Tools:
* Wrench Set: You'll need various sizes to potentially loosen the tensioner pulley(s). Check a repair manual for your specific engine to determine the exact sizes. Metric is likely, but double-check.
* Socket Set & Ratchet: Similar to the wrench set, necessary for potentially accessing and loosening bolts.
* Pliers: Possibly needed for gripping and manipulating the belt. Needle-nose pliers can be helpful in some situations.
* Screwdrivers: May be needed to remove various covers or access points. Both Phillips and flathead are possibilities.
* Socket Wrench Extension(s): Might be needed for better access to tight spots.
* Jack and Jack Stands (Highly Recommended): While not strictly required for all belt changes, jacking up the front end and using jack stands greatly improves access and safety. Never work under a vehicle supported only by a jack.
* Shop Rags or Paper Towels: For cleaning and preventing grease from contaminating the new belt.
* New Serpentine Belt: Obviously, you'll need a replacement belt. Make absolutely certain you get the correct belt for your specific engine. The wrong size or type will not work. The belt size and part number should be printed on the old belt, or you can find it in your owner's manual or a parts catalog (like AutoZone, Advance Auto Parts, or online).
Steps (General - Consult a repair manual for specifics):
1. Safety First: Disconnect the negative battery terminal to prevent accidental shorts. Engage the parking brake firmly. If jacking up the vehicle, use jack stands properly.
2. Locate the Tensioner(s): Your G20's serpentine belt system likely has one or more tensioner pulleys. These pulleys are designed to put tension on the belt, allowing you to easily remove and install the belt. A repair manual for your specific engine will clearly show their location.
3. Loosen the Tensioner(s): This is usually done by turning a bolt on the tensioner with a wrench or socket. This will release the tension on the belt, allowing you to slip it off the pulleys. Be extremely careful; some tensioners have strong springs and can snap back quickly if not properly controlled. You may need to use a pry bar or similar tool to gently hold the tensioner while loosening the bolt.
4. Remove the Old Belt: Once the tension is released, carefully work the belt off the pulleys. Start with the largest pulley.
5. Install the New Belt: Carefully route the new belt onto the pulleys in the same order as the old belt. This is crucial for proper functioning. Again, your repair manual is vital here.
6. Tighten the Tensioner(s): Once the belt is on all pulleys, tighten the tensioner bolt(s). Ensure the belt is properly seated on all pulleys.
7. Check Tension: After tightening the tensioner, give the belt a slight push in the middle. It should have some give but not be too loose. A repair manual will often have specifications for proper belt tension.
8. Reconnect the Battery: Reconnect the negative battery terminal.
9. Test Run: Start the engine and listen carefully for any unusual noises coming from the belt system. Check for belt slippage or any obvious problems.
Crucial Note: A 1992 Chevrolet G20 could have different engine options (e.g., V6, V8). You absolutely MUST consult a repair manual specific to your engine to accurately follow the steps. Repair manuals (Haynes or Chilton) are inexpensive and invaluable for this type of work. Improper belt routing can damage your engine. If you're uncomfortable performing this task yourself, take it to a qualified mechanic.
