How to Replace the Serpentine Belt in a 6.0 Powerstroke
- 1). Lift the hood and position a catch pan on the ground directly underneath the upper radiator hose, which runs off the top of the engine to the top of the radiator. If your 6.0L Powerstroke is equipped with the later hose design--in which the hose routes outside the belt--skip to Step 3.
- 2). Loosen the upper radiator hose clamp at the radiator with a socket set. Pull the hose off the radiator, making sure any coolant that escapes goes down into the catch pan. Bend the hose backward, through the belt, and wedge it out of the way next to the thermostat housing.
- 3). Connect a belt tensioner tool to the belt tensioner. Lever the belt tensioner aside so that you can move the belt off the tensioner pulley with your other hand. Slowly release the pressure on the tool and remove it. You can purchase a belt tensioner tool at most auto parts stores or professional tool retailers. Prices vary by brand and retailer.
- 4). Pull the belt off the remaining pulleys and take it out of the engine well. Compare the lengths of the old and new belts. It's not uncommon for the old belt to stretch up to 1 inch during its lifespan. If the difference in belt lengths is greater than that, you have the wrong replacement belt. Don't try to install it, but take the old one to the automotive parts store to match it up for a proper replacement. Belt prices vary by model year, engine accessory configuration, and brand.
- 5). Route the new belt around the crankshaft pulley and then around each of the other pulleys until only the tensioner pulley remains. Refer to the belt routing diagram, printed on a sticker adhered to the radiator shroud, when routing over each pulley to make sure you route the belt properly. Failure to route the belt properly can lead to damage of the engine components as well as personal injury.
- 6). Plug the tensioner tool back into the tensioner, use the tool to move the tensioner aside once more, and pull the belt over the tensioner pulley with your other hand. Hold the belt on the pulley while you slowly release the tensioner back to its natural position. Pull the tool out.
- 7). If you disconnected the upper radiator hose in Step 1, reconnect it now. If you lost any coolant in Step 1, top the overflow tank (known as the degas bottle) with the same amount of coolant.
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