Mallory Ignition ACCEL ULTRA OPTI-SPARK II CAP & ROTOR KIT 8136 - Manual

ULTRA OPTI-SPARK II DISTRIBUTOR P/N 59125
ULTRA OPTI-SPARK II CAP & ROTOR KIT P/N 8136
INSTALLATION INSTRUCTIONS
FORM INS-59125 (Rev A) 01/12
GENERAL
First make sure your vehicle is equipped with an
Opti-Spark II type (pin drive – with positive vent
system) distributor. It is not necessary to remove
the distributor from the engine to determine if it is an
Opti-Spark II or not. Simply look for the intake
manifold vacuum hose line and air intake hose line
running to the distributor. The older Opti-Spark I
distributors are not vented and do not have these hose
connections. If the distributor is removed from the
engine, the Opti-Spark II unit will have a
non-splined pin shaft.
REMOVING/INSTALLING NEW OPTI-SPARK II
DISTRIBUTOR
NOTE: It is best to have a vehicle service manual for
detailed reference on removal and installation of
sensor and accessories.
1. Disconnect the negative side of the battery.
2. Drain coolant from cooling system.
3. Disconnect the mass air flow (MAF) and the intake air
temperature (IAT) sensors. Next, remove the air intake
elbow.
4. Remove upper radiator hose.
5. Remove serpentine belt. Remove the belt tensioner.
6. If necessary remove the cooling fans.
7. Remove the crankshaft pulley.
Note: a balancer
removal tool may be required.
8. Position the crankshaft hub as in Figure 4
9. Disconnect and remove the air pump wires and hose’s
then remove the air pump.
10. Remove the air pump mounting bracket.
11. Disconnect the coolant temperature sensor (ECT) wire
harness from the water pump.
12. Remove the lower radiator and heater hoses from the
water pump.
13. Remove the water pump.
14. Be sure to mark the location of the spark plug wires
and then remove.
15. Remove vacuum lines and wire harness and coil wire
from existing Opt-Spark II.
16. Remove the 3 bolts holding the Opti-Spark II to the
engine.
17. Once the old distributor is removed, make sure that
both the old pin shaft drive seals are still in place on
the pin shaft drive assembly on the back side of the
distributor. If not, remove the seals from inside the
end of the cam shaft.
18. Important: DO NOT lube Opti-Spark hub or
timing cover seal, the seal MUST be installed dry
or it will leak oil.
19. When installing the ACCEL Ultra Opti-Spark II, be sure
to use the correct index on the pin drive shaft. See
Figures 1 & 2. This index is the only location that the
dowel pin on the camshaft
properly seats into.
20. Note: You will notice that if the correct index is not
used that the distributor will not seat properly and
rock against the engine see Figure 3.
DO NOT tighten the bolts down. Remove the ACCEL
Ultra Opti-Spark II and reinstall using the
correct index. Refer to Figures 1 & 2.
21.
DO NOT force the electrical connector in. If
you have difficulties seating the connector remove
the connector and check the pins in the Opti-
spark. If they are bent you can use a long flat
blade screwdriver and gently straighten the pins.
22. Reinstall accessories and sensors in reverse order to
complete installation.
NOTE: It is best to have a vehicle service manual for
detailed reference on removal and installation of sensor
and accessories.
REMOVING/INSTALLING NEW OPTI-SPARK II
CAP & ROTOR
Refer to the REMOVING/INSTALLING NEW
OPTI-SPARK II DISTRIBUTOR
1. Instructions above or a vehicle service manual for
instructions to provide access to the Opt-Spark II
distributor.
Note: it is very easy to change the cap
and rotor with the Opti-spark unit on a work bench.
It can be done in the vehicle but will be very difficult.
2. Remove the 4 distributor cap retaining screws using
an E4 Reverse Torx socket.
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