From 269ef92d5111648919da6cc20f32618c16e6ba03 Mon Sep 17 00:00:00 2001 From: John Loper II Date: Sun, 22 Mar 2026 19:32:48 -0400 Subject: [PATCH] docs: Add distributor cap/rotor installation instructions - Document that cap/rotor were on 2002 3500, need to be installed on 2002 1500 - Provide step-by-step installation instructions - Include tools needed, parts info (GM 10452459 cap, 10452457 rotor) - Add firing order reference (1-8-7-3-6-5-4-2) - Document verification steps after installation - Once installed, proceed with Issue #1 (ECU relay test) --- CrankNoStart/progress.md | 97 +++++++++++++++++++++++++++++++++++++++- 1 file changed, 96 insertions(+), 1 deletion(-) diff --git a/CrankNoStart/progress.md b/CrankNoStart/progress.md index 9456fd4..8868c0d 100644 --- a/CrankNoStart/progress.md +++ b/CrankNoStart/progress.md @@ -159,7 +159,102 @@ --- -**Next Step:** Check ECU power supply BEFORE replacing ECU again! +**Next Step:** Install distributor cap/rotor (removed for 2003 3500 parts), THEN continue ECU power tests! + +--- + +## 🔧 Immediate Action Required (2026-03-22 19:32 EDT) + +### Current Situation: +- Distributor cap and rotor were removed from **2002 Chevy 1500** (bad van) +- Installed on **2002 Chevy 3500** (good van) yesterday to fix crank no-start +- **Now:** Cap and rotor are on the 3500, need to be put back on the 1500 + +### Action Needed: +1. **Remove distributor cap and rotor from 2002 Chevy 3500** +2. **Install on 2002 Chevy 1500** +3. **Verify proper installation** before continuing ECU power tests + +### Why This Matters: +- Without distributor cap/rotor, the 1500 cannot run +- We need spark to continue testing +- ECU power tests require spark to verify results + +--- + +## 📋 Distributor Cap/Rotor Installation Instructions + +### Tools Needed: +- 7mm or 8mm socket (for cap clips) +- Dielectric grease (optional but recommended) +- Clean rag + +### Parts Being Installed: +- **Distributor Cap:** GM 10452459 (or ACDelco DR2031) +- **Distributor Rotor:** GM 10452457 (or ACDelco D465) +- **Part Numbers for 2002 Chevy Express 1500/3500 (5.7L V8)** + +### Installation Steps: + +#### Step 1: Prepare the Distributor +1. **Clean distributor housing** with rag - remove any debris +2. **Inspect distributor housing** for cracks or carbon tracking +3. **Apply dielectric grease** (optional) to cap terminals inside +4. **Check rotor condition** - should be clean, no carbon tracking + +#### Step 2: Install Rotor +1. **Align rotor** with distributor shaft (should only fit one way) +2. **Press rotor firmly** onto shaft until it seats +3. **Verify rotor spins freely** without wobble + +#### Step 3: Install Distributor Cap +1. **Orient cap correctly** - number 1 terminal should face the correct cylinder (check firing order) +2. **Align cap clips** with distributor housing +3. **Press cap down firmly** until clips snap into place +4. **Double-check all clips** are secured + +#### Step 4: Install Spark Plug Wires +1. **Follow firing order:** 1-8-7-3-6-5-4-2 +2. **Start with cylinder 1** - wire from cap terminal #1 to spark plug #1 +3. **Push wire firmly** onto both cap and plug until it clicks +4. **Route wires properly** - don't cross over hot exhaust manifolds +5. **Double-check all connections** are secure + +#### Step 5: Verify Installation +1. **Visual inspection** - all wires connected, cap secure +2. **Tug test** - gently pull on each wire to ensure firm connection +3. **Check for proper routing** - wires not touching hot surfaces + +--- + +### Firing Order Reference (2002 Chevy Express 5.7L V8): +``` + #1 #5 + / \ + #7 #3 + | | + | | + #6 #4 + \ / + #8 #2 +``` + +**Firing Order:** 1-8-7-3-6-5-4-2 (clockwise from #1) + +**Distributor Rotation:** Clockwise + +--- + +### After Installation: +1. **Verify spark plug wires are correct** +2. **Check for any loose connections** +3. **Ready for ECU power testing** + +--- + +**Once cap and rotor are installed, we can continue with Issue #1 (ECU Relay Test)!** + +**Action:** Install cap/rotor on 2002 Chevy 1500, then report back and we'll start testing! ---