How do you replace the belt tensioner on a 1991 cavalier?

Answer 1

How to change the serpentine belt tensioner on a 1991 2.2L Chevrolet Cavalier:

The tensioner comes as an assembly (aluminum plate with pre-loaded spring and pulley). These are EXACT instructions on how to do this year/model and is not a generic answer.

This tensioner plate assembly also fits on these models:

• 1987 1988 1989 Buick Skyhawk 2.0L
• 1993 1994 1995 1996 Buick Century 2.2L
• 1987 1988 1989 1990 1991 1992 1993 1994 Chevy Cavalier 2.2L or 2.0L
• 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 Chevy Corsica 2.2L or 2.0L
• 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 Chevy Beretta 2.2L or 2.0L
• 1987 1988 Oldsmobile Firenza 2.0L
• 1993 1994 1995 1996 Oldsmobile Ciera 2.2L
• 1993 1994 1995 1996 Oldsmobile Cutlass Ciera 2.2L

Step 1: Disconnect Battery.

Step 2: Remove Belt - 15mm wrench on pulley - turn clockwise to remove tension. There may be no spring tension - but that's why you're changing it - right?

Step 3: Remove Power Steering pump - Remove small bolt (10mm) on the back side of power steering pump (you are facing engine from passenger side). Use a box-end wrench or one of those ratchet box-end wrenches. Next, there are 3 bolts (13mm) in the front - behind the pulley. There are holes in the pulley specifically for the purpose of removing these bolts. I used a magnet to pull the bolts out after loosened but you may be able to reach under the pulley with your fingers to get them out. You should now be able to move the pump out of the way toward the firewall. Be careful to not break the plastic top. If you have to pry it, do it on the bottom metal part. No need to remove any hoses.

Step 4: Remove alternator - Remove all bolts holding the alternator in place. It should just be laying there (Upper alternator bracket removed).

Step 5: Remove belt tensioner assembly plate - Remove four 15mm bolts that hold the aluminum plate to the engine block. Mine were on pretty tight so I had to use a breaker bar to get 'em off.

Re-assembly:

Step 6: Compare new tensioner assembly with old one. They should match. Attach plate to engine block with four 15mm bolts. Make sure they're tight. You don't want this to come loose.

Step 7: Re-align power steering pump to 3 holes in tensioner plate and screw in the 3 bolts (don't tighten yet). Next - take the small 10mm bolt that goes in the back of the pump assembly and carefully get it started with your fingers (left hand) The 2 holes should be aligned because the 3 bolts in front are started. Tighten all 4 bolts.

Step 8: Alternator - Re-install the long bolt and nut that goes in the bottom of the alternator (you may have to loosen the lower alternator bracket so the holes align). Don't tighten bolt and nut yet. Let the alternator pivot/swing towards the engine. This will make it easier to get the belt on (This is the way I did it - you may be able to get the belt on with all alternator bolts in).

Step 9: Serpentine belt install - If new belt, make sure it's the same length as the old one. Route the belt like the diagram sticker. The alternator is the last pulley it will go over. If you can get someone to help you here, it's a lot easier. Turn the 15mm bolt on the tensioner pulley clockwise until there's enough slack to slip the belt over the alternator pulley. While keeping the tension off the pulley, replace the other 2 bolts/upper alternator bracket. Slowly let the the tensioner spring back. Replace and tighten the rest of the alternator/bracket bolts.

Step 10: Re-connect battery