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[pic][pic]PATH:  Suspension > Rear Suspension > Track Bar (Tie Bar) > Removal & Installation

Removal & Installation

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|Track bar replacement |

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1. Raise the rear of the vehicle, place jackstands under the rear axle, then lower the jack so that the stands are supporting all of the weight.

2. Remove the track bar mounting fasteners. Remove the track bar.

To install:

3. Clean all of the track bar fasteners.

4. Position the track bar in the body bracket, then loosely install the bolt and the nut.

5. Position the track bar to the axle assembly, then install the bolt and the nut. Torque the bolt to 59 ft. lbs. (80 Nm).

6. Torque the body bracket nut to 78 ft. lbs. (105 Nm).

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[pic][pic]PATH:  Fuel System > Fuel Level Sending Unit > Removal & Installation

Removal & Installation

1. Remove the fuel tank.

2. Clean the area surrounding the sender assembly to prevent contamination of the fuel system.

3. Using tool J-24187 or equivalent, remove the sending unit retaining cam. Remove the fuel sender and O-rings from the tank. Discard the O-rings.

4. If necessary, separate the fuel pump from the sending unit assembly.

To install:

5. If removed, install the fuel pump to the sending unit. If the strainer was removed, it must be replaced with a new one.

6. Inspect and clean the O-ring mating surfaces.

7. Install a new O-ring in the groove around the tank opening. If applicable, install a new O-ring on the fuel sender feed tube.

8. Install the fuel sender assembly as follows:

1. The fuel pump strainer must be in a horizontal position, and when installed, must not block the travel of the float arm. Gently fold the strainer over itself and slowly position the sending assembly in the tank so the strainer is not damaged or trapped by the sump walls.

5. Install the retaining cam using tool J-24187 or equivalent.

6. Install the fuel tank assembly.

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|Quick-connect fittings |

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|Fuel tank removal |

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[pic][pic]PATH:  Fuel System > Fuel Tank > Removal & Installation

Removal & Installation

1. Disconnect the negative battery cable.

2. Relieve the fuel system pressure.

3. Drain the fuel from the tank into an approved container. Use a hand-operated pump to drain the fuel through the filler neck.

4. Safely raise and support the vehicle.

5. Remove the fuel filler neck shield.

6. Remove the rear axle assembly.

7. Remove the rear portion of the exhaust system.

8. Remove the exhaust heat shield.

9. Clean all the fuel pipes and hoses in the surrounding areas to prevent contamination of the fuel system.

10. Disconnect the rear fuel feed, fuel return, vapor, and vent hoses at the fuel sender assembly.

11. Separate the electrical connection.

12. With the aid of an assistant, support the fuel tank.

13. Remove the fuel tank strap front attaching bolts. Do not bend the straps as this will damage them.

14. Remove the tank straps and the fuel tank.

To install:

15. Hook the rear end of the fuel tank straps into the underbody bracket.

16. With the aid of an assistant, position and support the fuel tank with the straps. Loosely install the front fuel tank attaching bolts.

17. Engage the electrical connection.

18. Connect the fuel hoses and lines separated during removal.

19. Install the muffler heat shield and the exhaust system.

20. Install the rear axle and the fuel filler neck shield.

21. Lower the vehicle.

22. Add fuel and install the filler cap.

23. Connect the negative battery cable.

24. With the engine OFF, turn the ignition switch to the ON position for 2 seconds, then turn it to the OFF position for 10 seconds. Again turn it to the ON position and check for fuel leaks.

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[pic][pic]PATH:  Fuel System > Gasoline Fuel Injection System > Fuel Pump > Removal & Installation

Removal & Installation

The fuel pump is part of the fuel sender assembly located inside the fuel tank.

1. Release the fuel system pressure and disconnect the negative battery cable.

2. Drain the fuel tank, then raise and safely support the vehicle.

3. Remove the fuel tank from the vehicle.

4. Clean the area surrounding the sender assembly to prevent contamination of the fuel system.

5. Remove the fuel sender from the tank as follows:

1. Use tool J-24187 or equivalent to remove the sending unit retaining cam. Remove the fuel sender and O-rings from the tank. Discard the O-rings.

1. If necessary, separate the fuel pump from the sending unit assembly.

To install:

7. If removed, install the fuel pump to the sending unit. If the strainer was removed, it must be replaced with a new one.

8. Inspect and clean the O-ring mating surfaces.

9. Install a new O-ring in the groove around the tank opening. If applicable, install a new O-ring on the fuel sender feed tube.

10. Install the fuel sender assembly as follows:

1. The fuel pump strainer must be in a horizontal position, and when installed, must not block the travel of the float arm. Gently fold the strainer over itself and slowly position the sending assembly in the tank so the strainer is not damaged or trapped by the sump walls.

7. Install the retaining cam using tool J-24187 or equivalent.

8. Install the fuel tank assembly.

9. Lower the vehicle.

10. Fill the fuel tank, tighten the fuel filler cap and connect the negative battery cable.

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|Fuel pump and sending unit assembly |

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|Fuel pump locking cam tool |

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The removal and installation procedures for the Crossfire injection system fuel pump is identical to the Throttle Body Injection (TBI) system.

The fuel pump is part of the fuel sender assembly located inside the fuel tank.

1. Release the fuel system pressure and disconnect the negative battery cable.

2. Drain the fuel tank, then raise and safely support the vehicle.

3. Remove the fuel tank from the vehicle.

4. Clean the area surrounding the sender assembly to prevent contamination of the fuel system.

5. Using tool J-24187 or equivalent, remove the sending unit retaining cam. Remove the fuel sender and O-rings from the tank. Discard the O-rings.

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|A special tool is usually available to remove or install the fuel pump locking cam |

|Click to Enlarge |

6. If necessary, separate the fuel pump from the sending unit assembly.

To install:

7. If removed, install the fuel pump to the sending unit. If the strainer was removed, it must be replaced with a new one.

8. Inspect and clean the O-ring mating surfaces.

9. Install a new O-ring in the groove around the tank opening. If applicable, install a new O-ring on the fuel sender feed tube.

10. Install the fuel sender assembly as follows:

1. The fuel pump strainer must be in a horizontal position, and when installed, must not block the travel of the float arm. Gently fold the strainer over itself and slowly position the sending assembly in the tank so the strainer is not damaged or trapped by the sump walls.

7. Install the retaining cam using tool J-24187 or equivalent.

8. Install the fuel tank assembly.

9. Lower the vehicle.

10. Fill the fuel tank, tighten the fuel filler cap and connect the negative battery cable.

11. Turn the ignition switch to the ON position for 2 seconds, OFF for 10 seconds, then back to the ON position. Check for fuel leaks.

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|Fuel pump assembly |

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[pic][pic]PATH:  Steering > Power Steering Pump > Removal & Installation

Removal & Installation

Animations and Tech Tips

[pic]Click to view: Pulley removal

[pic]Click to view: Pulley components

[pic]Click to view: A pressure relief valve

[pic]Click to view: Vane type pump internal components

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|Pulley removal |

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|Steering pump removal; V6 |

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|Steering pump removal; V8 |

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1. Remove the hoses at the pump and tape the openings shut to prevent contamination. Position the disconnected lines in a raised position to prevent leakage.

2. Remove the pump belt. Remove the pump pulley, as required

3. Loosen the retaining bolts and any braces, and remove the pump.

To install:

4. Install the pump on the engine with the retaining bolt handtight.

5. Connect and tighten the hose fittings.

6. Refill the pump with fluid and bleed by turning the pulley counterclockwise (viewed from the front). Stop the bleeding when air bubbles no longer appear.

7. Install the pump belt on the pulley and adjust the tension.

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[pic][pic]PATH:  Engine Electrical > Distributor Ignition System > Delco® High Energy Ignition (HEI) System > Distributor > Removal & Installation > Distributor Cap

Distributor Cap

1. If removing the ignition wires at the cap, take a moment to label the spark plug wire positioning for each cylinder, at each tower. This will avoid improper wire placement during assembly.

2. Disconnect the ignition switch wire from the distributor cap. Also disconnect the tachometer wire, if so equipped.

3. Release the coil connectors from the cap.

4. Remove the distributor cap by turning the four latches (the L4 distributor has 2 latches) counterclockwise.

5. Remove the cap. Installation is the reverse of removal. Be sure you get the ignition and tachometer wires connected to the correct terminals.

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|Release the retainers on the distributor cap by turning them counterclockwise |

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|Removing the distributor cap. Notice that all towers on cap are labeled with the corresponding engine cylinder number. |

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[pic][pic]PATH:  Engine Electrical > Distributor Ignition System > Delco® High Energy Ignition (HEI) System > Distributor > Removal & Installation > Rotor

Rotor

1. Disconnect the negative battery cable.

2. Remove the distributor cap.

3. Unscrew the two rotor attaching screws and then lift off the rotor.

4. For installation, make sure the rotor is positioned in the correct direction and tighten the retaining screws.

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