GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2002 🢒 Monte Carlo 🢒 Engine 🢒 Engine Mechanical - 3.8L 🢒 Drive Belt Tensioner Replacement

Removal Procedure
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  3. Remove the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
  4. Remove the drive belt. Refer to Drive Belt Replacement .
  5. Remove the generator. Refer to Generator Replacement in Engine Electrical.
  6. Remove the heater hose adapters with the heater hoses from the drive belt tensioner. Refer to Heater Inlet Hose Replacement and to Heater Outlet Hose Replacement in Heating, Ventilation and Air Conditioning.

    7. Object Number: 326960 Size: SH
  7. Remove the drive belt tensioner bolts.
  8. Remove the drive belt tensioner.
  9. If replacing the drive belt tensioner, remove the thermostat bypass upper and lower pipe assemblies.

Installation Procedure
  1. If replacing the drive belt tensioner, lubricate the thermostat bypass upper and lower pipe assembly seals with engine coolant and install the upper and lower pipe assemblies.

    2. Object Number: 326960 Size: SH
  2. Install the drive belt tensioner.

    3. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  3. Install the drive belt tensioner bolts.

    4. Tighten
    Tighten the bolts to 50 N·m (37 lb ft).

  4. Install the heater hose adapters with the heater hoses to the drive belt tensioner. Refer to Heater Inlet Hose Replacement and to Heater Outlet Hose Replacement in Heating Ventilation and Air Conditioning.
  5. Install the generator. Refer to Generator Replacement in Engine Electrical.
  6. Install the drive belt. Refer to Drive Belt Replacement .
  7. Install the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
  8. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.