GM Astro/Safari 1985-1996 Repair Guide

Distributor

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REMOVAL & INSTALLATION

See Figures 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12 and 13



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Fig. Fig. 1: Connector identification for distributor-2.5L engine



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Fig. Fig. 2: The HVS distributor mounts only one way. Do not try to rotate the distributor to change the timing



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Fig. Fig. 3: Align the indent hole on the drive gear with the cast-in arrow before installation on the HVS distributor



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Fig. Fig. 4: With the indent hole and cast-in arrow aligned, the rotor should point in this direction



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Fig. Fig. 5: Connector locations on the HVS distributor



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Fig. Fig. 6: With the HVS distributor properly aligned and installed, the rotor should point to the mark



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Fig. Fig. 7: Tag all the ignition wires before removing them from the cap or the spark plugs



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Fig. Fig. 8: Disconnect the harnesses from the module



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Fig. Fig. 9: Mark the alignment of the rotor before removing the distributor



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Fig. Fig. 10: Mark the distributor base-to-block alignment before removing the distributor



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Fig. Fig. 11: The distributor hold-down bolt must be removed to be able to draw out the distributor



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Fig. Fig. 12: Depending on the hold-down's shape, there may be a correct orientation, so note how it is mounted



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Fig. Fig. 13: Draw the distributor body straight up and out

Engine Not Rotated

This procedure applies if the engine has not been rotated with the distributor removed.

  1. Disconnect the negative battery terminal from the battery and remove the console cover.
  2.  
  3. Tag and disconnect the electrical connector(s) from the distributor.
  4.  
  5. Remove the distributor cap (DO NOT remove the spark plug wires) from the distributor and move it aside.
  6.  
  7. Using a crayon or chalk, make locating marks (for installation purposes) on the rotor, the ignition module, the distributor housing and the engine block.
  8.  
  9. Loosen and remove the distributor clamp bolt and clamp, then lift the distributor from the engine.
  10.  

Noting the relative position of the rotor and the module alignment marks, make a second mark on the rotor to align it with the one mark on the module.

To install:
  1. Install a new O-ring on the distributor housing.
  2.  
  3. Align the second mark on the rotor with the mark on the module, then install the distributor, taking care to align the mark on the housing with the one on the engine.
  4.  

It may be necessary to lift the distributor and turn the rotor slightly to align the gears and the oil pump driveshaft. The crankshaft may have to moved very slightly to engage the oil pump driveshaft with the distributor. Do NOT force the distributor into the engine with the distributor clamp.

  1. With the respective marks aligned, install the clamp and bolt finger tight.
  2.  
  3. Install and secure the distributor cap.
  4.  
  5. Connect the electrical connector(s) to the distributor.
  6.  
  7. Connect a timing light to the engine (following the manufacturer's instructions). Start the engine, then check and/or adjust the timing.
  8.  
  9. Turn the engine OFF , tighten the distributor clamp bolt and remove the timing light.
  10.  

Engine Rotated

This procedure applies when the engine has been rotated with the distributor removed.

  1. Disconnect the negative battery terminal from the battery and remove the console cover.
  2.  
  3. Tag and disconnect the electrical connector(s) from the distributor.
  4.  
  5. Remove the distributor cap (DO NOT remove the ignition wires) from the distributor and move it aside.
  6.  
  7. Using a crayon or chalk, make locating marks (for installation purposes) on the rotor, the ignition module, the distributor housing and the engine.
  8.  
  9. Loosen and remove the distributor clamp bolt and clamp, then lift the distributor from the engine.
  10.  

Noting the relative position of the rotor and the module alignment marks, make a second mark on the rotor to align it with the one mark on the module.

To install:
  1. Install a new O-ring on the distributor housing.
  2.  
  3. Rotate the crankshaft to position the No. 1 cylinder on the TDC of compression stroke. This may be determined by inserting a rag into the No. 1 spark plug hole and slowly turning the engine crankshaft. When the timing mark on the crankshaft pulley aligns with the 0 mark on the timing scale and the rag is blown out by the compression, the No. 1 piston is at top-dead-center (TDC).
  4.  
  5. Turn the rotor so that it will point to the No. 1 terminal of the distributor cap.
  6.  
  7. Install the distributor into the engine block. It may be necessary to turn the rotor, a little in either direction, in order to engage the gears.
  8.  
  9. Tap the starter a few times to ensure that the oil pump shaft is mated to the distributor shaft.
  10.  
  11. Bring the engine to No. 1 TDC again and check to see that the rotor is indeed pointing toward the No. 1 terminal of the cap.
  12.  
  13. With the respective marks aligned, install the clamp and bolt finger tight.
  14.  
  15. Install and secure the distributor cap.
  16.  
  17. Connect the electrical connector(s) to the distributor.
  18.  
  19. Connect a timing light to the engine (following the manufacturer's instructions). Start the engine, then check and/or adjust the timing.
  20.  
  21. Turn the engine OFF , tighten the distributor clamp bolt and remove the timing light.
  22.  

 
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