How hard is it to replace the tensioner pulley on the 2000 caravan?

ON PASSENGER SIDE YOU NEED SAFELY RAISE SUPPORT VECHICLE ON JACK STANDS.PARK VECHICLE ON SOLID LEVEL GROUND.REMOVE WHEEL OR TIRE ON PASSENGER SIDE REMOVE SPLASH SHIELD, THEN PLACE A OPEN END WRENCH ON THE TENSIONER PULLEY LUG ROTATE TENSIONER TO RELIEVE THE BELT TENSION.

Hi, I have pasted the procedure for belt replacement below. To replace the tensioner as well, first take the belt off. Then remove the pulley from the tensioner. This will expose the single bolt that holds the tensioner on. Replace the tensioner and then the pulley (if replacing all). Then reinstall the belt.

Alternator/Power Steering Pump Belt
The alternator/power steering pump belt is provided with a dynamic tensioner to maintain proper belt tension.

1. Disconnect the negative battery cable.
2. Raise the front of the vehicle and safely support it with jackstands.
3. Remove the right front splash shield.
4. Release tension by rotating the tensioner clockwise (use a box-end wrench on the tensioner bolt shown in the picture.
5. Remove the belt and install a replacement.
6. Proper belt tension is maintain by the dynamic tension.
7. Install the right front splash shield. Lower the front of the vehicle.
8. Connect the negative battery cable.
   

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   Fig. Alternator/power steering pump belt tensioner bolt location
   

There's a spring loaded Idler pulley that keeps tension on the belt. If the arm that puts the tension on the belt seizes it may not be putting enough tension on the belt. It will need to be replaced.

Click on the following free direct Link.
It has the correct Belt Diagrams for your 1992 Dodge Grand Caravan wirh either the 3.0L SOHC V6 or the 3.3L V6.

http://www.2carpros.com/car_repair_information/year/1992/make/dodge/model/grand_caravan/1992_dodge_grand_caravan_drive_belt_routing_diagram.htm

Included on the Diagrams are the Instructions on "Rotating" the Automatic Tensioner. See Below for additional Instructions to make your job easier.

"HOW TO": I professionally prefer the Serpentine Tensioner Tool.
Standard Rules to Removal the Serpentine Belt with an Automatic Tensioner:
1. Find the Tensioner(s).
2. Using a Serpentine Belt Tensioner Tool, Or Wrench OR Ratchet, Rotate/Move the Tensioner USING THE AVAILABLE NUT (located on the Pulley or Arm Base) OR the OPENING (3/8ths or 1/2 inch square opening located on the Tensioner Arm) rotating the Tensioner Pulley/Arm - moving it away from contact with the belt and towards the area where the belt is not in contact with the Tensioner Pulley. The Tensioner is spring loaded, and is hard to rotate/move.
3. Remove the loosened belt off one of the other more easily accessed Pulleys.
4. DO NOT quickly release the Tensioner, but gently allow the Tensioner to rest in its closed position.

Standard Rules for Installing the Serpentine Belt with an Automatic Tensioner:
a. Pick a Pulley that is most easily accessed. This will usually be on top. This will be the last Pulley that the belt will go on.
b. Using the Diagram: Install the new Serpentine Belt on the remainder of the Pulleys....over, under, left right.
c. Using a Serpentine Belt Tensioner Tool or Wrench or Ratchet Tool: Rotate/Move the Tensioner Pulley/Arm "away" from Belt contact area on the Tensioner. This spring is pretty hard and with a new belt, it will be even harder to install. Rotate/Move this to as-close to the maximum allowed inorder to have enough slack in the belt to get it up and over the last pulley.
d. Using your other hand - Pull the Belt up and over the Last remaining Pulley.
e. Before releasing the pressure on the Tensioner, visually inspect the remainder Pulleys and the Belts' Positioning on them.

Before You GO:
Let me know if this helped, or if you have additional information questions. Feel Free to contact me at FixYa.com!

This is due to a worn belt or worn tensioner pulley. If that's not the problemthen you have a power steering pump going out or steering gear box going bad.

OK, do you have a specific question? You'll need to jack up the front right tire and remove it. Pull the wheel well cover off to expose the belt. Use a vice-grip in the tensioner pulley (look for a 1.2 in square on the end of the pulley) to remove tension. Install as the sticker under the hood shows.

if belt is not worn beyond serviceability ,suspect tensioner pulley bearings--check pulley side play i.e. can you shake it back& forth?replace w/ a new one

you need a 15mm wrench and skinny hands or a long belt router. place wrench on tensioner bolt and pull to rotate clockwise,at same time undo belt always holding tensioner, after removing belt from a couple pulleys release tensioner and finish removing belt from engine,for installacion reverse procedure.

Edit a video on this job. That is right you do not have to remove the alternator! You go in from underneath. Here’s a video on the job that I made about a week ago.Works for 1998, 1999, 2000 & 2001 Dodge Caravan’s, town and country and grand Voyager’s. https://youtu.be/CrG8vBuy4xE

I've got the same problem. I bought a 15 mm wrench (the size necessary for the tensioner pulley) to carry with me in my minivan. When I feel the power steering go (the first sign that the belt have slipped off), I immediately stop. Once you do it a few times, putting the belt back on is not that hard, but you have to be fairly strong and be willing to get your hands dirty. Also, try to avoid the big puddles with the minivan. I think the problem is that the tension pulley is too slick, and when it gets wet the belt simply slips off.

Finally, I have not found it yet, but I heard from a cabby whose company drives Chrysler minivans that you can find an aftermarket product that will fit on the tensioner pulley to keep the serpentine belt in place. I am trying to find the product myself so as to keep this headache from happening again.