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Distributor
• REMOVAL & INSTALLATION
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REMOVAL & INSTALLATION
See Figures 1, 2, 3, 4 and 5
1. For 1995-96 vehicles, inspect the distributor ventilation system for proper ventilation.
2. Be sure the ignition is in the OFF or LOCK position. Disconnect the negative battery cable.
3. Detach the Intake Air Temperature (IAT) electrical connector.
4. Remove the air intake duct.
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Fig. Fig. 1: Unfasten the retainers, then remove the air intake duct
5. Remove the accessory drive belt, as outlined in General Information & Maintenance of this repair guide.
6. Drain the engine cooling system into a suitable container.
7. Disconnect the water pump coolant hoses, and allow any remaining coolant to drain.
8. Detach the Engine Coolant Temperature (ECT) sensor electrical connector.
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Fig. Fig. 2: Unplug the electrical connector from the ECT sensor
9. Remove the water pump and crankshaft balancer, as outlined in Engine & Engine Overhaul of this repair guide.
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Fig. Fig. 3: The water pump must be removed for access to the distributor
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Fig. Fig. 4: You must also remove the crankshaft torsional damper, also known as the balancer
10. Remove the drive belt tensioner.
The spark plug wire boots should be twisted1/2turn in each direction while removing. Do not pull on the wires to remove them from the spark plugs. Pull on the boots or use a tool specifically designed for this purpose.
11. Label and disconnect the spark plug wires/harness from the distributor.
12. Unplug the 4-terminal ECM/PCM electrical connector from the distributor.
13. If equipped, disconnect the distributor vacuum harness from the distributor.
14. Loosen and remove the distributor attaching bolts.
15. Pull the distributor assembly forward until the driveshaft disengages from the end of the camshaft.
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Fig. Fig. 5: Exploded view of the distributor mounting-5.7L (VIN P and 5) engines
16. Mark the top surface of the driveshaft for proper alignment during installation.
To install:
Replace the O-rings on the coupling shaft or ignition system performance may suffer. Lubricate the O-rings and the end of the camshaft.
WARNING
Don't try to fully seat the distributor using the distributor retainers. If the distributor will not seat by hand, it's not properly aligned with the camshaft. Rotate the crankshaft until the engine is at the number 1 cylinder TDC (camshaft sprocket pin at the 9 o'clock position). Rotate the distributor coupling until the camshaft sprocket pin slot aligns with the distributor base timing mark. Install the distributor using hand pressure to fully seat the distributor.
17. Install the distributor assembly into position with the driveshaft in the end of the camshaft. Rotate the distributor coupling until the camshaft sprocket pin slot aligns with the camshaft sprocket pin. Slide the distributor onto the end of the camshaft until fully seated on the engine front cover.
18. Install the distributor mounting bolts. Tighten to 8-9 ft. lbs. (11-12 Nm).
19. Attach the 4-pin ECM/PCM connector.
20. If equipped, attach the distributor vacuum harness to the distributor.
21. Connect the spark plug wires to the distributor, as tagged during removal.
22. Install the drive belt tensioner.
23. Install the crankshaft balancer and water pump, as outlined in Engine & Engine Overhaul of this repair guide.
24. Attach the ECT sensor connector.
25. Refill the cooling system with the proper type and amount of coolant.
26. Install the accessory drive belt.
27. Install the air intake duct and attach the IAT sensor electrical connector.
28. Connect the negative battery cable.
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Distributor Cap and Rotor
• REMOVAL & INSTALLATION
5.7L (VIN P & 5) Engines
See Figure 11
Removal of the distributor cap and rotor on these vehicles requires the use of two special tools; an ignition distributor cap socket (tool J 39997 or equivalent), and ignition distributor rotor socket (tool J 39998 or equivalent).
WARNING
The distributor and timing disc assembly must be kept clean and free of oil, dirt and engine coolant. Any contamination may cause engine misfire and/or distributor damage. Do not disassemble the distributor until all debris has been cleaned from the distributor and surrounding area.
1. Disconnect the negative battery cable.
2. Remove the water pump and crankshaft balancer assembly, as outlined in Engine & Engine Overhaul of this repair guide.
3. Tag and disconnect the spark plug wires from the distributor assembly.
4. Unplug the 4-terminal PCM connector and vacuum harness from the distributor. Plug or cap the vacuum line to prevent any debris from entering.
5. Use a suitable distributor cap socket, tool J 39997 or equivalent, to remove the distributor cap bolts/screws. Remove the distributor cap.
6. Use a suitable distributor rotor socket, tool J 39998 or equivalent bit, to unfasten the retaining bolts/screws, then remove the rotor.
7. If necessary, remove the distributor cover and shield at this time.
WARNING
Do NOT touch the timing disk sensor or distributor base.
8. Inspect the distributor base and timing disk for damage, corrosion, or plastic particles. If you find any, the entire distributor assembly must be replaced.
9. The distributor is driven by a camshaft pin that mates to one slot in the distributor driveshaft. Align the distributor driveshaft with the distributor base timing mark.
10. Rotate the engine crankshaft until number one piston is at Top Dead Center (TDC) with the intake and exhaust valves closed. The camshaft pin will be in the 9 o'clock position.
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Fig. Fig. 11: Exploded view of the distributor cap, cover, rotor and base assembly-5.7L (VIN P & 5) engines
To install:
11. If removed, install the distributor shield and cover.
12. Position the rotor, then secure with the retaining screws/bolts. Tighten the screws to 6 inch lbs. (0.7 Nm).
13. Place the distributor cap on the distributor assembly and install the retaining bolts/screws. Tighten the cap bolts/screws to 25 inch lbs. (2.8 Nm).
14. Unplug and connect the vacuum harness to the distributor.
15. Attach the 4-terminal PCM connector to the distributor. Connect the spark plugs to the distributor, as tagged during removal.
16. Install the crankshaft balancer and water pump, as outlined in Engine & Engine Overhaul of this repair guide.
17. Connect the negative battery cable.
Water Pump
• REMOVAL & INSTALLATION
5.7L (VIN P and 5) Engines
See Figure 2
1. Disconnect the negative battery cable.
2. Detach the Intake Air Temperature (IAT) sensor electrical connector.
3. Remove the air cleaner assembly and air intake duct.
4. Drain the cooling system into a suitable container. If necessary, remove the knock sensors for complete draining.
5. Unfasten the clamps, then disconnect the inlet and outlet radiator hoses from the water pump.
6. Remove the throttle body hose from the T-fitting.
7. Disconnect the heater hose from the water pump.
8. Detach the Engine Coolant Temperature (ECT) sensor electrical connector. Remove the ECT sensor wiring harness retainer from the front of the water pump.
9. Remove the serpentine drive belt.
10. Unfasten the bolts holding the water pump to the engine block, then remove the water pump from the vehicle.
11. Remove and discard the gasket, then thoroughly clean the mating surfaces.
12. Inspect the O-ring seals on the water pump driveshaft and front cover for cracks and dryness. If any of the O-rings are damaged, they must be replaced.
13. If replacing the water pump, transfer the ECT sensor to the new pump. Tighten the sensor to 17 ft. lbs. (23 Nm).
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Fig. Fig. 2: Exploded view of the water pump and related components-5.7L (VIN P and 5) engines
To install:
Before you assemble the coupling to the water pump, apply a light coat of grease to the seals and splines.
14. Install the coupling with the groove toward the engine.
15. Install new gaskets with the tabs up, the water pump with the drive coupling and the mounting bolts. Tighten the bolts to 30 ft. lbs. (41 Nm).
16. Install the serpentine drive belt.
17. Instlal the ECT sensor wire harness retainer on the front of the water pump, then attach the electrical connector.
18. Connect the heater hose to the water pump.
19. Attach the inlet and outlet radiator hoses and clamps to the water pump.
20. Install the throttle body hose at the T-fitting.
21. Install the air cleaner and intake duct.
22. Fill the radiator with the proper type and amount of coolant. Connect the negative battery cable.
23. Start the engine, and allow to run (with the radiator cap still removed), until the upper hose is hot (thermostat is open). With the engine idling, add coolant to the radiator until it reaches the bottom of the filler neck.
24. Install the filler cap. Inspect for leaks. Turn the engine OFF .
Crankshaft Damper
• REMOVAL & INSTALLATION
On some vehicles, the crankshaft damper is also referred to as the balancer.
5.7L (VIN P and 5) Engines
See Figure 5
This procedure covers both removal of the crankshaft balancer (damper) and hub assembly.
1. Disconnect the negative battery cable.
2. Remove the air intake duct.
3. Raise and safely support the vehicle.
4. Remove the motor mount nuts.
5. Remove the power steering fluid cooler.
WARNING
When raising and supporting the engine, NEVER place a jack under the oil pan, crankshaft pulley or any sheetmetal. There is a minimal clearance between the oil pan and the pump screen. Jacking against the pan could cause sufficient deformation to damage the oil pickup unit.
6. Raise the engine enough so that you can access the balancer with the removal tool.
7. Unfasten the balancer bolts/screws, then remove the balancer assembly.
8. Disconnect and plug the power steering line from the steering gear.
WARNING
Do NOT crank the engine over after marking the hub and front cover. Rotating the crankshaft will misalign the installation of the balancer to the crankshaft and possibly cause engine imbalance.
9. Matchmark the crankshaft hub to the engine front cover.
10. Remove the crankshaft hub bolt/screw and washer.
11. Remove the crankshaft hub using a suitable crankshaft hub removal/installation tool.
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Fig. Fig. 5: Exploded view of the crankshaft balancer and hub assemblies
To install:
12. If the engine was accidently cranked over after matchmarking the hub and front cover, you must perform the following steps before installing the crankshaft hub:
a. Set the No. 1 piston to Top Dead Center (TDC).
b. Install the crankshaft hub with the cast arrow on the hub in the 12 o'clock position.
13.
14.
15. Install the crankshaft hub using a suitable hub removal/installation tool.
16. Install the crankshaft hub washer and bolt/screw.
17. Raise the engine.
18. Install the crankshaft balancer and retaining bolts/screws.
19. Tighten the crankshaft hub bolt to 70-75 ft. lbs. (95-102 Nm), and the balancer bolts/screw to 60 ft. lbs. (81 Nm).
20. Unplug and connect the power steering line to the steering gear.
21. Carefully lower the engine.
22. Install the power steering fluid cooler.
23. Install the motor mount nuts and tighten to 40 ft. lbs. (54 Nm).
24. Carefully lower the vehicle.
25. Install the serpentine drive belt.
26. Install the air intake duct and connect the negative battery cable.
27. Properly bleed the power steering system, as outlined in Suspension & Steering of this repair guide.
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