air condition DODGE RAM 2003 Service Owner's Guide

CONDITION POSSIBLE CAUSES CORRECTION
10. Radiator or A/C condenser
fins are dirty or clogged.10. Remove insects and debris. (Refer to
7 - COOLING - STANDARD
PROCEDURE).
11. Radiator core is corroded or
plugged.11. Have radiator re-cored or replaced.
12. Fuel or ignition system
problems.12. Refer to 14 - Fuel System or 8 -
Electrical for diagnosis and testing
procedures.
13. Dragging brakes. 13. Check and correct as necessary.
(Refer to 5 - BRAKES - DIAGNOSIS AND
TESTING) for correct procedures.
14. Bug screen or cardboard is
being , reducing airflow.14. Remove bug screen or cardboard.
15. Thermostat partially or
completely shut.15. Check thermostat operation and
replace as necessary. (Refer to 7 -
COOLING/ENGINE/ENGINE COOLANT
THERMOSTAT - REMOVAL) .
16. Viscous fan drive not
operating properly.16. Check fan drive operation and replace
as necessary. (Refer to 7 - COOLING/
ENGINE/FAN DRIVE VISCOUS CLUTCH
- REMOVAL).
17. Cylinder head gasket
leaking.17. Check for cylinder head gasket leaks.
(Refer to 7 - COOLING - DIAGNOSIS
AND TESTING).
18. Heater core leaking. 18. Check heater core for leaks. (Refer to
24 - HEATING & AIR CONDITIONING/
PLUMBING - DIAGNOSIS AND
TESTING). Repair as necessary.
DRCOOLING 7 - 13
COOLING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
Temperature gauge reading is
inconsistent (flucttuates, cycles
or is erratic)1. During cold weather
operation, with the heater blower
in the high position, the gauge
reading may drop slightly.1. A normal condition. No correction
necessary.
2. Temperature gauge or engine
mounted gauge sensor defective
or shorted. Also, corroded or
loose wiring in this circuit.2. Check operation of gauge and repair if
necessary. (Refer to 8 - ELECTRICAL/
INSTRUMENT CLUSTER - DIAGNOSIS
AND TESTING).
3. Gauge reading rises when
vehicle is brought to a stop after
heavy use (engine still running)3. A normal condition. No correction is
necessary. Gauge should return to normal
range after vehicle is driven.
4. Gauge reading high after
re-starting a warmed up (hot)
engine.4. A normal condition. No correction is
necessary. The gauge should return to
normal range after a few minutes of
engine operation.
5. Coolant level low in radiator
(air will build up in the cooling
system causing the thermostat
to open late).5. Check and correct coolant leaks. (Refer
to 7 - COOLING - DIAGNOSIS AND
TESTING).
6. Cylinder head gasket leaking
allowing exhaust gas to enter
cooling system causing a
thermostat to open late.6. (a) Check for cylinder head gasket
leaks. (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
(b) Check for coolant in the engine oil.
Inspect for white steam emitting from the
exhaust system. Repair as necessary.
7. Water pump impeller loose on
shaft.7. Check water pump and replace as
necessary. (Refer to 7 - COOLING/
ENGINE/WATER PUMP - REMOVAL).
8. Loose accessory drive belt.
(water pump slipping)8. (Refer to 7 - COOLING/ACCESSORY
DRIVE/DRIVE BELTS - DIAGNOSIS AND
TESTING). Check and correct as
necessary.
9. Air leak on the suction side of
the water pump allows air to
build up in cooling system
causing thermostat to open late.9. Locate leak and repair as necessary.
PRESSURE CAP IS BLOWING
OFF STEAM AND/OR
COOLANT TO COOLANT TANK.
TEMPERATURE GAUGE
READING MAY BE ABOVE
NORMAL BUT NOT HIGH.
COOLANT LEVEL MAY BE
HIGH IN COOLANT RESERVE/
OVERFLOW TANK1. Pressure relief valve in
radiator cap is defective.1. Check condition of radiator cap and cap
seals. (Refer to 7 - COOLING/ENGINE/
RADIATOR PRESSURE CAP -
DIAGNOSIS AND TESTING). Replace cap
as necessary.
COOLANT LOSS TO THE
GROUND WITHOUT
PRESSURE CAP BLOWOFF.
GAUGE READING HIGH OR
HOT1. Coolant leaks in radiator,
cooling system hoses, water
pump or engine.1. Pressure test and repair as necessary.
(Refer to 7 - COOLING - DIAGNOSIS
AND TESTING).
7 - 14 COOLINGDR
COOLING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
DETONATION OR PRE-
IGNITION (NOT CAUSED BY
IGNITION SYSTEM). GAUGE
MAY OR MAY NOT BE
READING HIGH1. Engine overheating. 1. Check reason for overheating and
repair as necessary.
2. Freeze point of coolant not
correct. Mixture is too rich or too
lean.2. Check coolant concentration. (Refer to
LUBRICATION & MAINTENANCE/FLUID
TYPES - DESCRIPTION).
HOSE OR HOSES COLLAPSE
WHILE ENGINE IS RUNNING1. Vacuum created in cooling
system on engine cool-down is
not being relieved through
coolant reserve/overflow system.1. (a) Radiator cap relief valve stuck.
(Refer to 7 - COOLING/ENGINE/
RADIATOR PRESSURE CAP -
DIAGNOSIS AND TESTING). Replace if
necessary
(b) Hose between coolant
reserve/overflow tank and
radiator is kinked. Repair as
necessary.
(c) Vent at coolant reserve/
overflow tank is plugged. Clean
vent and repair as necessary.
(d) Reserve/overflow tank is internally
blocked or plugged. Check for blockage
and repair as necessary.
NOISY VISCOUS FAN/DRIVE 1. Fan blades loose. 1. Replace fan blade assembly. (Refer to 7
- COOLING/ENGINE/RADIATOR FAN -
REMOVAL)
2. Fan blades striking a
surrounding object.2. Locate point of fan blade contact and
repair as necessary.
3. Air obstructions at radiator or
air conditioning condenser.3. Remove obstructions and/or clean
debris or insects from radiator or A/C
condenser.
4. Thermal viscous fan drive has
defective bearing.4. Replace fan drive. Bearing is not
serviceable. (Refer to 7 - COOLING/
ENGINE/FAN DRIVE VISCOUS CLUTCH
- REMOVAL).
5. A certain amount of fan noise
may be evident on models
equipped with a thermal viscous
fan drive. Some of this noise is
normal.5. (Refer to 7 - COOLING/ENGINE/FAN
DRIVE VISCOUS CLUTCH -
DESCRIPTION) for an explanation of
normal fan noise.
DRCOOLING 7 - 15
COOLING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
INADEQUATE HEATER
PERFORMANCE.
THERMOSTAT FAILED IN
OPEN POSITION1. Has a Diagnostic trouble
Code (DTC) been set?1. (Refer to 25 - EMISSIONS CONTROL -
DESCRIPTION) for correct procedures
and replace thermostat if necessary
2. Coolant level low 2. (Refer to 7 - COOLING - DIAGNOSIS
AND TESTING).
3. Obstructions in heater
hose/fittings3. Remove heater hoses at both ends and
check for obstructions
4. Heater hose kinked 4. Locate kinked area and repair as
necessary
5. Water pump is not pumping
water to/through the heater core.
When the engine is fully warmed
up, both heater hoses should be
hot to the touch. If only one of
the hoses is hot, the water
pump may not be operating
correctly or the heater core may
be plugged. Accessory drive belt
may be slipping causing poor
water pump operation.5. (Refer to 7 - COOLING/ENGINE/
WATER PUMP - REMOVAL). If a slipping
belt is detected, (Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS -
DIAGNOSIS AND TESTING). If heater
core obstruction is detected, (Refer to 24 -
HEATING & AIR CONDITIONING/
PLUMBING/HEATER CORE - REMOVAL).
STEAM IS COMING FROM THE
FRONT OF VEHICLE NEAR
THE GRILL AREA WHEN
WEATHER IS WET, ENGINE IS
WARMED UP AND RUNNING,
AND VEHICLE IS STATIONARY.
TEMPERATURE GAUGE IS IN
NORMAL RANGE1. During wet weather, moisture
(snow, ice or rain condensation)
on the radiator will evaporate
when the thermostat opens. This
opening allows heated water
into the radiator. When the
moisture contacts the hot
radiator, steam may be emitted.
This usually occurs in cold
weather with no fan or airflow to
blow it away.1. Occasional steam emitting from this
area is normal. No repair is necessary.
COOLANT COLOR 1. Coolant color is not
necessarily an indication of
adequate corrosion or
temperature protection. Do not
rely on coolant color for
determining condition of coolant.1. (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
DESCRIPTION). Adjust coolant mixture as
necessary.
COOLANT LEVEL CHANGES IN
COOLANT RESERVE/
OVERFLOW TANK.
TEMPERATURE GAUGE IS IN
NORMAL RANGE1. Level changes are to be
expected as coolant volume
fluctuates with engine
temperature. If the level in the
tank was between the FULL and
ADD marks at normal operating
temperature, the level should
return to within that range after
operation at elevated
temperatures.1. A normal condition. No repair is
necessary.
7 - 16 COOLINGDR
COOLING (Continued)

CAUTION: Follow manufacturers instructions when
using these products.
STANDARD PROCEDUREÐDRAINING COOLING
SYSTEM 3.7L/4.7L/5.7L ENGINE
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS (Fig. 6) OR LOOSEN THE
RADIATOR DRAINCOCK WITH SYSTEM HOT AND
UNDER PRESSURE. SERIOUS BURNS FROM
COOLANT CAN OCCUR.
(1) With the engine cold, raise the vehicle on a
hoist and locate the radiator draincock.
NOTE: Radiator draincock is located on the left/
lower side of radiator facing to rear of vehicle.
(2) Attach one end of a hose to the draincock. Put
the other end into a clean container. Remove the
radiator cap, open the draincock and drain the cool-
ing system.
(3) If draining the entire engine is required,
remove the cylinder block drain plugs.
STANDARD PROCEDURE - REFILLING
COOLING SYSTEM 3.7L/4.7L/5.7L ENGINE
DO NOT WASTE REUSABLE COOLANT.Ifthe
solution is clean, drain the coolant into a clean con-
tainer for reuse.(1) Install the cylinder block drain plugs (if
removed). Coat the threads with MopartThread
Sealant with Teflon.
(2) Close the radiator draincock.
CAUTION: Failure to purge air from the cooling sys-
tem can result in an overheating condition and
severe engine damage.
(3) Fill system using a 50/50 mixture antifreeze
and low mineral content water. Stop filling when the
level in the degas bottle has reached the top of the
COLD FILL RANGE.
(4) Start and operate the engine until the thermo-
stat opens (upper radiator hose is warm to the
touch).
(5) If necessary, add a 50/50 mixture of anti-freeze
and water to the degass bottle to maintain the proper
coolant level in the degas bottle.
(6) Install the radiator cap.
STANDARD PROCEDUREÐDRAINING COOLING
SYSTEM 5.9L/8.0L ENGINE
WARNING: DO NOT REMOVE CYLINDER BLOCK
DRAIN PLUGS OR LOOSEN RADIATOR DRAIN-
COCK WITH SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
DO NOT WASTE reusable coolant. If solution is
clean, drain coolant into a clean container for reuse.
(1) Attach one end of a hose to the draincock. Put
the other end into a clean container.
(2)DO NOT REMOVE THE RADIATOR CAP
when draining the coolant from the reservoir/over-
flow tank. Open radiator draincock and when the
tank is empty, remove the radiator cap and continue
draining the cooling system.
(3) If draining the entire engine, remove the cylin-
der block drain plugs. Refer to (Fig. 7).
STANDARD PROCEDUREÐREFILLING
COOLING SYSTEM 5.9L/8.0L ENGINE
WARNING: DO NOT REMOVE CYLINDER BLOCK
DRAIN PLUGS OR LOOSEN RADIATOR DRAIN-
COCK WITH SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
DO NOT WASTE reusable coolant. If solution is
clean, drain coolant into a clean container for reuse.
Clean cooling system prior to refilling. (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(1) Install cylinder block drain plugs. Coat the
threads with MopartThread Sealant with Teflon.
(2) Close radiator petcock.
Fig. 6 Drain Plug - 3.7L/4.7L Engine
1 - CYLINDER BLOCK DRAIN PLUG
2 - EXHAUST MANIFOLD AND HEAT SHIELD
7 - 18 COOLINGDR
COOLING (Continued)

ACCESSORY DRIVE
TABLE OF CONTENTS
page page
BELT TENSIONERS - 3.7L / 4.7L
DESCRIPTION.........................22
OPERATION...........................22
REMOVAL.............................22
INSTALLATION.........................23
BELT TENSIONERS - 5.9L
DESCRIPTION.........................23
OPERATION...........................23
REMOVAL.............................23
INSTALLATION.........................24
BELT TENSIONERS - 5.9L DIESEL
DESCRIPTION.........................24
OPERATION...........................24
REMOVAL.............................25
INSTALLATION.........................25DRIVE BELTS - 3.7L / 4.7L
DIAGNOSIS AND TESTING - ACCESSORY
DRIVE BELT.........................25
REMOVAL.............................27
INSTALLATION.........................27
DRIVE BELTS - 5.9L
DIAGNOSIS AND TESTING - ACCESSORY
DRIVE BELT.........................28
REMOVAL.............................30
INSTALLATION.........................31
DRIVE BELTS - 5.9L DIESEL
DIAGNOSIS AND TESTINGÐACCESSORY
DRIVE BELT.........................31
REMOVAL.............................34
INSTALLATION.........................34
BELT TENSIONERS - 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) ofindexing 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.
Fig. 1 AUTOMATIC BELT TENSIONER
1 - AUTOMATIC TENSIONER ASSEMBLY
7 - 22 ACCESSORY DRIVEDR

NOTE: A used belt should be replaced if tensioner
indexing arrow has moved to the minimum tension
indicator. Tensioner travel stops at this point.
(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 TENSIONERS - 5.9L
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
3.9L or 5.9L engines. These engines are equipped
with an automatic belt tensioner (Fig. 3). The ten-
sioner maintains correct belt tension at all times.
Due to use of this belt tensioner, do not attempt to
use a belt tension gauge on 3.9L or 5.9L 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
WARNING: BECAUSE OF HIGH SPRING PRES-
SURE, DO NOT ATTEMPT TO DISASSEMBLE AUTO-
MATIC TENSIONER. UNIT IS SERVICED AS AN
ASSEMBLY (EXCEPT FOR PULLEY).
(1) Remove accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(2) Disconnect wiring and secondary cable from
ignition coil.
(3) Remove ignition coil from coil mounting
bracket (two bolts). Do not remove coil mounting
bracket from cylinder head.
(4) Remove tensioner assembly from mounting
bracket (one nut) (Fig. 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 - 5.9L Engines
1 - AUTOMATIC TENSIONER
2 - COIL AND BRACKET
3 - SCREW AND WASHER
DRACCESSORY DRIVE 7 - 23
BELT TENSIONERS - 3.7L / 4.7L (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
NOISE
(Objectionable squeal, squeak, 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 LET TENSIONER ARM SNAP
BACK TO THE FREEARM POSITION, SEVER DAM-
AGE MAY OCCUR TO THE TENSIONER.
Belt tension is not adjustable. Belt adjustment is
maintained by an automatic (spring load) belt ten-
sioner.
(1) Disconnect negative battery cable from battery.
(2) Rotate belt tensioner until it contacts it's stop.
Remove belt, then slowly rotate the tensioner into
the freearm position. (Fig. 8).
INSTALLATION
Belt tension is not adjustable. Belt adjustment is
maintained by an automatic ( spring load ) belt ten-
sioner.
(1) Check condition of all pulleys.CAUTION: When installing the serpentine accessory
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to the water pump
rotating in the wrong direction (Fig. 8).
(2) Install new belt (Fig. 8). Route the belt around
all pulleys except the idler pulley. Rotate the ten-
sioner arm until it contacts it's stop position. Route
the belt around the idler and slowly let the tensioner
rotate into the belt. Make sure the belt is seated onto
all pulleys.
(3) With the drive belt installed, inspect the belt
wear indicator (Fig. 9). On 4.7L Engines only, the gap
between the tang and the housing stop (measure-
ment A) must not exceed 24 mm (.94 inches). If the
measurement exceeds this specification replace the
serpentine accessory drive belt.
DRACCESSORY DRIVE 7 - 27
DRIVE BELTS - 3.7L / 4.7L (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
NOISE
(Objectionable squeal, squeak, 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
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. 11). 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. 11).
(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.
Fig. 11 Belt Tensioner - 5.9L Gas Engines
1 - IDLER PULLEY
2 - TENSIONER
3 - FAN BLADE
7 - 30 ACCESSORY DRIVEDR
DRIVE BELTS - 5.9L (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
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
NOISE (Objectional squeal, squeak,
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
DRACCESSORY DRIVE 7 - 33
DRIVE BELTS - 5.9L DIESEL (Continued)