How to Get a 1998 Cavalier Belt Tensioner Assembly Off

The Chevy Cavalier model run extended from 1982 through 2005. Chevy sold enough Cavaliers that it had the highest number of units sold in one particular model. This was due in part to its aesthetics, and to the Z-24's powerful Quad 4 engine, which produced over 1 horsepower per cubic inch, resulting in 150 horsepower. This was remarkable in light of the fact that it carried one of the worst safety ratings on the market. The belt tensioner was designed to maintain a constant tension of the serpentine belt. It consisted of a round housing containing a heavy coil spring, with an extended arm with a pulley on the end. This arm acted as a tensioned lever applying tension to the belt. The same tensioner is common to both the 2.4 and the 2.2 engines. Unfortunately GM allowed long service life to take back seat to cost effectiveness, and they made the pulley out of plastic. The result was a short service life. If the tensioner spring works well, the pulley can be replaced with a metal variant, solving the wear problem.

Instructions

1

Place the appropriate size wrench on the bolt in the center of the tensioner pulley and push the tensioner away from the belt. Lift the belt off the tensioner pulley only. There is no need to remove the belt from any other pulley. Gradually release the pressure on the tensioner.

2

Place the appropriate size socket on the bolt in the center of the tension spring housing on the block. Turn the bolt counterclockwise to remove the tensioner.

3

Insert the large bolt in the center hole of the new tensioner spring housing. Notice the locating pin on the back of the tensioner. This pin must be inserted into the corresponding locating hole in the block to keep the tensioner from turning when installed.

4

Align the locating pin on the back of the tensioner with the hole in the block, position the tensioner on the block and thread the bolt in clockwise by hand. Make sure the locating pin remained in the hole. The tensioner will not be flush with the block if the pin is not in the hole. Tighten the center bolt to 30 foot-pounds with a torque wrench.

5

Move the tensioner away from the belt. Install the belt and release the tension on the tensioner pulley.