Distributorless Ignition System (DIS) Application: LLV Part Number: (E) or (A) Time Required: Approx.

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1 / mip@teamwbi.com / Distributorless Ignition System (DIS) Application: LLV Part Number: (E) or (A) Time Required: Approx. 1 hour Quantity Part Number Description Trigger, Wheel, LLV Crankshaft Sensor Harness 2.5 A/E Power Harness 2.5 A/E / Distributor Harness 2.5E / Distributor Harness 2.5A Assembly EPROM (DIS) Kit, Hardware Coil Base (DIS) Kit, Hardware, Crankshaft Sensor (DIS) MOD Kit, Connector, Exhaust, O2 Sensor Required Tools Quantity Size Description 1 5/16 Box Wrench 1 ½ Drive Breaker Bar 1 13 MM Shallow Socket 1 6 MM Allen Wrench 1 Drive Available Ratchet 1 5 MM Allen Wrench 1 4 MM Allen Wrench 1 Sheet Emery Paper 1 10 MM Deep Well Socket 1 Heat Gun 1 Paint Marker 1 4 MM Box Wrench Procedure: 1. Disconnect negative battery lead from the battery using a 5/16 box wrench. 1

2 2. Raise the vehicle to a height that allows you to work underneath it following all USPS safety protocols. 3. Remove the serpentine belt by inserting the ½ breaker bar into the pulley end of the belt tensioner and relieving the tension on the belt. While the tension is off of the belt slip it off of the pulleys. 4. Remove the crankshaft pulley using a 13 MM socket and ratchet and retain the bolts. 5. Remove the 2 bolts that hold the timing indicator, and remove the bolt on the timing cover below it using a 10 MM deep well socket and 3/8 drive ratchet. Retain one bolt. 6. Re-install the top bolt of the three removed from the timing cover using the 10 MM deep well socket and ratchet. 7. Clean the front hub surface and the crankshaft pulley inside surface with emery paper so that they are clean and flat. 8. Install the crank position sensor and bracket assembly using the supplied cap screws into the bottom two holes of the timing cover and tighten with the 5 MM allen wrench. If the crankshaft sensor is too close to the target wheel (hitting or rubbing) WBI has included 2 small flat washers in the screw kit for adjustment. Place the washers over the cap screws between the sensor block and the timing cover. This will space the crankshaft sensor away from the target wheel. 9. Place the target wheel on the front hub and install the crankshaft pulley. Bolt the pulley and target wheel to the front hub using the 13 MM socket and ratchet. 10. Re-install the serpentine belt by slipping the belt back over the pulleys, move the tensioner with the ½ drive breaker bar, slip the belt over the tensioner pulley and slowly ease off on the breaker bar to put tension on the belt. 11. Lower vehicle to a work height that allows you to remove the right front tire and wheel and to reach into right side of the engine through the wheel opening. 12. Remove the right front tire and set to the side. 13. Remove the splash guard from the inner fender. 14. Mark the number one and number four spark plug wires (see illustration on next page). 2

3 15. Unplug the wires from the distributor cap. 16. Remove the distributor cap if needed. 17. Unplug the distributor from the wiring harness(s). 18. Unplug the coil from the wiring harness and remove the coil and bracket using a 13 MM socket and ratchet. 19. Remove the distributor hold down bolt using a 13 MM socket and ratchet and remove the hold down bracket. 20. Remove the distributor. (Incorrect harness bracket position) (Correct harness bracket position) 21. NOTE: Check the position of this bracket on the push rod cover. If it is wrong it will interfere with the coils and module. 22. Install the new mount by placing it into the distributor hole and using the allen cap screw provided to bolt it down in the bolt hole from the hold down bracket. This uses a 6 MM allen wrench. Tighten this securely (see illustration on next page). 3

4 23. Attach the ground lug from the white wiring harness ( P/N ) to the left side of the mounting block using the 4 MM ground screw provided (see illustration above). 24. Plug the three wiring harnesses ( , and either or depending on whether the truck is equipped with an E engine or an A engine) into the new ignition module. 25. Spread a layer of the silicon grease from the supplied packet over the metal plate on the bottom of the ignition module (P/N ) to provide for better heat transfer from the module to the mount. 26. Install coils (P/N D) onto the ignition module using the four coil screws that are provided. Tighten the assembly to the mount using a 4 MM allen wrench (see illustration below). 27. Plug the four pin connector harness (P/N or P/N depending on 2.5L A or E) into the engine wiring harness. 28. Route the white crankshaft sensor harness (P/N ) behind the thermostat housing and down the other side of the engine to the crankshaft sensor and plug it in (see illustration on next page). 4

5 29. Cut the pink coil power wire then splice into the included connector (P/N MOD) with the included butt splice connector. Crimp and apply heat as the butt splice connector is self-soldering and sealing. 30. Connect this pigtail to the power harness (P/N ) from the ignition module. 31. Remove the bolt attaching the negative battery lead to the engine block using a 13 MM socket and ratchet. Add the ground wire on the power harness to the other grounds and reinstall bolt. 32. Install the spark plug wires onto the coil packs. From left (firewall) to right (radiator) the wires should be #1 and #4 on the first coil, and #2 and #3 on the second coil. 33. Re-install the splash guard and right front tire. Return truck to ground level. 34. The included EPROM (RED Cover) is designed specifically for the DIS application. All other EPROMs WILL NOT function properly. Remove the existing EPROM from the ECM (blue cover) and replace with the EPROM (P/N MEMCAL-DIS, RED Cover) from the kit using the approved procedure from the LLV Service manual. 35. Reconnect the negative battery lead using a 5/16 wrench. 36. If procedures were followed correctly, the LLV will operate. 5

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