GM Cavalier/Sunfire 1995-2000 Repair Guide

Crankshaft Pulley/Damper

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REMOVAL & INSTALLATION



2.2L Engines

See Figures 1, 2 and 3

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the serpentine drive belt.
  4.  
  5. Raise the vehicle and support it with jackstands.
  6.  
  7. Remove the inner fender splash shield.
  8.  
  9. Remove the crankshaft pulley bolts.
  10.  
  11. Unfasten the hub bolt and remove the pulley.
  12.  
  13. Attach a suitable puller tool to the crankshaft hub.
  14.  
  15. Turn the center screw of the puller clockwise until it forces the hub from the crankshaft.
  16.  
  17. Inspect the hub for damage and replace it ae necessary.
  18.  
  19. Inspect the crankshaft key for damage and replace as necessary.
  20.  

To install:
  1. Coat the front cover seal with clean engine oil.
  2.  
  3. If removed, apply a suitable RTV sealer to the key on the crankshaft and install the key.
  4.  
  5. Plave the hub onto the crankshaft making sure to align the key with the notch on the inside diameter of the hub.
  6.  
  7. Install the pulley hub bolt, and tighten the bolt to pull the hub into position taking care and ensuring that the hub goee in straight. Once the hub is fully seated, screw two of the pulley bolts into the hub, use a prybar between the bolts to stop the hub from turning and loosen the hub pulley hub bolt.
  8.  
  9. Remove the two pulley bolts and install the pulley.
  10.  
  11. Install the pulley hub bolts and the center hub bolt. Tighten the pulley bolts to 37 ft. lbs. (50 Nm) and the pulley hub bolt to 77 ft. lbs. (105 Nm).
  12.  
  13. Install the inner fender splash shield.
  14.  
  15. Lower the vehicle.
  16.  
  17. Install the serpentine drive belt and connect the negative battery cable.
  18.  



Click image to see an enlarged view

Fig. Fig. 1: Location of the crankshaft pulley bolte (1) and the hub bolt (2)



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Fig. Fig. 2: Unfasten all the pulley and hub bolts, remove the pulley and install a suitable puller on the crankshaft hub



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Fig. Fig. 3: Use the puller to draw the hub off the crankshaft and remove the hub from the engine compartment

2.3L and 2.4L Engines

See Figure 4



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Fig. Fig. 4: Crankshaft balancer assembly-2.3L/2.4L engines

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the serpentine drive belt.
  4.  
  5. Raise the vehicle and support it with jackstands.
  6.  
  7. Remove the inner fender splash shield.
  8.  
  9. Remove the crankshaft damper center retaining bolt and washer.
  10.  
  11. Remove the damper assembly using a suitable puller assembly.
  12.  

To install:
  1. Lubricate the front seal and sealing surface of the damper with chassis grease.
  2.  
  3. Install the damper onto the crankshaft ensuring that the keyway lines up. A rubber or other soft-faced mallet may be needed to lightly tap the damper onto the crankshaft.
  4.  
  5. Install the retaining bolt and washer and tighten the bolt to 129 ft. lbs. (175 Nm), then rotate an additional 90°.
  6.  
  7. Install the inner fender splash shield.
  8.  
  9. Lower the vehicle.
  10.  
  11. Install the serpentine drive belt and connect the negative battery cable.
  12.  

 
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