ION 2006-2007

Accessory Drive Belts

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Adjustment



Belt Alignment
  1. Measure the distance from the front machined surface of the cylinder block to the inboard edge of the belt at the location as shown.
  2.  
  3. The distance should be 1.102-1.220 in. (28-31mm).
  4.  
  5. If the distance does not fall within the specification, check the following:

    Check that the belt is properly located within the pulley grooves.
     
    Check the drive belt for wear at the edges and, if necessary, replace a worn belt.
     
    Make sure the belt pulleys are not bent or damaged.
     
    Make sure the accessory assemblies have proper shaft and bearing end-play.
     
    Check the pulley hubs for proper installation on their shafts.

    Click image to see an enlarged view

    Fig. Measuring serpentine drive belt alignment

     

  6.  

Belt Tension

The belt is automatically adjusted using a spring loaded tensioner. If belt slippage is suspected or unusual belt noises occurs, the following procedure should be used to determine if the tensioner or belt is at fault.

  1. Start the engine and allow it to warm up to normal operating temperature with all accessories (such as the A/C) turned ON ; this should take approximately 10 minutes. If the vehicle is equipped with power steering, turn the steering wheel to the left and right several times during warm-up to make sure a proper load is placed on the belt.
  2.  
  3. Turn the engine and accessories OFF .
  4.  
  5. Using a 14mm or 9 / 16 in. wrench, depress the tensioner arm until the belt becomes loosened, then slowly allow the tensioner to return to position and apply tension to the belt. Do not allow the tensioner to snap against the belt.
  6.  
  7. Inspect the markings located on the tensioner arm. If the marks on the arm fall outside the operating range, the drive belt must be replaced.
    NOTE
    Inspection of the belt using a tension gauge must be performed with the upper engine mount removed.

  8.  
  9. Using tool SA9181-NE or an equivalent calibrated belt tension gauge, measure and note the tension readings at the 2 points located centrally between 2 belt pulleys as shown in the illustration. The dotted lines represent other possible paths which your belt may follow, depending on the engine and accessories with which your vehicle is equipped.
  10.  
  11. Repeat the measurements from the previous step 2 more times, then calculate the average result for each test location. The readings should be 50-65 lbs. (22.7-29.2 kg) for new belts or a minimum of 45 lbs. (20.4 kg) for used belts. If the readings are out of this range or do not meet the minimum and the drive belt passed the test in Step 4, the drive belt tensioner must be replaced.

    Click image to see an enlarged view

    Fig. Use a 14mm or 9/16in. wrench to depress the tensioner arm until the belt becomes loose



    Click image to see an enlarged view

    Fig. Read the belt tension at 2 points centrally located between the indicated pulleys

  12.  

Drive Belt Routings





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Fig. Serpentine drive belt routing-2.2L Saturn engines



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Fig. Serpentine drive belt routing-2.4L Saturn engines

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.

Click image to see an enlarged view

Fig. There are typically 3 types of accessory drive belts found on vehicles today



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Fig. An example of a healthy drive belt



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Fig. Deep cracks in this belt will cause flex, building up heat that will eventually lead to belt failure



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Fig. The cover of this belt is worn, exposing the critical reinforcing cords to excessive wear



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Fig. Installing too wide a belt can result in serious belt wear and/or breakage

Removal & Installation



2.0L Engine

NOTE
The drive belt tensioner is a hydraulic tensioner with high initial torque. Release slowly to ensure proper operation.


NOTE
Depending on the tolerances of the open end portion of different manufactures wrenches, ensure that care is taken so the wrench does not slip off of the lug.



Click image to see an enlarged view

Fig. Install a tight fitting 15 mm open end wrench to the drive belt tensioner lug on the rear of the tensioner.

  1. Very slowly push down and towards the back of the vehicle in order to slowly compress the drive belt tensioner.

    Click image to see an enlarged view

    Fig. Remove the drive belt from over the drive belt tensioner.

  2.  
  3. Very slowly, allow the drive belt tensioner to return to the extended position.
  4.  
  5. Remove the drive belt from around the supercharger and alternator pulleys.
  6.  
  7. Remove the right front fender liner.
  8.  
  9. Remove the drive belt from under the idler pulley and around the air conditioning (A/C) compressor and crankshaft balancer.
  10.  
  11. From through the wheel house opening, remove the drive belt.
  12.  

To install:

  1. From through the wheel house opening, install the drive belt.
  2.  
  3. Route the drive belt around the A/C compressor and crankshaft balancer and under the idler pulley.
  4.  
  5. Install the right front fender liner.
  6.  
  7. Route the drive belt around the supercharger and alternator pulleys.
  8.  
  9. Ensure that the drive belt is still properly seated in the pulley grooves.
  10.  
  11. Very slowly push down and towards the back of the vehicle in order to slowly compress the drive belt tensioner.
  12.  
  13. Install the drive belt over the drive belt tensioner.
  14.  
  15. Very slowly, allow the drive belt tensioner to return to the extended position until tension is applied to the drive belt.
  16.  
  17. Remove the 15 mm open end wrench from the drive belt tensioner lug on the rear of the tensioner.
  18.  

2.2L & 2.4L Engines
  1. Remove the front fender liner.
  2.  
  3. Use the special tool J44811 in order to rotate the drive belt tensioner counter-clockwise to release the spring tension.
  4.  
  5. Remove the drive belt.
  6.  

To install:

  1. Use the special tool J44811 in order to rotate the drive belt tensioner counter-clockwise to release the spring tension.
  2.  
  3. Install the drive belt.
  4.  
  5. Install the front fender liner.
  6.  

 
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