Hi all, I'm new to the forum, hope Dodge owners in the UK are welcome to join.
I do have a question / issue.
I have a 1993 5.2 V8 b250 dayvan.
I have removed the a/c and just fitted a replacement shorter belt and routed it as per diagram.
The problem I have is the belt is now catching on itself at the idler pulley and fan pulley. Have any of you guys out there had this problem? How did you get over it?

 

I think dodge had another pulley in place of the a/c compressor on non-a/c equipped vans.

What's wrong with your compressor?

 

Thanks for that, I will try to get a smaller diameter idler pulley.
I bought the van with the a/c not working, hoses missing and broken. So have decided to take the compressor off while I'm replacing the drive belt.

 

The only difference appears to be the bracket, perhaps the non-AC bracket is of a different shape as well as lacking the AC mount. http://johnmeister.com/jeep/JEEP-TEC...FS/94truck.pdf

I would consider replacing that little coolant hose shown in your photo as part of regular maintenance. That hose is not something that could be replaced on the side of the road should it pop...it was a nightmare on my van when I decided to replace it.

 

Another option may be, since compressor is gone is replace it with an AC bypass pulley similar to like this...
https://www.dormanproducts.com/p-23879-34178.aspx,
and use the same routing and size belt as is with AC

 

That is indeed the best option.

 

Thanks guys, I will look into that.

 

Thanks for all the advice guys, I decided in the end to make myself a new smaller diameter idler pulley. Turned the outside diameter down to 50mm. Works ok with good clearance as you can see. It did foul the pulley bracket a tiny bit so had to gently grind a few millimetres off of it. Thanks again for all the advice.

 

Glad to see you found a fix! Ther's more than one way to get the job done... you proved it

 

Good job but keep an eye on it for a bit. The smaller the pulley the faster it will turn and you'll want to make sure the bearing isn't overheating and breaking down the grease in it.