manual

REMOVAL
NOTE: The belt routing schematics are published
from the latest information available at the time of
publication. If anything differs between these sche-
matics and the Belt Routing Label, use the sche-
matics on Belt Routing Label. This label is located
in the engine compartment.
CAUTION: Do not attempt to check belt tension with
a belt tension gauge on vehicles equipped with an
automatic belt tensioner. Refer to Automatic Belt
Tensioner in this group.
Drive belts on these engines are equipped with a
spring loaded automatic belt tensioner (Fig. 12). This
belt tensioner will be used on all belt configurations,
such as with or without power steering or air condi-
tioning. For more information, (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/BELT TENSIONERS -
DESCRIPTION).(1) Attach a socket/wrench to pulley mounting bolt
of automatic tensioner (Fig. 12).
(2) Rotate tensioner assembly clockwise (as viewed
from front) until tension has been relieved from belt.
(3) Remove belt from idler pulley first.
(4) Remove belt from vehicle.
INSTALLATION
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 (Fig. 13) (Fig. 14) for correct
engine belt routing. The correct belt with correct
length must be used.
(1) Position drive belt over all pulleysexceptidler
pulley. This pulley is located between generator and
A/C compressor.
(2) Attach a socket/wrench to pulley mounting bolt
of automatic tensioner (Fig. 12).
(3) Rotate socket/wrench clockwise. Place belt over
idler pulley. Let tensioner rotate back into place.
Remove wrench. Be sure belt is properly seated on
all pulleys.
(4) Check belt indexing marks.
Fig. 12 Belt Tensioner - 5.9L Gas Engines
1 - IDLER PULLEY
2 - TENSIONER
3 - FAN BLADE
Fig. 13 Belt Routing - 5.9L Engines with A/C
1 - GENERATOR PULLEY
2 - A/C PULLEY
3 - POWER STEERING PULLEY
4 - CRANKSHAFT PULLEY
5 - WATER PUMP PULLEY
6 - TENSIONER PULLEY
7 - IDLER PULLEY
7 - 26 ACCESSORY DRIVEBR/BE
DRIVE BELTS - 5.9L (Continued)

DRIVE BELTS - 8.0L
DIAGNOSIS AND TESTINGÐACCESSORY
DRIVE BELT
VISUAL DIAGNOSIS
When diagnosing serpentine accessory drive belts,
small cracks that run across the ribbed surface of the
belt from rib to rib (Fig. 15), are considered normal.
These are not a reason to replace the belt. However,
cracks running along a rib (not across) arenotnor-
mal. Any belt with cracks running along a rib mustbe replaced (Fig. 15). Also replace the belt if it has
excessive wear, frayed cords or severe glazing.
Refer to ACCESSORY DRIVE BELT DIAGNOSIS
CHART for further belt diagnosis.NOISE DIAGNOSIS
Noises generated by the accessory drive belt are
most noticeable at idle. Before replacing a belt to
resolve a noise condition, inspect all of the accessory
drive pulleys for alignment, glazing, or excessive end
play.
Fig. 14 Belt Routing - 5.9L Engines Without A/C
1 - GENERATOR PULLEY
2 - IDLER PULLEY
3 - POWER STEERING PULLEY
4 - CRANKSHAFT PULLEY
5 - WATER PUMP PULLEY
6 - TENSIONER PULLEY
Fig. 15 Belt Wear Patterns
1 - NORMAL CRACKS BELT OK
2 - NOT NORMAL CRACKS REPLACE BELT
BR/BEACCESSORY DRIVE 7 - 27
DRIVE BELTS - 5.9L (Continued)

ACCESSORY DRIVE BELT DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
RIB CHUNKING (One or more ribs
has separated from belt body)1. Foreign objects imbedded in
pulley grooves.1. Remove foreign objects from
pulley grooves. Replace belt.
2. Installation damage 2. Replace belt
RIB OR BELT WEAR 1. Pulley misaligned 1. Align pulley(s)
2. Abrasive environment 2. Clean pulley(s). Replace belt if
necessary
3. Rusted pulley(s) 3. Clean rust from pulley(s)
4. Sharp or jagged pulley groove
tips4. Replace pulley. Inspect belt.
5. Belt rubber deteriorated 5. Replace belt
BELT SLIPS 1. Belt slipping because of
insufficient tension1. Inspect/Replace tensioner if
necessary
2. Belt or pulley exposed to
substance that has reduced friction
(belt dressing, oil, ethylene glycol)2. Replace belt and clean pulleys
3. Driven component bearing failure
(seizure)3. Replace faulty component or
bearing
4. Belt glazed or hardened from
heat and excessive slippage4. Replace belt.
LONGITUDAL BELT CRACKING 1. Belt has mistracked from pulley
groove1. Replace belt
2. Pulley groove tip has worn away
rubber to tensile member2. Replace belt
9GROOVE JUMPING9
(Belt does not maintain correct
position on pulley)1. Incorrect belt tension 1. Inspect/Replace tensioner if
necessary
2. Pulley(s) not within design
tolerance2. Replace pulley(s)
3. Foreign object(s) in grooves 3. Remove foreign objects from
grooves
4. Pulley misalignment 4. Align component
5. Belt cordline is broken 5. Replace belt
BELT BROKEN
(Note: Identify and correct problem
before new belt is installed)1. Incorrect belt tension 1. Replace Inspect/Replace
tensioner if necessary
2. Tensile member damaged during
belt installation2. Replace belt
3. Severe misalignment 3. Align pulley(s)
4. Bracket, pulley, or bearing failure 4. Replace defective component
and belt
7 - 28 ACCESSORY DRIVEBR/BE
DRIVE BELTS - 8.0L (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
NOISE (Objectional squeal, spueak,
or rumble is heard or felt while drive
belt is in operation)1. Incorrect belt tension 1. Inspect/Replace tensioner if
necessary
2. Bearing noise 2. Locate and repair
3. Belt misalignment 3. Align belt/pulley(s)
4. Belt to pulley mismatch 4. Install correct belt
5. Driven component induced
vibration5. Locate defective driven
component and repair
TENSION SHEETING FABRIC
FAILURE
(Woven fabric on outside,
circumference of belt has cracked or
separated from body of belt)1. Tension sheeting contacting
stationary object1. Correct rubbing condition
2. Excessive heat causing woven
fabric to age2. Replace belt
3. Tension sheeting splice has
fractured3. Replace belt
CORD EDGE FAILURE
(Tensile member exposed at edges
of belt or separated from belt body)1. Incorrect belt tension 1. Inspect/Replace tensioner if
necessary
2. Belt contacting stationary object 2. Replace belt
3. Pulley(s) out of tolerance 3. Replace pulley
4. Insufficient adhesion between
tensile member and rubber matrix4. Replace belt
REMOVAL
Drive belts are equipped with a spring loaded auto-
matic belt tensioner (Fig. 16). This belt tensioner will
be used on all belt configurations, such as with or
without power steering or air conditioning. For more
information, refer to Automatic Belt Tensioner, pro-
ceeding in this group.
(1) Attach a socket/wrench to pulley mounting bolt
of automatic tensioner (Fig. 16). The threads on the
pulley mounting bolt are left- hand.
(2) Relax the tension from the belt by rotating the
tensioner counterclockwise (as viewed from front)
(Fig. 16). When all belt tension has been relaxed,
remove belt from tensioner pulley first and other pul-
leys last.
INSTALLATION
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 (Fig. 17) (Fig. 18) for correct
engine belt routing. The correct belt with correct
length must be used.
CAUTION: If the pulley is to be removed from the
tensioner, its mounting bolt has left-hand threads.
Fig. 16 Belt Tensioner
1 - PULLEY BOLT
2 - IDLER PULLEY
3 - TENSIONER PULLEY
4 - TENSIONER
5 - TENSIONER MOUNTING BOLT
BR/BEACCESSORY DRIVE 7 - 29
DRIVE BELTS - 8.0L (Continued)

(1) Position drive belt over all pulleysexceptten-
sioner pulley.
(2) Attach a socket/wrench to pulley mounting bolt
of automatic tensioner (Fig. 16).
(3) Rotate socket/wrench counterclockwise. Install
belt over tensioner pulley. Let tensioner rotate back
into place. Remove wrench. Be sure belt is properly
seated on all pulleys.
DRIVE BELTS - 5.9L DIESEL
DIAGNOSIS AND TESTINGÐACCESSORY
DRIVE BELT
VISUAL DIAGNOSIS
When diagnosing serpentine accessory drive belts,
small cracks that run across the ribbed surface of the
belt from rib to rib (Fig. 19), are considered normal.
These are not a reason to replace the belt. However,
cracks running along a rib (not across) arenotnor-
mal. Any belt with cracks running along a rib must
be replaced (Fig. 19). Also replace the belt if it has
excessive wear, frayed cords or severe glazing.
Refer to ACCESSORY DRIVE BELT DIAGNOSIS
CHART for further belt diagnosis.
Fig. 17 Belt RoutingÐWith A/C
1 - AUTOMATIC TENSIONER
2 - GENERATOR PULLEY
3 - IDLER PULLEY
4 - A/C COMPRESSOR PUMP PULLEY
5 - POWER STEERING PUMP PULLEY
6 - WATER PUMP AND FAN PULLEY
7 - CRANKSHAFT PULLEY
8 - AIR PUMP (A.I.R.) PULLEY
Fig. 18 Belt RoutingÐWithout A/C
1 - AUTOMATIC TENSIONER
2 - GENERATOR PULLEY
3 - IDLER PULLEY
4 - POWER STEERING PUMP PULLEY
5 - WATER PUMP AND FAN PULLEY
6 - CRANKSHAFT PULLEY
7 - AIR PUMP (A.I.R.) PULLEY
Fig. 19 Belt Wear Patterns
1 - NORMAL CRACKS BELT OK
2 - NOT NORMAL CRACKS REPLACE BELT
7 - 30 ACCESSORY DRIVEBR/BE
DRIVE BELTS - 8.0L (Continued)

NOISE DIAGNOSIS
Noises generated by the accessory drive belt are
most noticeable at idle. Before replacing a belt toresolve a noise condition, inspect all of the accessory
drive pulleys for alignment, glazing, or excessive end
play.
ACCESSORY DRIVE BELT DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
RIB CHUNKING (One or more ribs
has separated from belt body)1. Foreign objects imbedded in
pulley grooves.1. Remove foreign objects from
pulley grooves. Replace belt.
2. Installation damage 2. Replace belt
RIB OR BELT WEAR 1. Pulley misaligned 1. Align pulley(s)
2. Abrasive environment 2. Clean pulley(s). Replace belt if
necessary
3. Rusted pulley(s) 3. Clean rust from pulley(s)
4. Sharp or jagged pulley groove
tips4. Replace pulley. Inspect belt.
5. Belt rubber deteriorated 5. Replace belt
BELT SLIPS 1. Belt slipping because of
insufficient tension1. Inspect/Replace tensioner if
necessary
2. Belt or pulley exposed to
substance that has reduced friction
(belt dressing, oil, ethylene glycol)2. Replace belt and clean pulleys
3. Driven component bearing failure
(seizure)3. Replace faulty component or
bearing
4. Belt glazed or hardened from
heat and excessive slippage4. Replace belt.
LONGITUDAL BELT CRACKING 1. Belt has mistracked from pulley
groove1. Replace belt
2. Pulley groove tip has worn away
rubber to tensile member2. Replace belt
9GROOVE JUMPING9
(Belt does not maintain correct
position on pulley)1. Incorrect belt tension 1. Inspect/Replace tensioner if
necessary
2. Pulley(s) not within design
tolerance2. Replace pulley(s)
3. Foreign object(s) in grooves 3. Remove foreign objects from
grooves
4. Pulley misalignment 4. Align component
5. Belt cordline is broken 5. Replace belt
BR/BEACCESSORY DRIVE 7 - 31
DRIVE BELTS - 5.9L DIESEL (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
BELT BROKEN
(Note: Identify and correct problem
before new belt is installed)1. Incorrect belt tension 1. Replace Inspect/Replace
tensioner if necessary
2. Tensile member damaged during
belt installation2. Replace belt
3. Severe misalignment 3. Align pulley(s)
4. Bracket, pulley, or bearing failure 4. Replace defective component
and belt
NOISE (Objectional squeal, spueak,
or rumble is heard or felt while drive
belt is in operation)1. Incorrect belt tension 1. Inspect/Replace tensioner if
necessary
2. Bearing noise 2. Locate and repair
3. Belt misalignment 3. Align belt/pulley(s)
4. Belt to pulley mismatch 4. Install correct belt
5. Driven component induced
vibration5. Locate defective driven
component and repair
TENSION SHEETING FABRIC
FAILURE
(Woven fabric on outside,
circumference of belt has cracked or
separated from body of belt)1. Tension sheeting contacting
stationary object1. Correct rubbing condition
2. Excessive heat causing woven
fabric to age2. Replace belt
3. Tension sheeting splice has
fractured3. Replace belt
CORD EDGE FAILURE
(Tensile member exposed at edges
of belt or separated from belt body)1. Incorrect belt tension 1. Inspect/Replace tensioner if
necessary
2. Belt contacting stationary object 2. Replace belt
3. Pulley(s) out of tolerance 3. Replace pulley
4. Insufficient adhesion between
tensile member and rubber matrix4. Replace belt
REMOVAL
CAUTION: Do not attempt to check belt tension with
a belt tension gauge on vehicles equipped with an
automatic belt tensioner. Refer to Automatic Belt
Tensioner in this group.
NOTE: The belt routing schematics are published
from the latest information available at the time of
publication. If anything differs between these sche-
matics and the Belt Routing Label, use the sche-
matics on Belt Routing Label.This label is located in
the engine compartment.
Drive belts on diesel engines are equipped with a
spring loaded automatic belt tensioner (Fig. 20).
(Fig. 20) displays the tensioner for vehicles
without air conditioning.
This belt tensioner will be used on all belt configura-
tions, such as with or without air conditioning. For
more information, (Refer to 7 - COOLING/ACCESSORY
DRIVE/BELT TENSIONERS - DESCRIPTION).
(1) A 3/8 inch square hole is provided in the auto-
matic belt tensioner (Fig. 20). Attach a 3/8 inch
drive-long handle ratchet to this hole.
(2) Rotate ratchet and tensioner assembly counter-
clockwise (as viewed from front) until tension has
been relieved from belt.
(3) Remove belt from water pump pulley first.
(4) Remove belt from vehicle.
INSTALLATION
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 (Fig. 21) (Fig. 22) for correct
engine belt routing. The correct belt with correct
length must be used.
(1) Position drive belt over all pulleysexcept
water pump pulley.
(2) Attach a 3/8 inch ratchet to tensioner.
7 - 32 ACCESSORY DRIVEBR/BE
DRIVE BELTS - 5.9L DIESEL (Continued)

(3) Rotate ratchet and belt tensioner counterclock-
wise. Place belt over water pump pulley. Let ten-
sioner rotate back into place. Remove ratchet. Be
sure belt is properly seated on all pulleys.
VACUUM PUMP - 5.9L DIESEL
DESCRIPTION
The vacuum pump and the power steering pump
are combined into a single assembly on diesel engine
models (Fig. 23). Both pumps are operated by a drive
gear attached to the vacuum pump shaft. The shaft
gear is driven by the camshaft gear.
The vacuum pump is a constant displacement,
vane-type pump. Vacuum is generated by four vanes
mounted in the pump rotor. The rotor is located in
the pump housing and is pressed onto the pump
shaft.
The vacuum and steering pumps are operated by a
single drive gear pressed onto the vacuum pump
shaft. The drive gear is operated by the engine cam-
shaft gear.
The vacuum and power steering pump shafts are
connected by a coupling. Each pump shaft has an
adapter with drive lugs that engage in the coupling.
The vacuum pump rotating components are lubri-
cated by engine oil. Lubricating oil is supplied to the
pump through an oil line at the underside of the
pump housing.
Fig. 20 Belt TensionerÐ5.9L DieselÐTypical
(non-A/C shown)
1 - WATER PUMP
2 - ACCESSORY DRIVE BELT
3 - AUTOMATIC BELT TENSIONER
4 - 3/89SQUARE BOLT
5 - MOUNT. BOLT
Fig. 21 Belt RoutingÐ5.9L Diesel EngineÐWith A/C
1 - GENERATOR PULLEY
2 - WATER PUMP PULLEY
3 - FAN PULLEY
4 - CRANKSHAFT PULLEY
5 - AUTOMATIC TENSIONER
6 - A/C COMPRESSOR PUMP PULLEY
Fig. 22 Belt RoutingÐ5.9L Diesel EngineÐWithout
A/C
1 - GENERATOR PULLEY
2 - FAN PULLEY
3 - CRANKSHAFT PULLEY
4 - AUTOMATIC TENSIONER
5 - WATER PUMP PULLEY
BR/BEACCESSORY DRIVE 7 - 33
DRIVE BELTS - 5.9L DIESEL (Continued)

(5) Do not attempt to remove fan/viscous fan drive
assembly from vehicle at this time.
(6) Do not unbolt fan blade assembly (Fig. 6) from
viscous fan drive at this time.
(7) Remove four fan shroud-to-radiator mounting
bolts.(8) Remove fan shroud and fan blade/viscous fan
drive assembly as a complete unit from vehicle.
(9) After removing fan blade/viscous fan drive
assembly,do notplace viscous fan drive in horizon-
tal position. If stored horizontally, silicone fluid in
the viscous fan drive could drain into its bearing
assembly and contaminate lubricant.
CAUTION: Do not remove water pump pulley-to-wa-
ter pump bolts. This pulley is under spring tension.
(10) Remove four bolts securing fan blade assem-
bly to viscous fan drive (Fig. 6).
CAUTION: Some engines equipped with serpentine
drive belts have reverse rotating fans and viscous
fan drives. They are marked with the word
REVERSE to designate their usage. Installation of
the wrong fan or viscous fan drive can result in
engine overheating.
CLEANING
Clean the fan blades using a mild soap and water.
Do not use an abrasive to clean the blades.
INSPECTION
WARNING: DO NOT ATTEMPT TO BEND OR
STRAIGHTEN FAN BLADES IF FAN IS NOT WITHIN
SPECIFICATIONS.
CAUTION: If fan blade assembly is replaced
because of mechanical damage, water pump and
viscous fan drive should also be inspected. These
components could have been damaged due to
excessive vibration.
(1) Remove fan blade assembly from viscous fan
drive unit (four bolts).
(2) Lay fan on a flat surface with leading edge fac-
ing down. With tip of blade touching flat surface,
replace fan if clearance between opposite blade and
surface is greater than 2.0 mm (.090 inch). Rocking
motion of opposite blades should not exceed 2.0 mm
(.090 inch). Test all blades in this manner.
(3) Inspect fan assembly for cracks, bends, loose
rivets or broken welds. Replace fan if any damage is
found.
INSTALLATION
(1) Install fan blade assembly to viscous fan drive.
Tighten bolts (Fig. 6) to 23 N´m (17 ft. lbs.) torque.
(2) Position fan shroud and fan blade/viscous fan
drive assembly to vehicle as a complete unit.
(3) Install fan shroud.
Fig. 5 Using Special Tool 6958 Spanner Wrench
1 - SPECIAL TOOL 6958 SPANNER WRENCH WITH ADAPTER
PINS 8346
2-FAN
Fig. 6 Fan Blade/Viscous Fan Drive - Gas Engines -
Typical
1 - WATER PUMP BYPASS HOSE
2 - FAN BLADE ASSEMBLY
3 - VISCOUS FAN DRIVE
4 - WATER PUMP AND PULLEY
7 - 42 ENGINEBR/BE
RADIATOR FAN - 5.9L/8.0L (Continued)

(4) Install fan blade/viscous fan drive assembly to
water pump shaft (Fig. 6).
(5) Except 8.0L V-10 Engine: Install coolant
reserve/overflow tank to fan shroud. Snaps into posi-
tion.
(6) Install throttle cable to fan shroud.
(7) Connect negative battery cable.
NOTE:
Viscous Fan Drive Fluid Pump Out Requirement:
After installing a new viscous fan drive, bring the
engine speed up to approximately 2000 rpm and
hold for approximately two minutes. This will
ensure proper fluid distribution within the drive.
RADIATOR FAN - 5.9L DIESEL
REMOVAL
CAUTION: If the viscous fan drive is replaced
because of mechanical damage, the cooling fan
blades should also be inspected. Inspect for fatigue
cracks, loose blades, or loose rivets that could
have resulted from excessive vibration. Replace fan
blade assembly if any of these conditions are
found. Also inspect water pump bearing and shaft
assembly for any related damage due to a viscous
fan drive malfunction.
(1) Disconnect the battery negative cables.
(2) Remove the fan shroud mounting bolts. Posi-
tion fan shroud towards engine.
CAUTION: Do not remove the fan pulley bolts. This
pulley is under spring tension.
(3) The thermal viscous fan drive/fan blade assem-
bly is attached (threaded) to the fan hub shaft (Fig.
7). Remove the fan blade/fan drive assembly from fan
pulley by turning the mounting nut clockwise (as
viewed from front). Threads on the viscous fan drive
areLEFT-HAND.A Snap-On 36 MM Fan Wrench
(number SP346 from Snap-On Cummins Diesel Tool
Set number 2017DSP) can be used. Place a bar or
screwdriver between the fan pulley bolts to prevent
pulley from rotating.
(4) Remove the fan shroud and the fan blade/vis-
cous drive as an assembly from vehicle.
(5) Remove fan blade-to-viscous fan drive mount-
ing bolts.
(6) Inspect the fan for cracks, loose rivets, loose or
bent fan blades.
CAUTION: Some engines equipped with serpentine
drive belts have reverse rotating fans and viscous
fan drives. They are marked with the wordREVERSE to designate their usage. Installation of
the wrong fan or viscous fan drive can result in
engine overheating.
CLEANING
Clean the fan blades using a mild soap and water.
Do not use an abrasive to clean the blades.
INSPECTION
WARNING: DO NOT ATTEMPT TO BEND OR
STRAIGHTEN FAN BLADES IF FAN IS NOT WITHIN
SPECIFICATIONS.
CAUTION: If fan blade assembly is replaced
because of mechanical damage, water pump and
viscous fan drive should also be inspected. These
components could have been damaged due to
excessive vibration.
(1) Remove fan blade assembly from viscous fan
drive unit (four bolts).
(2) Lay fan on a flat surface with leading edge fac-
ing down. With tip of blade touching flat surface,
replace fan if clearance between opposite blade and
surface is greater than 2.0 mm (.090 inch). Rocking
motion of opposite blades should not exceed 2.0 mm
(.090 inch). Test all blades in this manner.
(3) Inspect fan assembly for cracks, bends, loose
rivets or broken welds. Replace fan if any damage is
found.
Fig. 7 Fan Blade/Viscous Fan Drive
1 - THREADED SHAFT
2 - BOLT (4)
3 - FAN BLADE
4 - THREADED NUT
5 - VISCOUS FAN DRIVE
BR/BEENGINE 7 - 43
RADIATOR FAN - 5.9L/8.0L (Continued)