Eletril System Ignition System Tle of Contents Setion 4C - Ignition System Exploded View Distriutor nd Relted Components...4C-4 Preutions...4C-2 Timing Speifitions...4C-6 3.0 TKS...4C-6 3.0 MPI ECT...4C-6 Sprk Plug Speifitions...4C-7 3.0 TKS...4C-7 3.0 MPI ECT...4C-7 3.0 Four Cylinder In Line Firing Order...4C-7 Ignition System 3.0 MPI ECT...4C-7 Ignition System Desription 3.0 MPI ECT...4C-7 Propulsion Control Module (PCM)...4C-7 Ignition System 3.0 TKS...4C-8 Ignition System Desription 3.0 TKS...4C-8 Eletroni Sprk Timing (EST) Ignition System Opertion 3.0 TKS...4C-9 Sprk Plugs...4C-11 Removl...4C-11 Clening nd Inspetion...4C-11 Instlltion...4C-12 Sprk Plug Wires...4C-12 Removl...4C-12 Inspetion...4C-12 Instlltion...4C-12 Ignition Coil...4C-12 Removl...4C-12 Inspetion nd Testing...4C-13 Instlltion...4C-13 Distriutor...4C-14 Removing the Distriutor...4C-14 Distriutor Disssemly...4C-16 Clening nd Inspeting...4C-16 Distriutor Assemly...4C-16 Instlling the Distriutor...4C-17 Distriutor Component Testing 3.0 TKS...4C-19 Generl Informtion...4C-19 Testing the Ignition Module...4C-19 Testing the Pikup Coil...4C-19 Ignition Timing 3.0 TKS...4C-19 4 C 90-899883197 AUGUST 2011 Pge 4C-1
Preutions! WARNING Avoid fire or explosion hzrd. Eletril, ignition, nd fuel system omponents on Merury Mrine produts omply with federl nd interntionl stndrds to minimize risk of fire or explosion. Do not use replement eletril or fuel system omponents tht do not omply with these stndrds. When serviing the eletril nd fuel systems, properly instll nd tighten ll omponents.! WARNING Neglet or improper mintenne, repirs, or inspetions of the power pkge n result in produt dmge or serious injury or deth. Perform ll proedures s desried in this mnul. If you re not fmilir with proper mintenne or servie proedures, onsign the work to n uthorized Merury Mrine deler.! WARNING Performing servie or mintenne without first disonneting the ttery n use produt dmge, personl injury, or deth due to fire, explosion, eletril shok, or unexpeted engine strting. Alwys disonnet the ttery les from the ttery efore mintining, serviing, instlling, or removing engine or drive omponents.! WARNING Explosive fumes ontined in the engine omprtment n use serious injury or deth from fire or explosion. Before strting the engine, operte the ilge lower or vent the engine omprtment for t lest five minutes.! WARNING Fuel is flmmle nd explosive. Ensure tht the key swith is off nd the lnyrd is positioned so tht the engine nnot strt. Do not smoke or llow soures of sprk or open flme in the re while serviing. Keep the work re well ventilted nd void prolonged exposure to vpors. Alwys hek for leks efore ttempting to strt the engine, nd wipe up ny spilled fuel immeditely. NOTICE Without suffiient ooling wter, the engine, the wter pump, nd other omponents will overhet nd suffer dmge. Provide suffiient supply of wter to the wter inlets during opertion. IMPORTANT: To void dmging the eletril system, follow these preutions: Do not tp essories into the engine hrness. Do not punture wires for testing (proing). Do not reverse the ttery leds. Do not splie wires into the hrness. Do not ttempt dignostis without the proper, pproved servie tools. Lurints, Selnts, Adhesives Tue Ref No. Desription Where Used Prt No. Silione dieletri ompound Coil high-tension led tower 25 Liquid Neoprene High tension wire oil tower 92-25711 3 154 Merury MerCruiser Full- Syntheti Engine Oil 20W-40, NMMA FC-W rted Distriutor shft 92-858087K01 Pge 4C-2 90-899883197 AUGUST 2011
E F Speil Tools Computer Dignosti System (CDS G3) 4520 Order from SPX Ignition System Monitors ll eletril systems for proper funtion, dignostis, nd lirtion purposes. For dditionl informtion, priing, or to order the Computer Dignosti System G3 ontt: SPX Corportion 28635 Mound Rd. Wrren, MI 48092 or ll: USA 1 800 345 2233 Cnd 800 345 2233 Europe 49 6182 959 149 Austrli (03) 9544 6222 Timing Light 91 99379 Allows tehniin to hek ignition timing. 11561 Servie Thometer/Dwell Meter 91 59339. Aids in heking engine RPM (0 10,000); lso heks the dwell on reker point ignition systems. 13472 90-899883197 AUGUST 2011 Pge 4C-3
Exploded View Distriutor nd Relted Components 2 1 16 3 15 14 7 17 6 8 18 6 5 8 19 4 9 10 13 12 11 46828 Pge 4C-4 90-899883197 AUGUST 2011
Ref. No. Qty. Desription 1 1 Distriutor omplete ssemly 2 1 Cp 3 1 Rotor 4 1 Module 5 2 Srew 6 1 Coil piee 7 1 Shft ssemly 8 1 Pole piee 9 1 Ger 10 1 Roll pin 11 1 Gsket 12 1 Hold down lmp 13 1 Srew 14 1 Sprk plug wire (represents 1 set) 15 4 Sprk plug (represents 1 set) 16 1 Plug wire retiner 17 1 Ignition oil 18 2 Srews 19 1 Hrness ssemly Ignition System Exploded View Distriutor nd Relted Components 90-899883197 AUGUST 2011 Pge 4C-5
Timing Speifitions 3.0 TKS Timing t Idle RPM Timing (t idle rpm)¹ Seril numer rek: 0L341000 nd ove. 2 ATDC ¹:Timing must e set using speil proedure s outlined in this setion. Timing nnot e properly set using the onventionl method. Timing Advne Curve nd RPM IMPORTANT: Advne urve inludes initil timing. Do not dd initil timing degrees to the totl dvne degrees. d 48013 - Totl sprk dvne - Engine RPM - Mxiumum d - Minimum 3.0 MPI ECT Timing (t idle rpm) Seril numer: All models Not djustle Pge 4C-6 90-899883197 AUGUST 2011
Sprk Plug Speifitions 3.0 TKS Sprk plug gp Sprk plug type 1.14 mm (0.045 in.) AC MR43LTS NGK BPR6EFS Chmpion RS12YC 3.0 MPI ECT Sprk plug gp Sprk plug type 1.14 mm (0.045 in.) AC MR43LTS Chmpion RS12YC NGK BPR6EFS 3.0 Four Cylinder In Line Firing Order Ignition System 3.0 MPI ECT Ignition System Desription 3.0 MPI ECT 3.0 firing order: 1 3 4 2 When the ignition key swith is turned to the "RUN" position, ttery voltge is pplied to oth the PCM nd the min power rely (MPR) through the wiring. As the PCM reeives the "RUN" signl, it internlly ompletes the ground iruit of the min rely for period of two seonds, energizing the ignition/injetion systems for strt up. As the engine is rnked with the strter motor, the PCM reeives the run signl from the rnk position sensor (CPS) nd ompletes the ground iruit to the min rely for engine opertion. With the min rely losed (ompleted iruit), D.C. urrent from the ttery/hrging system is trnsferred through the 20 mp min rely fuse to the positive terminl of the ignition oil primry windings. The negtive terminl of the ignition oil primry is onneted to the engine ground through the oil's internl driver, whih is triggered y the PCM. With the oil driver losed, n eletri mgneti field is llowed to uild up within the ignition oil. As the rnkshft pulley mounted trigger wheel rottes, the CPS senses the lotion of the teeth nd supplies the trigger signl informtion to the PCM. The PCM utilizes the CPS informtion nd determines when to remove the trigger signl from the oil driver of the ignition oil. The oil driver then opens the oil primry ground iruit whih llows its mgneti field to rpidly ollpse ross the oil seondry winding, whih indues high voltge hrge (50,000 volts) tht fires the sprk plugs. The distriutor rotor distriutes the sprk to eh ylinder in firing order through the distriutor p nd plug wires. Propulsion Control Module (PCM) The PCM requires 8 VDC minimum to operte. If the PCM should fil, the engine will stop running. Some inputs to the PCM n e monitored nd tested using the omputer dignosti system (CDS). 47960 NOTE: The model yer 2004 PCM softwre does not support ignition lod tests. Computer Dignosti System (CDS G3) Order from SPX The PCM ontrols the following funtions: 90-899883197 AUGUST 2011 Pge 4C-7
Clultes the preise fuel nd ignition timing requirements sed on engine speed, throttle position, mnifold pressure, mnifold ir temperture, nd ylinder lok oolnt temperture. Diretly ontrols the ground iruit to: fuel injetors, diret injetors, ignition oil driver, min power rely tivtion, dignostis, engine gurdin, thometer link (nlog thometer output or link guge driver). Indiretly ontrols the positive iruit to: fuel injetors, ignition oils, min power rely tivtion. When the key swith is moved to the "RUN" position, ut the engine is not strted, the PCM ompletes the ground iruit for the min power rely nd 5 VDC referene to the engine sensors. The PCM monitors engine sensors, SmrtCrft vessel sensors, nd will trnsmit fult informtion from these sensors to the helm. One the engine hs strted, the PCM ontrols nd monitors ll engine funtions. Ignition System 3.0 TKS Ignition System Desription 3.0 TKS EST or Eletroni Sprk Timing is high energy ignition system (HEI). The distriutor hs no entrifugl dvne mehnism or devies. The sprk plug wires re ron impregnted ord ondutors with silione ruer jkets. It is importnt tht they e hndled with re nd routed so s not to ross eh other or to e in ontt with other prts of the engine to prevent ruing. The EST System uses squre oil with epoxy overed windings to protet ginst moisture nd r over. The timing nnot e set the sme wy s other ignition systems. h d g e i f 47961 - Distriutor with sprk plug wires - White wires (used in timing proedure) TKS - Wire from shift interrupt swith TKS d - Distriutor hrness TKS e - Engine hrness wire (purple nd gry) f - Coil g - Distriutor hrness MPI h - White wires MPI i - Wire from shift interrupt swith MPI EST uses mgneti pulse genertor nd n eletroni module to generte primry iruit urrent. Internlly, the pulse genertor, or mgneti pik up ssemly, tkes the ple of onventionl points. A timer ore on the min shft of the distriutor hs externl teeth tht lign with n equl numer of pole piee teeth (four for four ylinder engine). The eletroni module is smll enough to llow it to e mounted inside the distriutor nd ontins the iruits neessry for dwell ontrol nd dvne of the timing. Pge 4C-8 90-899883197 AUGUST 2011
Molded into the module is two pin onnetor (for the distriutor hrness tht tthes to the oil terminls) nd four pin onnetor. Only three of the four terminls of the seond onnetor re used y MerCruiser (one wire for the shift interrupt nd two white wire leds, on TKS models, re used to "freeze" dvne for properly setting initil timing). Inside the distriutor, the pik up oil tthes to the module with molded onnetor. d - Externl teeth - Pole piee teeth - Mgneti pulse genertor d - Pik up oil onnetor e - Four pin onnetor f - Two pin onnetor g - Eletroni module h - Timer ore h g f Eletroni Sprk Timing (EST) Ignition System Opertion 3.0 TKS e 47964 To provide primry urrent for the ignition oil, EST uses mgneti pulse genertor nd n eletroni module. The pulse genertor onsists of timer ore on the min distriutor shft nd pole piee round the outside. The mgneti pole piee is designed with the sme numer of internl teeth s engine ylinders (four ylinder engines = four teeth). The timer ore rottes inside of the pole piee nd hs n equl numer of externl teeth. As the internl nd externl teeth strt to lign, voltge output from the mgneti pikup oil inreses, nd s the teeth lign nd pss eh other, the voltge reverses polrity nd dereses. As the distriutor shft rottes, the pikup ssemly produes AC voltge. Ignition Control Module - Engine Running Distriutor Assemly (4 yl. shown) To help understnd how EST iruits operte, rely with doule set of ontt points is shown. Solid stte iruitry is used in the module, ut dding the rely mkes it esier to visulize. On the 3.0 TKS models with the engine running the rely is in the de energized stte. This onnets the pikup oil to the se of the trnsistor. The voltge output from the mgneti pikup ssemly is used to turn the trnsistor in the module on nd off. A trnsistor hs polrity, so s result, it turns on like swith, ut only when the polrity is orret to flow through in one diretion only. When the time ore teeth strt to pproh the pole piee teeth, voltge rises losing the trnsistor nd llowing urrent to flow through the primry ignition oil to ground. As the pole piees lign nd pss, the polrity of the pikup voltge egins to reverse. As the polrity reverses, the trnsistor will turn off, using the urrent to stop flowing through the primry ignition oil windings. The moment the trnsistor is turned off, sprk ours in ylinder. 42949 90-899883197 AUGUST 2011 Pge 4C-9
The length of time there is urrent flowing through the oil is lled dwell. Dwell is mesured in terms of degrees of distriutor rottion. As the engine RPM inreses, the time ville for dwell is deresed, using the seondry (oil) output to derese. To help redue the effet of deresed seondry output, s engine RPM inreses the dwell inreses y strting the ground pth of the primry ignition oil erlier, so s not to ffet ignition timing. The module monitors the mperge required y the ignition oil nd lters strt of the ground pth. Ignition ontrol module engine running 42951 Pge 4C-10 90-899883197 AUGUST 2011
Ignition Control Module - Timing Bypss Ignition System Sine dvne will our elow 1000 RPM, the dvne must e disled efore ttempting to set initil timing. On the 3.0 TKS models, ypssing the interrupter swith energizes the rely, using the points from the pikup oil s well s the grounding points to open. By onneting jumper etween the white wires from the distriutor, pulse is pulled from the signl onverter nd routed to the trnsistor. This ypsses the timer iruit nd disles the dvne. 42950 Sprk Plugs Removl Ignition ontrol module timing ypss 1. Remove the sprk plug wires. Note the lotion for reinstlltion. 2. Clen ny dirt or deris round the sprk plug. 3. Remove the sprk plugs. Clening nd Inspetion 1. Inspet eh plug for worn eletrodes nd glzed, roken or listered porelin. Reple ny exessively worn or dmged plugs. f 2. Use solvent to len ny deposits from the eletrode or porelin. e d - Porelin insultor - Side eletrode (gp djusting) - Proper gp d - Center eletrode (flt tip) e - Shell f - Chek for rks in porelin in this re 3. Chek the type of sprk plug. Reple sprk plugs tht re the inorret type. Refer to Sprk Plug Speifitions. 4. Chek the gp of the sprk plugs with round feeler guge. Adjust if neessry. Refer to Sprk Plug Speifitions. 47970 90-899883197 AUGUST 2011 Pge 4C-11
Instlltion IMPORTANT: Tpered set sprk plugs re not interhngele with non tpered sprk plugs. Do not use gskets on tper set plugs. 1. Clen the sprk plug seting re. 2. Instll the sprk plugs nd tighten to speifition. Desription Nm l in. l ft Sprk plugs 30 22 Sprk Plug Wires Removl NOTE: Use re when removing the sprk plug wires nd the oots from the sprk plugs. 1. Lel the sprk plug wires nd lotions for reinstlltion. 2. Twist the oot one hlf turn efore removing the sprk plug wire. 3. Firmly grsp nd pull on the oot nd wire to remove the wire. Inspetion 1. Visully inspet the sprk plug wires nd the oil wire for dmge. 2. Visully inspet the sprk plug oots for dmge. 3. Chek the sprk plug wires nd the oil wire for ontinuity using multimeter. Reple ny wires tht do not show ontinuity from end to end. 4. Reple ny wires tht re rked, ut, or hve dmged sprk plug oots. Instlltion IMPORTANT: Only use sprk plug wires reommended for mrine pplitions. NOTE: Reple one sprk plug wire t time to redue the risk of routing error. 1. Disonnet eh individul sprk plug wire s it is to e repled. 2. Instll the replement sprk plug wires in the proper order. Oserve the following:. Reinstll the wires in the sprk plug wire retiners.. Atth the plug wires to the pproprite sprk plug nd terminl on the distriutor p. Eh end should fit seurely. 3. Apply selnt to the outside of the high tension wire oil tower. Insert the oil wire (high tension led) to enter terminl on distriutor p, push the oot down over the oil tower, nd wipe off exess selnt. Tue Ref No. Desription Where Used Prt No. 25 Liquid Neoprene High tension wire oil tower 92-25711 3 NOTE: Ensure tht the oot on the high tension wire does not ome loose when pushing the wire into the terminl. Ignition Coil Removl 1. Deth the onnetors for the engine hrness nd distriutor from the ignition oil. 2. Remove the high tension oil led. Pge 4C-12 90-899883197 AUGUST 2011
3. Remove the oil rket srews nd rket with the ignition oil. d e 3.0 TKS ignition oil nd relted - Coil led - Connetor (to engine hrness) - Ignition oil d - Brket srew e - Connetor (to distriutor) 46846 3.0 MPI EC - Brket srew - Connetor (to distriutor) - Connetor (to engine hrness) Inspetion nd Testing 1. Disonnet the wiring from the ignition oil. Connetors re molded nd keyed to ssure proper positioning. 46845 2. Set ohmmeter to "Rx100" sle nd onnet one led to 12 volt terminl (+) of the oil nd the other led to ground ( ), suh s ny len metl on the oil frme. The reding should e infinite (no ontinuity). If not, reple the oil. 3. Set the ohmmeter to "Rx100" sle nd onnet to the 12 volt terminl (+) nd the distriutor trigger signl ( ) terminl. Reding should e pproximtely 0.4 ohms. If not, reple oil. 4. Set the ohmmeter to "Rx1" sle nd onnet to the12 volt terminl (+) nd the thometer terminl. Reding should e pproximtely 0.4 ohms. If not, reple oil. 5. Set the ohmmeter to "Rx100" high sle. Connet the ohmmeter to the 12 volt terminl (+) nd to the oil high tension post. Reding should e etween 7800 nd 8800 ohms. If it reds outside of this rnge, reple the oil. - High tension post - 12 volt (+) - Thometer d - Trigger signl ( ) from distriutor e - Filtered power (+) to distriutor NOTE: During instlltion, first instll the lk onnetor (distriutor hrness) to the oil. Instll the gry onnetor (engine hrness) lst. Instlltion e d 1. Instll the ignition oil nd rket to the engine rket. Tighten the two srews to speifition. 47915 90-899883197 AUGUST 2011 Pge 4C-13
Desription Nm l in. l ft Ignition oil mounting srew 24 18 IMPORTANT: The oil on these models produes n extremely high energy sprk. Speil steps re required to sel the oil wire (high tension led) to the oil to void orrosion nd misfiring. 2. Apply pproximtely 1/2 oz. of the speified selnt round the top of the oil high tension led tower. Ensure tht the selnt is not pplied inside the oil high tension led tower. Tue Ref No. Desription Where Used Prt No. Silione dieletri ompound Coil high-tension led tower 3. Connet the high tension oil led. IMPORTANT: When reonneting or instlling the oil, first tth the lk onnetor (distriutor hrness) to the oil. Then, tth the gry onnetor (from engine hrness) to the oil. 4. Atth the distriutor wire hrness onnetor (lk) nd then, the engine hrness onnetor (gry) to the ignition oil. 3.0 MPI EC - Brket srew - Blk onnetor (to distriutor) - Gry onnetor (to engine hrness) 46845 d e 3.0 TKS ignition oil nd relted - Coil led similr on 3.0 MPI EC - Gry onnetor (to engine hrness) - Ignition oil d - Brket srew e - Blk onnetor (to distriutor) Distriutor Removing the Distriutor 46846 1. Lift the loking ts nd remove the two pin nd four pin onnetor from the distriutor. MPI engine shown TKS similr - Two pin onnetor - Loking ts - Four pin onnetor 47972 Pge 4C-14 90-899883197 AUGUST 2011
2. Remove the oil nd sprk plug wires from the distriutor p. 3. Srie n in line mrk on the distriutor ody nd the engine lok for referene. 4. Remove the hold down lmp nd srew. 47976 - Hold down lmp - Srew 5. Lift the distriutor up nd out of its position in the engine lok. To ssist in instlltion, note the orienttion of the slotted shft. - Distriutor - Slotted shft - Position in lok 6. Loosen the two srews retining the distriutor p. 47977 47978 Distriutor p srews 7. Remove the distriutor p. 90-899883197 AUGUST 2011 Pge 4C-15
8. Remove the rotor. d Distriutor Disssemly e 1. Remove the rotor from the distriutor shft. 2. Disonnet the oil piee wiring from the module. i - Module - Srew - Connetor d - Timer ore e - Rotor f - Externl teeth g - Pole piee teeth h - 4 Pin onnetor i - 2 Pin Connetor 3. Loosen the two srews nd remove the module from the distriutor housing. f g h 47979 4. Remove roll pin, wsher (if equpped), nd drive ger from distriutor shft using enter punh nd light hmmer. Typil - Shft - Punh - Roll pin 29330 5. Remove the distriutor shft from the housing. 6. Remove the oil piee nd pole piee. 7. Chek for side ply etween shft nd distriutor housing ushings. Distriutor Shft to housing side ply 8. Chek the distriutor shft runout with dil inditor nd V loks. 0.05 mm (0.002 in.) Mximum Distriutor Shft runout 0.05 mm (0.002 in.) Mximum Clening nd Inspeting 1. Clen the p with solution of wrm sop nd wter. Dry with ompressed ir. 2. Chek the p enter ontt for exessive urning, orrosion, or deteriortion. IMPORTANT: Distriutor ps (for mrine use) should hve rss ontts; luminum ontts should not e used. 3. Chek the p for rks nd ron trks using mgneto nlyzer. 4. Chek the rotor for rks nd ron trks using mgneto nlyzer. Distriutor Assemly 1. Instll the oil piee nd pole piee. 2. Lurite distriutor shft nd instll into the housing. Pge 4C-16 90-899883197 AUGUST 2011
Tue Ref No. Desription Where Used Prt No. 154 Merury MerCruiser Full- Syntheti Engine Oil 20W-40, NMMA FC-W rted 3. Using the srie mrks mde during distriutor removl, lign the drive ger nd the housing. 4. Instll the wsher (if equipped) nd the drive ger onto the shft. 5. Instll the roll pin through the drive ger nd the distriutor shft. 6. Spin the distriutor shft to ensure tht it spins freely. 7. Instll the rotor onto the distriutor shft. Instlling the Distriutor Distriutor shft 92-858087K01 1. Align nd instll the rotor on the shft of the distriutor ssemly. Ensure the rotor is ompletely seted on the shft. d e 2. Instll new gsket on the distriutor housing. i f g h 47979 - Module - Srew - Connetor d - Timer ore e - Rotor f - Externl teeth g - Pole piee teeth h - 4 Pin onnetor i - 2 Pin Connetor - Gsket - Housing - Gsket instlled 47996 3. If the engine ws distured fter the distriutor ws removed, rotte the engine s needed to set the engine to TDC on ylinder numer 1. Typil - Timing mrk on pulley - Timing t 0 TDC 46688 4. Turn the rotor pproximtely 1/8 turn ounter lokwise pst the mrk previously mde on the distriutor housing. 5. Insert the distriutor shft into the engine lok with the distriutor housing nd rotor positioned s noted during removl. 90-899883197 AUGUST 2011 Pge 4C-17
IMPORTANT: It my e neessry to move the rotor slightly to strt ger mesh with mshft ger, ut the rotor should line up with the referene mrk (mde during removl) when the distriutor is seted in ple. The distriutor shft must enter the oil pump shft for omplete instlltion. 3.0 MPI shown 3.0 TKS similr - Distriutor - Slotted shft - Position in lok 47977 6. Reple nd tighten the distriutor hold down srew nd lmp. 47976 - Hold down lmp - Srew Desription Nm l in. l ft Distriutor hold down srew 27 20 7. instll the distriutor p nd seurely tighten the two srews retining the p. 8. Connet the primry led to the oil. Distriutor p srews 9. Instll the sprk plug wires nd oil wire, if removed. IMPORTANT: Wires must e instlled in supports, if equipped, to prevent ross firing. Firing order is 1 3 4 2. 10. On 3.0 TKS models: set the ignition timing s outlined under Ignition Timing 3.0 TKS, in this setion. 11. On 3.0 MPI models: the ignition timing is not djustle. Use timing light to verify tht the ignition timing flls within the timing rnges. 47978 Pge 4C-18 90-899883197 AUGUST 2011
Distriutor Component Testing 3.0 TKS Generl Informtion Ignition System The following tests n e mde with the distriutor nd oil mounted on or off the engine. The test proedures will hek eh omponent of the distriutor nd ignition oil. Distriutor p nd rotor should e heked for orrosion, rks, ron trks, or wer. Reple if needed. Testing the Ignition Module In order to test the module, n pproved module tester, suh s Kent Moore Tester (J24642 or equivlent), must e used. Be ertin to follow the mnufturer s diretions preisely for proper results. However, rememer tht orrosion on the terminls of the module ould use improper ignition tion nd should therefore e inspeted nd lened s needed. Testing the Pikup Coil 1. Remove the distriutor p. 2. Identify the two pikup oil leds. On lmost ll pplitions, one of these leds is white nd the other is green. Remove the onnetor tht houses these two leds from the module. 3. Set ohmmeter to "Rx1" sle. Connet one led of ohmmeter to WHITE led nd the other to distriutor housing. Reding should e infinity. If not, reple the pikup oil. 4. Repet Step 3 with ohmmeter onneted to green led. Reding should e infinity. If not, reple the pikup oil. 5. Set ohmmeter to "Rx100" sle. Connet ohmmeter to green nd white pikup oil leds. Reding should e onstnt, unhnging vlue in the rnge of 500 1500 ohms. If not, reple the pikup oil. Be ertin to flex leds y hnd during this test to lote possile intermittent "open" iruits (loss of ontinuity). If ny exist, reple the pikup oil. Ignition Timing 3.0 TKS IMPORTANT: Filure to follow the timing proedure instrutions will result in improper timing, using performne prolems nd possile severe engine dmge. 1. Connet the timing light to the ylinder numer 1 sprk plug wire. Refer to Speifitions for ylinder numering nd lotion. Timing Light 91 99379 2. Connet the timing light power supply leds to 12 volt ttery. 3. Connet shop thometer to the engine. Servie Thometer/Dwell Meter 91 59339 NOTE: Before strting engine ensure tht the timing t nd mrk on dmper re len. Chlk or white pint on timing mrk on dmper my help visiility. 4. Supply ooling wter to the engine nd strt the engine. 5. Operte the engine t idle speed until it rehes norml operting temperture. 6. Instll jumper wire etween the two white wire leds on the distriutor. Use Quiksilver 91 818812A1, or frite jumper wire using 15 m (6 in.) length of 16 guge wire with two mle ullet terminl ends onneted. - White wire leds - Jumper wire leds 42953 90-899883197 AUGUST 2011 Pge 4C-19
7. Bypss the shift interrupt swith, s follows:. Disonnet the shift interrupt swith wires from the engine hrness wires. Typil - Shift plte - Shift interrupt swith - Swith wires 48000. Temporrily plug the mle nd femle ullet onnetors together on the engine hrness wires. - Engine hrness wires - Shift interrupt swith wires IMPORTANT: Do not fil to reonnet these two wires to the shift interrupt swith when timing proedures re omplete. 8. Aim the timing light t timing t, loted on the timing ger over nd rnkshft torsionl dmper. Chek the timing. Refer to Speifitions. 47999 3.0 MPI shown 3.0 TKS similr - Timing mrk - Timing t 9. Adjust timing y loosening distriutor lmp nd rotting distriutor ody s required until timing mrk on dmper or pulley lines up with the mrk on t speified in Speifitions. Tighten lmp nd rehek lotion of timing mrk. 10. Aim the timing light t the timing t nd rehek the lotion of timing mrk. Repet Step 8 until timing is orret. 11. Stop the engine. 12. Tighten the distriutor hold down srew to speifitions. 46688 Desription Nm l in. l ft Distriutor hold down srew 27 20 13. Reonnet the two wires from the shift interrupt swith to the engine hrness wires. IMPORTANT: Be sure to remove the jumper wire efore returning the engine to servie, otherwise timing will not dvne. 14. Remove the jumper wire onneted etween the distriutor white leds. 15. With timing light still onneted, strt the engine. Operte t idle nd t RPM indited. Verify initil timing nd totl dvne s listed for your model: Pge 4C-20 90-899883197 AUGUST 2011
If initil timing is 1 BTDC: 12 BTDC, plus or minus 2. At 2400 2800 RPM mximum (totl) dvne is otined nd should e 23 BTDC (plus or minus 2 ). If initil timing is 1 ATDC: 14 BTDC, plus or minus 2. At 2400 2800 RPM mximum (totl) dvne is otined nd should e 25 BTDC (plus or minus 2 ). If initil timing is 2 ATDC: 15 BTDC, plus or minus 2. At 2400 2800 RPM mximum (totl) dvne is otined nd should e 26 BTDC (plus or minus 2 ). 16. Stop the engine nd remove the timing light. 90-899883197 AUGUST 2011 Pge 4C-21
Notes: Pge 4C-22 90-899883197 AUGUST 2011