Question about 1994 Chevrolet Cavalier

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Bolt broke? we think off of cavalier tensioner for serpentine

We went to put the belt on the car and the tensioner bolt broke as we lifted
it the bolt either broke off or screwed out and fell out and it seems so hard to get into how can we fix this I had a video on this site about the serpentine belt and it showed how to put it on i thought i saved it yet i cant find it anyone out there know about it and where it is please send me a link to Slivick@msn.com thanks

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  • bashful53 Dec 31, 2008

    a 1994 chevy cavalier 4 door he said that the bolt as it looks like it is broke off that the tension realesser is now loose can he pull out the old bolt and put a new one in? i am affraid for him to do it he is good with cars but mostly older modles with regular fan belts and thats all, but he says he thinks he knows, but if the tension

    release is just hanging there is sounds like the bolt is off. my question is can he just put an another bolt on to hold the tensioner? if so what size that would be of great help also has anyone located that video that showed a man put the serpentine belt on a 94 4 door chevy cavalier. it looked a u tube video yet it was here on the site. I really appreiciat all your help and forgive spelling just having a rough time here happy new year two you .

  • bashful53 Dec 31, 2008

    i am sorry what is a 2.5 iron duke MTR KDC 744?

  • bashful53 Dec 31, 2008

    the car is a 4 door chevy cavalier v.6 cruse control so what is a 744 please

  • bashful53 Jan 01, 2009

    ok thanks again i am sooo sry for asking help on new year he said that he isnt even sure if bolt just is unscrewed and made the tensioner loose and dangle or if it is infact broke off. he said it is so hard for his hand to get in there between the block and unibody

    so he said he is going to have trouble get the tensior liffted to see if the bolt is broke unscrewed . I am so frustrated with him. also i asked about this video is that video available has anyone seen it it showed such clear pick for him, I wish i could find it again. you people are great go have a safe and fun night and get back to me as soon as your hang over is gone LOL thanks soooo much.

  • bashful53 Jan 01, 2009

    sounds like your all getting upset understandable i have a husband who isnt very kind,, anyway i dont recall saying fan was in the way the compartment to get to the tensonier is so tight it is hard to reach have a rest a nice new year i wont but you please do you have been so kind and i am sorry to bother you.I will write more when he starts working on it ok if that is fine??? he is off work now for the holliday till monday he has no excuse to do this he just hates it. but a dissabled person needs a car. as soon as he starts working on it if it is ok to write you may i ??? thanks

  • bashful53 Jan 02, 2009

    thanks again he said since it is raining so hard today that he will look at A.M he said he dosent think the bolt broke he thinks it is unscrewed to where he cant see much of it i know the belt doesnt run the fan yet he said the tensioner is just dangling which makes him think its the bolt loose or broke. it isnt all the way off it's just dangling on the obviously to me by the bolt!!!!



    he took off my right front tire? question why? is that nessasry? he told me it's because he cant get is hand between the block and

    unibody? does he have too? I am thinking by taking of right front pass. tire he's going to work under the car? is this crazy or not? I found the video and it looks so easy

  • bashful53 Jan 02, 2009

    I am worried because he took off the right pass. front tire, does that mean he is going to reach the tensioner from underneath? is this nessasary? he said it is to hard for his hand to reach between the unibody and mtr block? maybe the spring just poped off is this possible instead of the screw? if so then what? there isnt anyone to tow us and the cost of towing and having it serviced is hard for now. and he is good with cars but likes to just jerry rig them if you know what i mean? (LOL) i will keep in touch now snow is gone and is raining very hard we have a car port but and the front of the car is in the car port but that is his excuse not to fix it now, he hates working on cars. if it is just the spring and the screw is there yet broke or maybe just loose is the spring for tensioner hard to buy and or put on? Also i got the car in 96 and have had little trouble with it just my air conditoner went out when he fixed my heater core. oh well that an other story. i will keep in touch i just dont understand why he didnt use a socket like your supposed to he said he just to like pliars and lifted the the tensioner and thats when all heck blew. i hope it is ok to keep writting to this board and you? thank you again silvia

  • bashful53 Jan 03, 2009

    ok all you people he is going to try and fix it today the 3rd and i am getting worried like i said he has trouble fitting his hand between the block and the unibody? anyway he is going to attempt it. any last helpful words ? i am going to have him read all you wrote about doing this job but if the tensioner is just hanging there what does that sound like to you all, he wont explain much because he says i am a women and wont under stand but i need to know so i can explain back to you people the tensioner spring loaded too? could the spring of broken off? please give me any last words if possible and i will let you know how it all is going he said it is going to be an all day job I just cant see how it would? and towing to a dealer isnt an option at this point in time because of cash flow. i will try and donate to the site as soon as i can thank you very much silvia

  • kevin carpenter May 11, 2010

    for starters this is a frt wheel drive vech tavers mounted mtr so there is know fan in the way and in 94 the belt routing is not there ,have you removed the old tensouir to see if one the bolt fell out our if it is broke kdc744

  • kevin carpenter May 11, 2010

    sorry about that its a 94 cav dose it have the 2.5 iron duke mtr ? kdc744

  • kevin carpenter May 11, 2010

    what type off vech are we working on? kdc744

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Ok now that we know that it is a six cyclinder that helps, you have to remove the tensouir so we can find what damages there are. your right nothing is going to be easy. if you call the dealer they should be able to help you with the correct bolt size and pitch. and the part, help your husband by doing this your self , when you call the dealer have the vin number ready you can get that number from the vin plate thats located in the left corner of the windsheild copy the whole number. be patient this repair is not as hard as it looks you guys can handle it, keep my advise on how you are doing kdc744

Posted on Jan 01, 2009

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For as little as it will cost to repair this whole issue.........take the car to your GM deler, and they'll do the job for you......depending on where you live and labor rates the whole job along with replacement parts shouldn'r be more then $150...Problem solved!

Ford had some of the same issues in that stretch of model years also.

Posted on Jan 01, 2009

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Seems like we have two issues: 1. the tensioner bolt and 2. the threading the new serpentine belt. #2 may be the easiest solved. Look on the front radiator coul or the cross member over the radiator. All GM vehicles have a picture decal stuck there or on the fender well or fan shroud etc. Inspect all these places to see if it there and it should be unless removed.

Back to #1. I assume you found the bolt? If so and it isn't obviously damaged then replace it and the tensioner should work perfectly well. I would grease the bolt prior to replacing it in the block however. If the bolt is lost or broken then replace it from Pep Boys or a salvage yard. This will be a metric bolt so be careful not to get SAE standard threaded one. Also, you should get the exact repacement of hardness which I am sure a grade 8 bolt and it should only be threaded the same distance from the end as the original. Be sure to replace the washer also if lost. Be sure that the spring is properly placed in the pivot body and tighten it up to about 35-40 ft lbs. ps. If the bolt is broken in the block, then you may be able to remove it by spraying wd-40 on it and using a tiny chisel or perhaps a concrete nail and small hammer and peck at the bolt on the side that would apply pressure to turn the broken bolt piece in a loosening movement to back it out of the bolt hole. Remember righty tighty, lefty loosen.

Now for threading the belt. If this goes behind the fan then you can thread it over a blade and turn the fan, thus not having to remove the fan. Once the fan issue is resolved or not an issue and you cannot find the threading picture, then you can use your common sense to figure that the belt bust be driven by the crankshaft and look at the ridges on the belt to decide which side of the next pulley that needs power and continue this process over each auxilary unit until you are sure of the threading then put your 1/2 drive ratchet into the tensioner and move it asside making sure that all the little ridges are in place on the ridged pulleys then release the tensioner.

Thats all there is to it. Good luck, glenn and happy new year!

Posted on Dec 31, 2008

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  • 81 Answers

Go to a junk yard and buy another tensioner and bolt.

Posted on Dec 31, 2008

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