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Distributor: Service and Repair

Crankshaft Top Dead Center (TDC) Mark:





REMOVAL
- Align the timing pointer with the Top Dead Center (TDC) mark on the crankshaft pulley. Verify the No. 1 piston is on the compression stroke.
- Mark the position of the No. 1 cylinder wire tower on the distributor base for reference when installing the distributor.
- Disconnect the harness connector from the distributor.
- Using a screwdriver, remove the distributor cap. Position the cap and wires aside.
- Remove the distributor bolt and clamp. Remove the distributor by pulling upward.
- Cover the distributor opening in the cylinder block with a clean shop towel.

DISASSEMBLY
Rotor
- Remove the rotor by pulling upward to remove it from the distributor shaft and armature.


View: Ignition Distributor:





Armature
- To ease assembly, mark the armature and the gear with a felt tip pen to note orientation.
- Remove the two screws holding the armature and remove the armature.

NOTE:
Hold the gear to loosen the armature screws, do not hold the armature.


Special Service Tool (SST) Distributor Gear Puller:





Distributor Gear
- Remove and discard the pin in the gear.
- Invert the distributor and place in the Special Service Tool (SST) and press off the gear.

Shaft Assembly
- Deburr and polish the shaft with emery paper or crocus cloth and wipe clean so that the shaft slides out freely from the distributor.
- Remove the shaft assembly.


INSPECTION
Distributor
- Inspect the base bushing for wear or signs of excess heat concentration. Replace the complete distributor assembly if damaged.
- Inspect the base O-ring for cuts or damage and replace if necessary.
- Inspect the base for cracks and wear. Replace the complete distributor assembly if any damage is found.

ASSEMBLY
Hall Effect Vane Stator Assembly
- Place the stator assembly over the bushing and press down to seat.
- Place the stator connector in position. The tab should fit in the notch on the base so that the eyelets are aligned with the screw holes.
- Install the stator screws.

Tightening torque: 1.7 - 4.0 Nm (15 - 35 in.lb.)

Shaft assembly
- Apply a light coat of clean engine oil to the distributor shaft, below the armature.
- Install the shaft through the base bushing.

Distributor Gear And Thrust Washer
- Place a 13 mm (1/2 in) deep well socket over the shaft, invert and place it on the arbor plate.
- Install the gear thrust washer.
- Install the gear and press it onto the shaft.

NOTE: The hole in the shaft and gear must be lined up as accurately as possible to ensure ease of roll pin insertion.

CAUTION:
The gears on the distributor are not released for service. The distributor gears are matched to the distributor at assembly and should never be replaced.
Do not replace the distributor gear. If the distributor gear requires replacement, install a new distributor assembly.

- Place a 5/8 in deep well socket over the shaft and the gear. Press the gear to align it with the original drill hole.

NOTE:
If the gear holes do not align, the gear must be removed and repressed on. A drift punch will not align the holes.

- Insert the new roll pin through the gear and shaft. The pin should have the proper extrusion.

Armature
- Install the armature.

Tightening torque: 2.9 - 3.9 Nm (26 - 34 in.lb.)

- Check the distributor for free movement over full rotation of the shaft.

NOTE:
If the armature contacts the stator, replace the entire distributor.


View: Rotor:





Cap And Rotor
- Align the locating boss in the rotor with the hole on the armature.
- Fully seat the rotor on the distributor shaft.
- Position the distributor cap on distributor base, noting the position of the square alignment locator.

INSTALLATION
NOTE:
Before Installation, visually inspect the distributor O-ring for tightness and cuts. The drive gear should be free of nicks, cracks and excessive wear. Rotate the distributor drive shaft. It should move freely, without binding.

- To correctly install the distributor, the No. 1 piston must be at Top Dead Center (TDC) of the compression stroke.
- Rotate the distributor shaft so that the blade on the rotor is pointing toward the mark on the distributor base, that was previously made in the removal procedure.
- While installing the distributor, continue rotating the rotor slightly so that the leading edge of the vane is centered in the vane switch assembly.
- Rotate the distributor in the cylinder block to align the leading edge of the vane and the vane switch stator assembly. Verify that the rotor is pointing at the No. 1 mark on the distributor case.

NOTE:
If the vane and the vane switch stator cannot be aligned by rotating the distributor in the cylinder block, remove the distributor just enough to disengage the distributor from the camshaft gear. Rotate the rotor enough to engage the distributor gear on another tooth of the camshaft gear. Verify engine is at TDC if necessary.

- Install the distributor clamp and bolt. Tighten the bolt, but leave it loose enough to rotate the distributor.
- Install the distributor cap, the No.1 spark plug if removed, and the high-tension leads. Check that the high-tension leads are securely connected to the cap and spark plugs. Tighten the distributor cap screws to the specified torque.

Tightening torque: 2.1 - 2.5 N.m (19 - 22 in.lb.)

- Connect the harness connector to the distributor.
- Adjust the ignition timing.
- After the ignition timing is adjusted, tighten the distributor hold-down bolt to the specified torque.

Tightening torque: 19 - 28 Nm (14 - 20 ft.lb.)

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