How to Loosen a Tension Pulley on a 1997 Cavalier

The Chevrolet Cavalier was introduced in 1982. The 1997 Chevrolet Cavalier base model was equipped with a 120-horsepower, 2.2-liter in-line four-cylinder engine and a five-speed manual transmission. A 2.4-liter engine was available as an upgrade for the 1997 Cavalier. The tensioner pulley on the 1997 Cavalier is attached to the tensioner assembly. The tensioner assembly applies the proper amount of tension to the serpentine belt during the operation of the car. Loosening and removing the tensioner pulley involves the same process on both the 2.2-liter and 2.4-liter engines on the 1997 Cavalier.

Instructions

1

Open the hood of the Cavalier and set the hood prop. Position yourself over the passenger side front fender. Inspect the area underneath the hood and locate the "Belt Routing Diagram." If a routing diagram does not exist, then draw a box on a piece of paper, representing the engine. Draw each pulley as they appear in their positions on the car. Draw a thick line between each pulley to represent the routing of the serpentine belt.

2

Insert an open-end wrench onto the tensioner pulley. Depress the tensioner to release the belt tension. Remove the serpentine belt from the tensioner pulley.

3

Use the same open-end wrench to turn the pulley bolt counterclockwise. Continue turning the bolt counterclockwise until it comes free from the belt tensioner. At some point when you are turning the bolt, you may have to use your fingers, as the space between the pulley bolt and the inner fender wall is a very tight space. Remove the pulley once the bolt is removed.

4

Installation of the tesioner pulley is the opposite of removal. Torque the bolt to 60 foot-pounds with a torque wrench and socket. If you cannot get a torque wrench between the bolt head and the inner fender wall, turn the bolt clockwise until you cannot turn it with one hand any farther.

5

Install the serpentine belt starting with the rearmost pulleys, around the front side of the engine. Make the alternator the last stop of your belt routing. Depress the tensioner assembly, with the belt already looped around it. Pull the serpentine belt up and onto the alternator pulley. Double-check your alignment vertically on all of the pulleys. The belt should be centered on each pulley. Depress the tensioner and adjust the belt, as needed.