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Jeep Commander XH XK 2006-2010 Workshop Repair Manual digital download

Quick overview
- The drive belt(s) on your Jeep (serpentine or V-belt style depending on engine) transfers mechanical power from the crankshaft pulley to engine accessories: alternator, water pump (on many engines), power steering pump, A/C compressor, and sometimes the fan or air pump. Think of the belt like a rubber conveyor or big rubber band that pulls several tools from a single crank “motor.”
- Replacing the belt is a common maintenance task. Belts wear, crack, glaze, stretch, or get contaminated; a broken belt can leave you without charging, steering assist, or engine cooling — immediate roadside trouble.

What each component is and what it does (detailed)
- Crankshaft pulley / harmonic balancer:
- The primary driving pulley bolted to the engine’s crankshaft. It provides the torque to the belt. Often incorporates a rubber damper (harmonic balancer) to reduce vibration.
- Serpentine/drive belt:
- Multi-ribbed rubber belt that wraps around several pulleys. Ribs engage grooved pulleys for friction drive.
- Signs of wear: cracks across ribs, chunks missing, glazing (shiny/black), rib separation, fraying, or oil/coolant contamination.
- Tensioner (spring-loaded automatic or manual adjuster):
- Keeps belt tight. Automatic tensioners use an internal spring and pulley; manual systems use an adjustable bolt or eccentric.
- If a tensioner is weak or seized, the belt will slip or wear prematurely.
- Idler pulleys:
- Smooth or grooved pulleys that route the belt and maintain contact/wrap. They contain bearings; noisy or loose idlers cause belt problems.
- Accessory pulleys (alternator, power steering, A/C, water pump, etc.):
- Driven devices that must spin freely. If any one seizes, it locks the belt and can snap it or damage the accessory.
- Fasteners and brackets:
- Bolts holding accessories and tensioner. Must be secure and torqued to spec.

Why the repair is needed — the theory
- Friction transfers torque from the crank pulley to the belt ribs; ribs fit into grooves on the accessory pulleys. Proper tension keeps the belt from slipping and ensures adequate contact (wrap) on each pulley.
- Over time the rubber degrades (heat, ozone, oil), ribs wear, and tensioners lose preload. A stretched/old belt slips or slips under load causing squeal, charging problems, or overheating (if water pump driven).
- Like a bicycle chain: if chain gets slack or dirty, it slips and won’t drive the wheel. The belt is similar but uses friction ribs instead of teeth.

What can go wrong (symptoms & causes)
- Squealing on startup or under load — slipping belt, glazed surface, weak tensioner, or contaminated belt.
- Battery/charging light or dead battery — alternator not spinning because of belt slip or break.
- Overheating — if water pump driven by that belt has stopped turning.
- Loss of power steering assist — heavy steering effort.
- Vibrations or intermittent noise — worn idler/tensioner bearings or misaligned pulleys.
- Rapid belt wear — misalignment, seized accessory, or oil/coolant contamination.
- Pulley wobble — bent pulley or worn bearing, causes uneven belt wear.

Tools and supplies you’ll need
- New belt (correct part number/length for your engine) — always match the belt. If unsure, measure old belt or consult parts book.
- Basic socket set and ratchets (common sizes 10–19 mm) and possibly deep sockets for tensioner fastener.
- Breaker bar or long ratchet to move the tensioner (or a dedicated belt tensioner tool depending on design).
- Torque wrench (to torque any bolts to spec).
- Screwdrivers, pliers, pry bar (light).
- Flashlight.
- Gloves and safety glasses.
- Rag and cleaner/degreaser (to remove oil from pulleys if contaminated).
- Belt dressing is not recommended as a fix; replace the belt and fix root cause.
- Service manual or routing diagram (very important).

Preparation and safety
- Park on level ground, set parking brake. Engine off and cooled down.
- Disconnect the negative battery terminal if you will be loosening alternator bolts or working near electrical connectors (optional for belt-only swaps, but safer).
- Put on safety glasses and gloves.
- If needed, raise the front of vehicle and secure on jack stands to gain access. Never work under a car supported only by a jack.

Step-by-step replacement (beginner-friendly, detailed)
1. Study and document the belt routing
- Find the belt routing sticker under the hood or in the manual. If there isn’t one, take clear photos from multiple angles and draw a routing diagram with the belt path around each pulley and the direction of wrap. This is critical.

2. Inspect the system before removal
- Examine the old belt: cracks across ribs, missing chunks, shiny glazing, loose ribs or fraying.
- Spin each pulley by hand (with engine off): pulleys should rotate smoothly with no roughness, grinding, or play. Listen for bearing noise.
- Wiggle accessories by hand to check for side-to-side play in bearings.
- Inspect pulleys for corrosion, nicks, or misalignment (look at pulley faces — grooves should line up).
- If any pulley/tensioner is noisy or has play, plan to replace it at the same time.

3. Relieve tension and remove the belt
- Identify the tensioner pulley (spring-loaded pulley). It will be on a pivot and push against the belt.
- Fit the correct socket or wrench on the tensioner nut/bolt. Use a breaker bar/ratchet to rotate the tensioner in the direction that relieves tension (usually clockwise on most engines, but check movement — tensioner will move away from belt).
- Hold the tensioner back and slip the belt off an easy-access accessory pulley (alternator or idler) — slow and controlled motion. Release the tensioner slowly back to position.
- If your system has a manual adjuster tensioner, loosen the adjuster pivot bolt and move the accessory to release tension; then remove the belt.
- Remove the old belt and compare it visually to the new belt to confirm size.

4. Inspect and clean pulleys
- Clean any oil/coolant off pulleys with a rag and degreaser. Contamination will quickly ruin a new belt.
- Check pulley alignment using a straightedge across multiple pulleys or visually ensure grooves line up.
- If pulleys are damaged or bearings rough, replace them now.

5. Install the new belt
- Route the new belt following the routing diagram, leaving it over the easiest-to-remove pulley (often the alternator) so you can use the tensioner to slip it on.
- Make sure ribs seat into grooves on each pulley — the belt should sit flush and centered.
- If using an automatic tensioner: rotate the tensioner again, slip the belt over the last pulley, and gently release the tensioner so it applies preload. Verify the belt sits properly on every pulley.
- If using a manually adjusted tensioner: pull the accessory to apply proper tension, then tighten the pivot/adjuster bolts to the correct torque (consult spec); double-check tension.

6. Check belt tension and alignment
- For automatic tensioner: ensure the tensioner arm is within its normal operating range (there may be a service mark or indicator). It should not be on full compression against its stop.
- For manual tension: if you don’t have a tension gauge, a common rule-of-thumb is about 1/4 to 1/2 inch (6–13 mm) deflection at the midpoint of the longest span with moderate thumb pressure; better: use a tension gauge or follow manufacturer spec.
- Verify all ribs are properly seated in grooves and no part of the belt is off any pulley.

7. Reconnect battery if disconnected
- Reconnect negative terminal and tighten.

8. Start engine and observe
- Start the engine and watch the belt at idle. Look for:
- Proper seating and that the belt runs true.
- No squealing or chirping within the first 30 seconds (a brief squeal can happen with a new belt but should stop).
- Tensioner movement that is smooth (it may oscillate a little as the belt beds in).
- Turn on accessories: headlights, A/C, and steering (park turn) to load the belt and listen for issues.

9. Road test and re-check
- After a short drive, re-check tension, pulleys, and belt seating. Re-inspect for any sign of oil contamination or movement of tensioner beyond normal position.

Troubleshooting after installation
- Squeal persists:
- Double-check belt routing and proper seating.
- Confirm pulleys are aligned and tensioner is good.
- Replace any glazed pulley or accessory that’s misbehaving.
- Belt wears quickly:
- Look for oil/coolant leaks. Fix leak and replace belt/pulleys as necessary.
- Check pulley alignment and replace any bent pulley or spacer.
- Tensioner bounces or makes noise:
- Replace the tensioner (cheap insurance); these often fail after tens of thousands of miles.
- Alternator light or overheating appears after install:
- Re-check belt tightness and water pump operation; do not drive hard if water pump isn’t turning.

Maintenance and replacement intervals
- Many manufacturers recommend replacing the serpentine belt every 60,000–100,000 miles, but inspect it every oil change after ~40k miles. Replace belts showing cracks, glazing, or contamination immediately.
- Replace the tensioner and idler pulleys while replacing the belt if they show wear or if vehicle mileage is high. They are inexpensive relative to the time saved later.

Helpful analogies and tips
- Belt = rubber band; tensioner = the person holding the rubber band tight. If the person gets tired (weak spring), the band sags and slips.
- Always photograph belt routing before removal — it’s your roadmap back.
- If a pulley locks up while driving, it’s like someone grabbing and stopping one gear in a bicycle drive train — the chain (belt) will snap or throw the whole system out of sync.

Final safety notes
- Don’t work on a hot engine—wait to cool, especially near the water pump and pulleys.
- Use proper supports if you raise the vehicle. Keep body parts, hair, and clothing away from moving belts while engine is running.
- If you’re unsure about tensioner replacement, torque specs, or pulley condition, consult the factory service manual or a qualified mechanic.

This covers the components, why belts fail, how the system works, what can go wrong, tools, and a safe step-by-step replacement. If any pulley or tensioner shows roughness or play, replace it at the same time as the belt — it prevents immediate rework and failure.
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