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 1/06
GENERAL
First make sure your vehicle is equipped with an
Opti-Spark II type (pin drive – with positive vent sys-
tem) 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 mani-
fold vacuum hose line (13) and air intake hose line (9)
running to the distributor. The older Opti-Spark I dis-
tributors 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 drive (12).
NOTES ON INSTALLING NEW
OPTI-SPARK II DISTRIBUTOR
1. Refer to the vehicle service manual for instructions
to provide access to the Opti-Spark II distributor.
2. Label and remove the spark plug and coil leads
from the distributor cap (2). Remove the air intake
hose (9) from the distributor cap (2). Remove the
vacuum line (13) from the distributor housing (8).
Remove the harness connector (10) from the
distributor.
3. Refer to the vehicle service manual for instructions
to remove the Opti-Spark II distributor.
4. Once the old distributor is removed, make sure
that both the old pin drive shaft seals (11) are still
in place on the pin drive shaft assembly (12) on
the back side of the distributor. If not, remove the
seals from inside the end of the cam shaft.
5. Refer to vehicle service manual to complete
installation of the Opti-Spark II distributor.
INSTALLING NEW OPTI-SPARK II CAP, ROTOR,
AND COVER ASSEMBLY
1. Refer to the vehicle service manual for instructions
to provide access to the Opti-Spark II distributor.
2. Label and remove the spark plug and coil leads
from the distributor cap (2). Remove the air intake
hose (9) from the distributor cap (2). Remove the
harness connector (10) for the distributor.
3. Remove the four distributor cap retaining screws
(1) using a J39997 (E4 Reverse Torx) socket. This
socket is available in the Kent Moore tool catalog.
4. Remove the distributor cap (2).
5. Remove the two rotor retaining screws (3) using a
T-8 Torx socket and remove the rotor (4).
6. Carefully remove the cover assembly (5). Do NOT
pry the cover off from the center opening. Do NOT
make contact with the stainless steel slotted vane
wheel (7) visible thought the center opening in the cover.
7. There is a loose metal shield (6) behind the cover
assembly (5) that may come off as well. It is meant
to protect the stainless steel slotted vane wheel
(7). Carefully clean the sealing surface on the
distributor housing (8). Do NOT make contact with
the stainless steel slotted vane wheel (7).
8. Make sure the top and bottom seals are
positioned correctly on the new cover assembly
(5). If necessary reposition the metal shield (6).
Carefully install the new cover assembly (5) by first
aligning the two location pins on the back side of
the cover assembly with the two holes in the
distributor housing (8). Making sure the metal
shield (6) remains located properly as you install
the cover assembly (5). Make sure the cover
assembly (5) is fully seated on the distributor
housing (8). Again Do NOT make contact with the
stainless steel slotted vane wheel (7) visible
thought the center hole in the cover.
9. Install the new rotor (4) by first aligning the locator
pin on the bottom of the rotor with the mating hole
in the distributor hub assembly. Install the two
new rotor retaining screws (3) and tighten to 6
in/lbs to torque.
10. Install the new distributor cap (2). Install the four
new distributor cap screws (1) and tighten to 24 in/lbs.
11. Reinstall the spark plug and coil leads and the
vacuum line onto the distributor cap. Reinstall the
harness connector to the distributor.
12. Refer to vehicle service manual to complete installation.
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