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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 678 (ENGINE CONTROLS - 4.3L - INTRODUCTION (2 OF 2))REPAIR INSTRUCTIONSDISTRIBUTOR REPLACEMENTINSTALLATION PROCEDURE 2
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Installation Procedure 2

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Installation Procedure 2
WARNING: This page is about a different car, the 2006 GMC Sierra and 2006 Chevrolet Silverado. However, it is still accessible from the selected car via links, so may be relevant.
IMPORTANT: Rotate the number 1 cylinder to top dead center (TDC) of the compression stroke. The engine front cover has 2 alignment tabs and the crankshaft balancer has 2 alignment marks (spaced 90 degrees apart) which are used for positioning the number 1 piston at TDC. With the piston on the compression stroke and at TDC, the crankshaft balancer alignment mark (1) must align with the engine front cover tab (2) and the crankshaft balancer alignment mark (4) must align with the engine front cover tab (3).
  1. Rotate the crankshaft balancer clockwise until the alignment marks on the crankshaft balancer are aligned with the tabs on the engine front cover and the number 1 piston is at TDC of the compression stroke.
    Fig 1: View Of Crankshaft Balancer Alignment Mark & Engine Front Cover Alignment Tab
    GM334551Courtesy of GENERAL MOTORS CORP.
  2. Align the white paint mark on the bottom stem of the distributor, with the pre-drilled indent hole in the bottom of the gear (3).
    Fig 2: Aligning Distributor Marks
    GM301395Courtesy of GENERAL MOTORS CORP.
    3. NOTE: The ignition system distributor driven gear and rotor may be installed in multiple positions. In order to avoid mistakes, mark the distributor on the following components in order to ensure the same mounting position upon reassembly:
    • The distributor driven gear
    • The distributor shaft
    • The rotor holes

    Installing the driven gear 180 degrees out of alignment, or locating the rotor in the wrong holes, will cause a no-start condition. Premature engine wear or damage may result.
  3. With the gear in this position, the rotor segment should be positioned as shown for a V6 engine (1).
  4. Using a long screwdriver, align the oil pump drive shaft to the drive tab of the distributor.
  5. Guide the distributor into the engine.
    Fig 3: Installing Distributor
    GM34397Courtesy of GENERAL MOTORS CORP.

    Ensure that the spark plug towers are perpendicular to the centerline of the engine.

  6. Once the distributor is fully seated, the rotor segment should be aligned with the pointer cast into the distributor base.
    Fig 4: Confirming Rotor Alignment
    GM4350Courtesy of GENERAL MOTORS CORP.
    • This pointer may have a 6 cast into it, indicating that the distributor is to be used on a 6 cylinder engine.
    • If the rotor segment does not come within a few degrees of the pointer, the gear mesh between the distributor and the camshaft may be off a tooth or more.
    • If this is the case, repeat the procedure again in order to achieve proper alignment.
  7. Install the distributor hold down bolt.
    Fig 5: Installing Distributor Hold Down Bolt
    GM366609Courtesy of GENERAL MOTORS CORP.

    Tighten:  Tighten the bolt to 25 N.m (18 lb ft).

  8. Install the distributor cap.
    Fig 6: View Of Distributor Cap
    GM301393Courtesy of GENERAL MOTORS CORP.
  9. Install NEW distributor cap screws.

    Tighten:  Tighten the screws to 2.4 N.m (21 lb in).

  10. Connect the following electrical connectors:
    • CMP sensor (2)
    • Fuel pump/oil pressure sensor (3)
    Fig 7: View Of Ground Strap And CMP & Fuel Pump/Oil Pressure Sensor Connectors
    GM782680Courtesy of GENERAL MOTORS CORP.
    11. IMPORTANT: The coil wire nipple must be positioned such that it is between 35 and 60 degrees aft of perpendicular as referenced from the engine centerline on the outboard side of the coil.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.