IGNITION SYSTEM IGNITION SYSTEM CIRCUIT ............:c:e cere 82 DISTRIBUTOR ...............:ccecsccseceeecteeeene cette eneeeenee 8-7 HIGH TENSION CORD 8-23 SPARK PLUGS 8-248-2 IGNITION SYSTEM — Ignition System Circuit IGNITION SYSTEM CIRCUIT Fig. 84 USA & Canada Distributor Sional Rotor Sional Generator |! (Prekeup Coil a 1 pattery + To Starter Motor (KP36 LHD) Ignition Switch To Starter Motor (KP36 LHO) Ignition Switch ah Distributor 3 en i | 7 3 r | sary | Spark PlugIGNITION SYSTEM — Ignition System Circuit 8-3 Timing Light Fig. 8-5 ON-VEHICLE INSPECTION Spark Test 1, Seta timing light to the engine. 2. Crank the engine. 3. Check the spark condition with the timing light. Connector Check the connector and Turn on the ignition switch. (But do not start engine) 2. Disconnect the ignition coil cover. 3. Check the battery voltage Using a voltmeter, connect the positive (+) probe to the resistor positive (+) terminal and negative (—) probe to the body ground. Voltage: Approx. 12V Check the power transistor in igniter. (1) Usinga voltmeter, connect the positive (+) probe to the ignition coil negative (—) terminal and negative (—) probe to the body ground {power transistor OND. Voltage: Less than 3V8-4 IGNITION SYSTEM — Ignition System Circuit Fig. 86 a White % LA] (f | evo 7 | ra | Fig. 8-7 Fig. 88 (2) Unplug wiring connector from distri butor. (3) Using a voltmeter, connect the positive (4) probe to the ignition coil negative (=) terminal and negative (—) probe to the body ground. (4) Using a dry cell battery (1.5V), con: nect the positive (+) pole to the white wire terminal and negative (—) pole to the pink wire terminal (power tran- sistor OFF) = Caution — To avoid destroying the power transistor in the do not apply voltage more than 5 (5) Check the voltage reading, Voltage: Approx, 12V Distributor 1. Distributor cap Check for cracks, carbon tracks, burnt or corroded terminals, and check the center contact for wear. 2. Check the governor. Turn the rotor counterclockwise and release it. The rotor should return smoothly to its original position.IGNITION SYSTEM — Ignition System Circuit 8-5 Fig. 89 USA & Canada 3. Check the air gap. Check the air gap between the timing rotor and pick up coil projection with a thickness gauge. Air gap: 0.2—0.4mm (0.008 — 0.016 in.) Air Gap Fig. 8-10 aap aon 4, Check the signal generator. Check the resistance of the signal generator with an ohmmeter. n Resistance: 140 — 180 2 Q Fig. 8-11 Except USA & Canada 3. Check the rubbing block gap. Rubbing block gap: 0.45 mm. (0.017 in.) Fig, 812 Resistor ‘Check the resistor resistance with an ohmmeter.8-6 Fig. 8-13 IGNITION SYSTEM — Ignition System Circuit Fig. 815 Ignition Coil 1, Check the ignition coil resistances with an ohmmeter, (1) Primary coil resistance: between Posi- tive (+) and negative (~) terminals Resistance: with Igniter 1.31.79 without Igniter 1,2— 1.5.2 (2) Secondary coil resistance: between positive (+) terminal and high tension terminal, Resistance: with Igniter 10 — 15k without Igniter 8 — 12k 2. Check the insulation resistance between the positive (+) terminal and coil case with an ohmmeter Resistance: InfinityIGNITION SYSTEM — Distributor 8-7 DISTRIBUTOR DISASSEMBLY Disassemble the parts in the numerical order shown in the figure. Fig. 8.16 General Destinations Cop, Rotor & Cover Terminal Breaker Point Vacuum Advancer Breaker Plate Cam8-8 IGNITION SYSTEM — Distributor Fig. 8-17 General Destinations. Breaker Plate Stationary Plate nar = a HR snap Ring Bg rere sins | Ce overncr Weight = Steel Washer Bakelite Washer ‘Stoel Washer Governor Shaft | Ring: StareFig. 8-18 Sweden 4K-C n IGNITION SYSTEM — Distributor 8-9 Disassemble the parts in the numerical order shown in the figure. Cap, Rotor, Cover & Packing Terminal Breaker Point Damping Spring Ground Wire ‘Vacuum Advancer Breaker Plate Cam8=10 IGNITION SYSTEM — Distributor Fig. 8-19 ‘Sweden 4K-C SGovenor Soring ergIGNITION SYSTEM — Distributor 8-11 Disassemble the parts in the numerical order shown in the figure. Fig. 8-20 USA & Canada nd wp y ap, Rotor & Packing 8. Governor Weight Dustproof Cover & Signal Generator 9. Cord Clamp Steel Plato Washer 10, Vacuum Advancer Breaker Plate 11. Pin Grease Stopper 12. Spiral Gear & Washer Governor Spring 13. Governor Shaft Signal Rotor 14, Stee! Washer seeeepe8-12 IGNITION SYSTEM — Distributor reas INSPECTION & REPAIR Cap Inspect for cracks, carbon wacks, burnt or corroded terminals and check the center contact, for wear Rotor Inspect for cracks, carbon tracks, burnt or corroded terminals. Breaker Plate Check the breaker plate for smooth rotation. Governor Weight & Pin Check the fitting portions of the governor weights with support pins for binding.IGNITION SYSTEM — Distributor 8-13 Fig. 8-25 Vacuum Advancer Diaphragm The diaphragm should move when you inhale through the port. Cam & Shaft Inspect cam for wear, damage and fit between ‘cam and shaft, Governor Shaft & Housing 1, Check shaft thrust clearance. Thrust clearance: 0,15 — 0.50 mm (0,006 — 0,020 2. Remove gear and pin Grind off the pin end and remove the pin and gear.8-14 IGNITION SYSTEM — Distributor Fig. 8-29 3. Inspect the governor shaft for wear or damage. Fig. 8-30 Inspect housing bushings, and O ring for wear, deformation or damage. Fig. 8-31 General Destinations 5. Insert the washers onto the governor shaft and plate in the following order. (1) 2mm (0.08 in.) (2) 0.2 mm (0,008 in.) (3) Bakelite washer (4) 0.2 mm (0.008 in.) (5) 0.2mm (0,008 in) Adjust to standard clearance by varying the number of washers 2, 4 and 5 listed above. Steel Washer . Except General Destinations +! 5-1 Assemble the washer as shown in the figure Washer (for adjustment) Thickness mm (in) 2.5 (0.098) 2.7 (0.106) 2.9 (0.114) 2.3 (0.091) 90099-01385 90099-01386 90099-01387 90099-01412IGNITION SYSTEM — Distributor e15 Fig. 8-33 5-2 Assemble the bearing between the pin and weight. Fig. 834 Assemble the washers and gear in order as shown in the figure and check the thrust clearance. Fig. 8:35 a 7. Peen both pin ends with a vise.8-16 IGNITION SYSTEM — Distributor ASSEMBLY Assemble the parts in the numerical order shown in the figure. Fig. 836 General Destinations i | fants pss : ‘ . Se “8B | --- xy O > Ww 9 Cam Advancer Point 7 Cover, Rotor & CapIGNITION SYSTEM — Distributor 8-17 Assemble the parts in the numerical order shown in the figure. Fig. 8.37 Sweden 4K-C cam Breaker Plate ‘Vacuum Advancer Damping Spring Cover, Rotor, Cap & Packing Presson8-18 IGNITION SYSTEM — Distributor Assemble the parts in the numerical order shown in the figure. Fig. 8-38 USA & Canada 7—__———_ 1. Governor Weight Governor Spring 2. Stee! Washer Breaker Plate 3. Governor Shaft ‘Steel Plate Washer 4. Spiral Gear & Washer Signal Generator & Dustproot Cover 5. Pin ‘Vacuum Advancer 6. Signal Rotor Cord Clamp 7 Gre ‘& Packing StopperIGNITION SYSTEM — Distributor 8-19 |. 8:39 General Destinations Install the governor springs in the direction shown in the figure. USA, Canada & Sweden 1. Insure installation of the E ring into the groove. 2. Match the mark 14 with the stopper and install the cam. Fig. 8-42 be] 3. Insure proper installation of the governor spring.8-20 IGNITION SYSTEM — Dist itor Fig. 8.43 Center Line | Setting farie Setting ADJUSTMENT 1. Adjust the air gap. (Except USA & Canada) Rubbing block gap: 0.45 mm (0.0177 in.) (USA & Canada) Airgap: 0.2—0.4mm (0.008 — 0.016 in.) 2. Set the octane selector at the standard line, (2K, 3K-H & 4K) 3. Check the breaker plate for smooth rotation,Fig. 8-47 IGNITION SYSTEM — Distributor 8-21 INSTALLATION 1. Set the crankshaft pulley to No. 1 cylinder ition timing. Ignition timing (BTDC): 8° at Align the center line of the slot at the top end of the oil pump shaft against the mark (il hole) at the top side of the oil pump body. Fig. 8-50 Position the distributor rotor toward the right side of No. 3 plug tube, and insert the distributor housing. 3 + 4, When the housing is inserted, the rotor should be positioned near the center of No, 2 plug tube. be]8-22 Fig. 851 IGNITION SYSTEM — Distributor A? ON Position Turn ignition switch to the ON position. Do not turn the starter motor. Rotate the distributor body counterclock- wise until there is a spark between the points, and tighten the clamp bolt in that position. (Except USA & Canada) Adjust the housing by moving it so that the signal rotor will just begin to cut the lines of the flux, and then tighten the set bolt. (USA & Canada) 7. Check ignition timing during idling. Ignition timing (BTDC): 8° at idle speed If necessary, align the timing marks by turning the distributor body.IGNITION SYSTEM — High Tension Cord 8-23 Fig. 8:55 HIGH TENSION CORD — Note — Carefully remove the high tension cords by pulling on the rubber boots. Fig. 856 2. Do not bend the cords as the conductors will Wrong Correct break. eer INSPECTION 1. Check the condition of the cord terminals. If any terminal is corroded, clean it. If broken . or distorted, replace the cord N Fig. 8-58 Check the resistance of each cord between both ends. If the reading exceeds the limit, replace the cord. Resistance: Less than 25 k®/cordIGNITION SYSTEM — Spark Plugs SPARK PLUGS INSPECTION Inspect for the following. Clean or replace the plugs if necessary. 1, Cracks or damages in the threads or in- sulator. 2. Damaged or deteriorated gaskets. ‘Wear on the electrodes. Burnt electrode and the amount of carbon deposit. Fig. 8-61 GAP ADJUSTMENT Check the plug gap with plug gap gauge. If not to specified value, adjust by bending the ground (outer) electrod ‘Spark plug gap: USA (ex. Calif.) & Canada 1.1 mm (0.043 in.) General, Europe & Calif. 0.8 mm (0.031 in.)MEMOMEMO: