Repair And Fix it

Putting a new belt on a supercharged Pontiac Grand Prix is nearly identical to putting the belt on a standard Grand Prix. The Grand Prix GTP was introduced in 1997, and with it the supercharged 3800 Series II. The Grand Prix GTP with the supercharged 3800 motor was capable of producing between 200 and 240 horsepower, depending on the use of L36 or L67 engine models. The belt routing between the L36 and L67 is an identical procedure. The Grand Prix was replaced by the Pontiac G6 and G8, before Pontiac was removed in 2009 from the General Motors line of vehicles. Pontiac produced cars since 1926.

Instructions

1

Open the hood and stand on the passenger side of the car facing the belt side of the engine. Loop the belt underneath the bottom pulley or the crank pulley, in the outer track provided. The supercharger belt on the 3800 SC is the outermost belt, as there are two belts on this engine.

2

Hold the belt taught in your right hand so you do not lose your grip on the crank pulley. Run the belts smooth side or back on the front side of the two supercharger idler pulleys. These two idler pulleys are are about three inches in diameter. The lower supercharger idler pulley sits at the two oclock position, just inches above the crank pulley. The upper idler pulley sits on the top front face of the engine.

3

Loop the inside of the belt, or the grooved side, up and over the supercharger. Maintain your grip with your right hand on the belt to maintain your positioning of the belt.

4

Set your left hand on the top of the supercharger pulley and hold the belt still. Slide your right hand down the belt toward the front of the car until you reach the tension pulley.

5

Pull the belt tight again with your right hand, and use a 3/8-inch ratchet and socket with your left hand to push the tension pulley down towards the bottom of the engine. If you feel uncomfortable in this position, set the ratchet down and grab the belt with your left hand. Use your right hand on the tension pulley if this feels more comfortable to you. Slide the belt over the tension pulley, making sure that you keep your hands clear from the point between the belt and pulley.

6

Release the tension pulley and let it retract to its upright position, and remove the ratchet and socket from the tension assembly.

7

Inspect your work to make sure the belt is centered on each pulley, and sitting in the proper channels provided in the crank pulley. Clockwise from the supercharger, your belt should go to the front side of the tension pulley, down and around the bottom of the crank pulley, up around the front sides of both idler pulleys, and back to the supercharger.

Changing the fuel tank on a recent Dyna Super Glide is much more difficult now that it was as recently as 2005. Since 2006, all Harley Dyna Models have been equipped with the closed loop, Delphi electronic fuel injection. This electronic black box system often confuses the diagnosis of engine problems and complicates what were once routine maintenance and repair chores. The good news is that you will not need a laptop to remove and replace your gas tank. The bad news is that the job is now considerably less intuitive than it used to be.

Instructions

Remove the Old Tank

1

Pull the electrical caddy cover off -- on the right side of the bike near the battery compartment -- with your hands. Put the blades of two, small flat-head screwdrivers on either side of the fuel pump fuse and pry out the fuse.

2

Shift the bike into neutral, start the engine and wait for the engine to die. Try to start the bike for another five seconds.

3

Remove the seat fender tab screw and washer with an Allen wrench. Pull the seat back and up to expose the battery. Disconnect the cable from the negative battery post with an open end wrench.

4

Reach under the tank and pull up on the fuel tank fitting and simultaneously pull down on the fuel line.

5

Unscrew the acorn nut in the middle of the instrument panel with an Allen wrench. Pull the panel up and pull apart the plug and socket ends of the fuel pump module connector.

6

Plug one end of a short section of 5/16-inch diameter hose with a 5/16-inch diameter bolt. Constrict a worm-style hose clamp around the bolt by turning the adjusting screw with a screwdriver.

7

Position a large gas can next to the left side of the motorcycle near the fuel tank. Cut off one of the two clamps from the ends of the crossover hose with tin snips.

8

Hold the open end of the short section of 5/16 hose next the crossover hose fitting that you just unclamped. In as close to one motion as possible, replace the unclamped end of the crossover hose with the short section of 5/16-inch hose and insert the free end of the crossover hose into the fill hole of the pre-positioned gas can.

9

Drain the gasoline into the gas can. Clean up any spillage with rags and immediately carry the rags to a well-ventilated location.

10

Loosen the remaining hose clamp on the crossover line and the clamp on the continuous vent line with a screwdriver. Pull both lines off their fittings.

11

Loosen and remove both the front and rear mounting bolts, washers and nuts under the tank with an open end wrench. Pull the male and female halves of the fuel gauge connector apart.

12

Remove the tank by lifting straight up. Carry the tank to a well-ventilated location and allow the tank to air out.

13

Remove the 10 top plate screws from the top plate of the old tank with a Torx socket and socket wrench. Remove the top plate and top plate gasket. Discard the gasket and the screws.

14

Reach into the tank and push down on the fuel pump to remove it from the fuel pump housing so it will fit through the hole. Remove the complete fuel pump assembly including the fuel pump, fuel pump housing, fuel filter screen, hose, fuel level sender and float from the old fuel tank.

Install the New Tank

15

Loosely attach the new fuel tank to the mounting brackets with the front and rear tank mounting bolts, washers and nuts using an open-end wrench. Install the old crossover line and vent line to the new tank using new hose clamps and a screwdriver. Tighten the front and rear mounting bolts with an open-end wrench.

16

Install the old fuel pump hose and a new fuel line hose clamp on the fuel filter fitting. Install the complete old fuel pump assembly in the new tank until the rubber spacer on the bottom of the assembly rests on the bottom of the new fuel tank.

17

Reconnect the fuel line. Reconnect the fuel pump module connector.

18

Replace the instrument panel and tighten the acorn nut with an Allen wrench.

19

Re-install the fuel pump fuse in the electrical caddy. Replace the electrical caddy cover.

20

Reconnect the loose cable to the negative battery post with an open-end wrench. Replace the seat. Refasten the seat mounting tab to the rear fender with an Allen wrench.

21

Refuel the motorcycle.