Here's how to try and free it up:
1. Safety First:
* Disconnect the battery negative terminal. This prevents accidental shorts and protects your electrical system.
* Wear safety glasses. Pieces of the belt or tensioner could break loose.
2. Identify the Tensioner:
Locate the tensioner pulley. It's usually a pulley with an arm that's spring-loaded. It will be on the serpentine belt system, likely near the alternator or power steering pump. Consult a repair manual or online diagrams specific to your 1992 Grand Caravan AWD to be certain.
3. Attempt to Free the Tensioner:
* Penetrating Oil: Liberally spray a penetrating oil (like PB Blaster, Liquid Wrench, or Kroil) onto the tensioner pulley's pivot point. Allow it to soak for at least 30 minutes, or even overnight for best results. Reapply as needed.
* Gentle Leverage: Once the oil has had time to penetrate, use a wrench or socket (the correct size for the tensioner bolt – if accessible) to gently try and rock the tensioner pulley back and forth. Avoid applying excessive force, as you could damage the tensioner. If you can't access the bolt, you might try using a pry bar with a block of wood to carefully lever against the pulley arm (but be extremely cautious not to damage anything).
* Heat (Use Caution!): As a last resort, you can carefully apply heat to the tensioner pulley with a heat gun or propane torch. Be extremely cautious not to overheat anything or start a fire. Keep the heat moving constantly and never apply it directly to plastic or rubber components. The goal is to expand the metal slightly to break the rust or corrosion.
4. If it's Still Stuck:
* Professional Help: If you cannot free the tensioner pulley using these methods, it's highly recommended to take your vehicle to a mechanic. A seized tensioner pulley usually means the tensioner itself needs replacing, and attempting further force could cause more damage.
* Replacement Parts: Be prepared for the possibility of needing to replace the tensioner pulley. These parts are relatively inexpensive and readily available.
Important Note: Working on a car's serpentine belt system requires some mechanical aptitude. If you're not comfortable working on your car, it's best to leave this repair to a qualified mechanic. Improperly attempting to free a seized tensioner could result in injury or further damage to your vehicle.
