Tools you'll likely need:
* Socket wrench set: Various sizes, including likely a 13mm, 15mm, and possibly others.
* Wrench set: Open-ended and/or combination wrenches.
* Ratchet and extensions: To reach hard-to-access bolts.
* Jack and jack stands: To safely lift and support the vehicle.
* Wheel chocks: To secure the vehicle.
* New belt tensioner assembly: Ensure you get the correct replacement part.
* New serpentine belt (recommended): Since you're replacing the tensioner, it's a good idea to replace the belt too.
* Pliers or a belt tensioner tool (optional but highly recommended): A special tool can make this job significantly easier.
General Steps (Consult your repair manual for specifics):
1. Vehicle Preparation: Park on a level surface, engage the parking brake, and use wheel chocks for added safety. Jack up the vehicle and securely support it on jack stands.
2. Battery Disconnect: Disconnect the negative battery cable.
3. Access the Tensioner: Locate the belt tensioner. On a 1990 Caravan, it's likely located on the front of the engine, near the serpentine belt. You may need to remove some components (e.g., air intake components, plastic covers) to gain better access.
4. Release Belt Tension: This is the trickiest part. The tensioner will have a bolt or mechanism to release the tension on the belt. This is where a specialized belt tensioner tool is highly beneficial. Without one, you might need to use a wrench (the correct size) on a specific bolt, often while carefully prying the tensioner to relieve pressure on the belt. Be extremely cautious not to damage any components. Refer to your repair manual for the correct procedure.
5. Remove the Old Belt: Once the tension is released, carefully remove the serpentine belt from the pulleys.
6. Remove the Old Tensioner: Remove the bolts securing the old tensioner to the engine block.
7. Install the New Tensioner: Install the new tensioner, making sure it's correctly aligned and tightened to the manufacturer's specifications (found in your repair manual).
8. Install the New Belt: Route the new serpentine belt around the pulleys, following the correct path (consult your repair manual or diagram).
9. Re-tension the Belt: Use the new tensioner's mechanism to properly tension the belt. The repair manual will usually provide a method for checking tension (e.g., deflection with a specified amount of pressure).
10. Reassemble: Reinstall any components you removed to access the tensioner.
11. Reconnect the Battery: Reconnect the negative battery cable.
12. Check and Test: Start the engine and check for any squealing or unusual noises. Also visually inspect the belt for proper alignment and tension.
Important Considerations:
* Repair Manual: A repair manual specific to your 1990 Dodge Caravan 3.0L V6 is absolutely essential. It will show you exactly where the tensioner is located, how to access it, and provide torque specifications for all the bolts.
* Safety First: Always prioritize safety. Work in a well-lit area, use jack stands properly, and disconnect the battery before starting.
* Torque Specifications: Use the correct torque specifications for all bolts. Over-tightening can damage components, while under-tightening can lead to loose parts.
If you're uncomfortable performing this repair yourself, take your vehicle to a qualified mechanic. This is not a simple task for those without experience.
