Cavalier, Sunfire 2001-2005

Accessory Drive Belts

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Adjustment



All engines use an automatic drive belt tensioner. No adjustment is necessary. If the tensioner is at Maximum travel, the belt is most likely stretched or the incorrect belt was installed.

Belt Tension Inspection



Inspect the drive belt for signs of glazing or cracking. A glazed belt will be perfectly smooth from slippage, while a good belt will have a slight texture of fabric visible. Cracks will usually start at the inner edge of the belt and run outward. All worn or damaged drive belts should be replaced immediately.

Drive Belt Routings





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Fig. Serpentine drive belt routing with A/C-2.2L engine



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Fig. Serpentine drive belt routing without A/C-2.2L engine



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Fig. Serpentine drive belt routing-2.4L engine



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Fig. Serpentine drive belt routing with A/C-GM 2.2L engine



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Fig. Serpentine drive belt routing without A/C-GM 2.2L engine



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Fig. Serpentine drive belt routing-GM 2.4L engine

Removal & Installation



  1. Disconnect the negative battery cable.
    NOTE
    The proper belt routing is included in this section, however, it is a good idea to make a simple drawing of the belt routing of your engine for installation reference before removing the belt.

  2.  
  3. Rotate the drive belt tensioner to relieve the belt tension. The procedure is as follows:
    1. On the 2.2L engine, use a 15 mm drive tool or a special belt removal tool to rotate the tensioner clockwise.
    2.  
    3. On the 2.4L engines, use a 13mm drive tool or a special belt removal tool to rotate the tensioner clockwise.
    4.  
    5. While holding the tensioner back, remove the belt from around one pulley.

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      Fig. The belt tensioner is released by rotating the tensioner pulley bolt in a CLOCKWISE direction-2.2L engine



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      Fig. The belt routing for the vehicle you are working on can usually be found on a label attached to the underside of the hood

    6.  

  4.  
  5. Remove the belt from around the remaining pulleys.

    Click image to see an enlarged view

    Fig. Serpentine drive belt routing with A/C-2.2L engine



    Click image to see an enlarged view

    Fig. Serpentine drive belt routing without A/C-2.2L engine



    Click image to see an enlarged view

    Fig. Serpentine drive belt routing-2.4L engine

  6.  

To install:

  1. Position the belt around the pulleys in the proper routing with the exception of one pulley. It is easiest to keep the belt off of the easiest pulley to access. Hold the belt tight with your hands and using the proper tool for your engine, rotate the tensioner clockwise and place the belt around the final pulley.
  2.  
  3. Release the tensioner slowly until it sits firmly against the belt.
    NOTE
    If the tensioner does not touch the belt or the wear indicator marks are not within specification, the belt is routed incorrectly or the wrong belt has been installed.

  4.  
  5. Connect the negative battery cable.
  6.  
  7. Start the engine and ensure that the belt runs smoothly and no abnormal noises exist.
  8.  

 
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