Tools You'll Need:
* New serpentine belt: Make sure you get the correct size for your specific engine. The size is usually printed on the old belt or can be found in your owner's manual or a parts store catalog.
* Socket wrench set: Including the correct size for your tensioner pulley bolt.
* Ratchet: To turn the socket wrench.
* Wrench: Possibly needed for some tensioner mechanisms.
* Gloves: To protect your hands.
* Jack and jack stands (optional but recommended): Makes access easier.
* Shop rags: To clean up any grease or grime.
* Possibly a belt tensioner tool: While some tensioners can be manually loosened, a specialized tool can make the job much easier and safer.
Steps:
1. Preparation: Park the van on a level surface, engage the parking brake firmly, and chock the wheels. If you're comfortable, raise the van using a jack and secure it with jack stands. This gives you better access to the engine compartment.
2. Locate the Tensioner: Identify the belt tensioner pulley. It's usually a pulley with a mechanism (often a spring-loaded arm or a hydraulic cylinder) to adjust belt tension. The tensioner pulley's location varies slightly depending on the engine type. Consult your repair manual to be certain.
3. Release Tension: This is the trickiest part. The method for releasing tension on the tensioner varies.
* Manually-operated tensioners: These often require you to use a wrench (or your hands depending on design) to move the tensioner pulley away from the belt path. You may have to use a wrench to turn a bolt on the tensioner to loosen it or to compress a spring. Use firm but controlled pressure.
* Hydraulic tensioners: These are often more complex. Sometimes a special tool is required; you may need to carefully observe the mechanism to understand how to relieve tension. Your repair manual will be essential here.
4. Remove the Old Belt: Once tension is released, carefully work the belt off the pulleys. Start with the loosest pulley, working your way around.
5. Install the New Belt: Route the new belt onto the pulleys in the same order as the old one. Again, consult the repair manual; the routing is crucial. Double check each pulley to make sure the belt is seated correctly on the grooves.
6. Release Tension (and then reapply it): Once the new belt is on all pulleys, release the tensioner pressure you’ve applied. The tensioner will naturally tighten the belt.
7. Check Belt Tension: After releasing the tensioner, give the belt a slight tug. It should feel taut but not excessively tight. A poorly tensioned belt can cause premature wear or damage to the pulleys and alternator.
8. Double-Check Routing: Before lowering the van, make another visual inspection to confirm that the belt is correctly routed over every pulley.
9. Lower the Van: If you used a jack, carefully lower the van and remove the jack stands.
10. Start the Engine: Start the engine and listen for any squealing or unusual noises. If you hear squealing, the belt might be too loose, too tight, or improperly routed. Turn the engine off immediately if you hear these sounds.
Important Considerations:
* Safety First: Always disconnect the negative battery terminal before starting any work on the vehicle's electrical system.
* Repair Manual: A repair manual specific to your 2002 Chevy Van is invaluable. It will have diagrams showing the exact belt routing and tensioner mechanism for your particular engine.
* Professional Help: If you're uncomfortable performing this task, consider taking your van to a qualified mechanic. A poorly installed belt can cause serious engine damage.
This guide provides a general overview. Always refer to your vehicle's repair manual for specific instructions and safety precautions. Remember, working on your vehicle involves risk. Proceed with caution and prioritize safety.
