I have changed all the pulleys except for my A/C pulley on my 2002 chevy tracker 2.0 liter engine. The serpentine belt has been changed at least 8 times over the last 5 years. i changed to pulleys in January and replaced the serpentine belt. the belt broke two weeks ago and i replaced it. The same thing happened yesterday. What would you suggest i do to start troubleshooting the problem.

change serpentine belt or one of the pulleys in seized! remove belt and with hand move all pulleys except for the crank pulley! if your able to move all pulleys then u good! just change belt and tensioner pulley! let mme know what happens when done!

1. Removing the Serpentine Belt
   • 1 Park your Subaru on a level surface and open the hood.
     
   • 2 Disconnect the ground (black) battery cable using a wrench. This will prevent the cooling fan from activating.
     
   • 3 Locate the serpentine belt routing diagram in your engine compartment and compare it to the actual routing of the installed belt. Make sure the routing on the label matches the actual routing. If they do not match or there is no label, note the actual routing on a piece of paper for later reference.
     
   • 4 Locate the belt tensioner pulley on your Subaru model. If the tensioner is equipped with a squared hole, use a large breaker bar with a 1/2-inch (13 mm) drive. Otherwise, use a ratchet and socket of the proper size on the tensioner pulley center bolt.
     
   • 5 Rotate the tensioner pulley away from the belt to release the belt tension.
     
   • 6 Pull the belt off of one of the pulleys and slowly release the tensioner pulley back into position. Do not let the tensioner pulley snap back or you may damage an internal component.
     
   • 7 Finish removing the serpentine belt from the rest of the pulleys and the engine compartment.
     
   Installing the New Serpentine Belt
   • 1 Match the old belt to the new one and make sure they are of the same length and configuration. It is normal for the new belt to be slightly shorter since the old one has been stretched through use.
     
   • 2 Route the new serpentine belt through all of the pulleys except the tensioner pulley. Use the diagram on the engine compartment or your notes, as a reference, to properly route the belt.
     
   • 3 Insert the large breaker bar into the square hole or the ratchet and socket into the tensioner pulley center bolt.
     
   • 4 Rotate the tensioner pulley in the same direction you did to release the belt tension.
     
   • 5 Slide the serpentine belt onto the tensioner pulley.
     
   • 6 Release the tensioner pulley back into position.
     
   • 7 Look at all the pulleys and make sure the serpentine belt is properly seated on each one. Otherwise, release the belt tension and adjust the belt.
     
   • 8 Connect the ground (black) battery cable using the wrench.
     

Pop the hood of the car and locate the serpentine belt routing diagram. The diagram on the 2003 Chevrolet Impala is on top of the fan shroud. The diagram will be a picture of all of the accessory pulleys and how the serpentine belt is routed among the pulleys. This diagram will give you the exact direction for routing the new belt onto the pulleys. If you cannot find a serpentine belt routing diagram, take a notepad and pen and draw out the exact routing diagram of the old belt across the pulleys.

2 Locate the serpentine belt tensioner. It is located below the alternator on the left front side of the engine. The tensioner on the 3.4 liter, 3.5 liter and the 3.9 liter engines will require a 3/8 ratchet to release the belt tensioner. The 3.8 liter engine will require a ratchet and a 15 mm socket for the belt tensioner. Rotate the belt tensioner clockwise to loosen and remove the belt from the belt tensioner pulley.

3 Slide the old belt from the belt tensioner pulley. Remove the belt from the remaining pulleys and pull the belt from the engine compartment.

4 Route the new belt across the crankshaft pulley first. The crankshaft pulley is the big pulley on the bottom of the engine in the center. Then route the serpentine belt across the remaining pulleys as directed by the serpentine belt routing diagram. Leave the belt tensioner pulley for last.

5 Rotate the belt tensioner clockwise again to relieve the tension and slide the new belt across the top of the belt tensioner pulley. Release the belt tensioner and the belt will tighten up as the tensioner applies pressure to the belt. Make sure the new belt is properly seated in all the pulleys.

6 Crank the engine and inspect the belt again to make sure that it stays seated in the pulleys.

Read more: How to Replace a Serpentine Belt on a 2003 Chevrolet Impala ' eHow.co.uk http://www.ehow.co.uk/how_6120665_replace-belt-2003-chevrolet-impala.html#ixzz1Yi6QLAjb

GM use a particular item on one of the idlers
there will be a 1/2" square hole in the center of it
use a strong bar and lift the pulley up against a spring
install the new belt and when properly installed let the pulley back onto the belt

Serpentine belts are easy to change. The key is knowing where the 1/2" square drive tensioner is and to remove tension to the belt at this point.

If you remove the belt, it's easy to put the new one on because the pulleys are designed with grooves for the groove side of the belt, and smooth pulleys for the smooth back of the belt to ride on the pulleys.

Just go over, under, over, under until the belt is threaded on, except for the last idler pulley which is smooth.

Use the 1/2" breaker bar to turn the pulley until one can slip the belt onto the last 'idler' pulley and you're done.

Hope this helps ya.. Cobra... :-)


Item Part Number Description 1 10344 Generator pulley 2 8620 Drive belt 3 8A528 Water pump pulley 4 3D673 Power steering pump pulley 5 63126 Crankshaft vibration damper 6 2E884 A/C clutch pulley 7 6B209 Drive belt tensioner 8 19A216 Belt idler pulley 9 19A216 Belt idler pulley

Try removeing the serpent belt ...take idler pulley...if it lose in any way ..before doing all this just listen to the front of it ...look care fully at idler ...if it looks kind of cocky in any way change it ...check your belt too ...and all fluid levels for power steering ect ....good luck

Not specific to S-10 truck, but here you go.
Before you start, you might want to make a sketch, or take a couple of digital photos of alternator wiring and belt routing to make reassembly easier.
Disconnect negative (-) battery cable from battery.
Find serpentine belt tensioner pully. Should be a square hole in arm that holds that pulley. Insert a 3/8" socket wrench or breaker bar into hole to remove tension on belt.
Remove belt from alternator pulley.
Diconnect all wires from the rear of the alternator.
Remove alternator mounting bolts, make note of order and location of any nuts/washers/spacers.
Remove old alternator.
Installation is reverse of removal.

My sincere apologies for the delayed response.
I am personally going back to answer your unanswered questions.
I have only been a free contributor to this site for the past 4-months.

I do not know if you still need this information, but I am going ahead and answering it anyway.

CLICK on the following LINK. It has several Belt Diagrams, one which will match your specific engine and options (AC/No AC, Power Steering, .etc) that you will need.

Regarding HOW:
Standard Rule to Removal the Serpentine Belt:
1. Find the Tensioner(s). (See the Diagrams on Link)
2. Using a Serpentine Belt Tensioner Tool or Wrench or Ratchet Tool: Rotate/Move the Tensioner Pulley/Arm 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.
Standard Rules for Installing the Serpentine Belt:
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 etc.
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 ("open") allowed inorder to have enough slack in the belt to get it up and over the last pulley.
d. While keeping the Tensioner Pulley/Arm "open" 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.
As you can see in the last Diagram on this Link: there are three (3) Bolts for the FAN Belt that must be loosened inorder to successfully remove this Belt

Let me know if this helped...
Again my apologies..

http://www.2carpros.com/car_repair_information/year/2004/make/chevrolet/model/tracker/2004_chevrolet_tracker_drive_belt_routing_diagram.htm