Here's a general outline. Specifics may vary slightly depending on the engine (3.0L or 3.3L) and any variations in your particular vehicle. Always consult a repair manual specific to your 1996 Plymouth Voyager for detailed instructions, torque specifications, and diagrams. A Haynes or Chilton manual is a worthwhile investment.
Tools you'll likely need:
* Socket wrench set (metric)
* Ratchet and extensions
* Wrenches (metric)
* Jack and jack stands (essential for safety)
* Wheel chocks
* Pry bar (potentially)
* New tensioner assembly
* New serpentine belt (recommended, since you'll have it off)
* Gloves
* Safety glasses
Steps (General):
1. Preparation: Jack up the front of the van and securely support it on jack stands. Place wheel chocks behind the rear wheels. Disconnect the negative battery terminal.
2. Locate the Tensioner: The tensioner is usually located on the front of the engine, part of the serpentine belt system. It might be on the passenger side or driver's side depending on the engine. Identify it visually – it will have a pulley and a mechanism to apply tension to the belt.
3. Identify and Remove Related Components (If Necessary): Depending on the access, you might need to remove components like the air intake housing, or other ancillary belts and pulleys to get better access to the tensioner. Your repair manual will guide you here.
4. Release Tension: This is the crucial step and varies based on the tensioner design. Some have a bolt that you loosen to release tension, some have a lever that you can manipulate with a tool, and others may require a special tensioner tool. Consult your repair manual for the *exact* procedure for your vehicle. Improperly releasing tension can lead to injury. The belt will be under significant pressure.
5. Remove the Old Tensioner: Once the tension is released, the belt should be loose enough to remove. Then, you'll need to remove the bolts securing the tensioner assembly to the engine. These bolts are usually located in fairly accessible locations, but sometimes they can be awkward to reach.
6. Install the New Tensioner: Carefully install the new tensioner assembly, ensuring it's properly aligned. Tighten the mounting bolts to the manufacturer's specified torque (found in your repair manual).
7. Install the Serpentine Belt: Route the new (or old if you choose not to replace it) serpentine belt according to the routing diagram in your repair manual. Ensure the belt is correctly seated on all pulleys.
8. Re-install Components: Reinstall any components you removed earlier (e.g., air intake housing).
9. Check Belt Tension: Make sure the belt tension is correct. You should be able to deflect it slightly with moderate thumb pressure. Again, your repair manual will give you guidelines.
10. Lower the Vehicle: Carefully lower the vehicle from the jack stands.
11. Reconnect the Battery Terminal: Reconnect the negative battery terminal.
12. Start the Engine: Start the engine and check for any unusual noises or belt slippage.
Important Considerations:
* Repair Manual: This is absolutely crucial. Pictures and diagrams in a repair manual will be invaluable, especially for the tension release mechanism and belt routing.
* Torque Specifications: Use the correct torque specifications from your repair manual to avoid damaging the engine or the tensioner.
* Safety: Always prioritize safety. Use jack stands, wheel chocks, and appropriate safety gear.
This is a general guide. Without knowing the exact engine in your 1996 Plymouth Voyager, I cannot give more precise instructions. Always refer to a repair manual specific to your vehicle for detailed, accurate instructions. If you're not comfortable performing this repair yourself, take it to a qualified mechanic.
