Overhaul of the Distributor For the 8- Valve Engine

Tools: Puller P/N 02-75-123 Soft jaws or wood blocks for the vise Loctite 601 or equivalent

FIGURE 1 - DISTRIBUTOR FOR THE 8-VALVE ENGINE:

Distributor Disassembly

1. Remove the ignition distributor from the engine as shown in the Service Manual. NOTE

All the following steps apply to Figure 1 unless otherwise noted.
2. Remove the seal ring from the distributor body.


CAUTION

IF THE DISTRIBUTOR IS MOUNTED IN A VISE WITHOUT SOFT JAWS OR WOOD BLOCKS, THE DISTRIBUTOR BODY WILL BE DAMAGED.


3. Mount the distributor in a vise with soft jaws or wood blocks. Be careful not to damage the distributor body.

NOTE

Make sure that no fragments of the crushed rotor get into the distributor.


4. Remove the rotor. If the rotor is secured to the shaft with Loctite, carefully crush it with a pair of pliers. Remove the rotor from the distributor.

5. Remove the dust protection cover.


6. Remove the screws securing the bearing cap to the lock ring. Remove the bearing cap and lock ring.

7. Remove the large c-clip located on top of the slotted rotor. Do not remove the small inner c-clip.

FIGURE 2 - USING THE PULLER TO REMOVE THE SLOTTED ROTOR.:

8. Install the puller on the distributor and slotted rotor as shown in Figure 2. Be sure that the puller is centered on the distributor shaft and fully engaged to the slotted rotor.

9. Remove the slotted rotor with the puller (Figure 2) and remove the straight pin from the distributor.
10. Remove the screws securing the vacuum control unit and one spring clip. Remove the clip then unhook and remove the vacuum control unit.

11. Remove the screws - securing the remaining spring clip and remove the screws securing the Hall sensor.

12. Remove the clip securing the socket. Pull the socket out of the distributor body, and carefully unplug the Hall sensor from the socket.

13. Remove the small c-clip directly over the Hall sensor on the distributor shaft.
14. Remove the plastic cover (if applicable) and Hall sensor.

15. While the distributor is apart check for:

a. Shaft bushing wear.

b. Any signs of metal deterioration.

c. Mechanical advance mechanism operation.


Distributor Reassembly


CAUTION

NEVER BRING ANY METAL TOOLS INTO CONTACT WITH THE HALL SENSOR. TO MOVE IT, USE EITHER A FINGER OR A SUITABLE PLASTIC TOOL, AND ALWAYS EXERCISE GREAT CARE.


1. Select the appropriate distributor rebuilding kit from the Distributor

Rebuilding Kit Application Chart.


NOTE

All the following steps apply to Figure 1 unless otherwise noted.


2. Install the Hall sensor and plastic cover. Be sure to correctly position the sensor in the distributor body.

3. Install the small c-clip into the retaining groove on the distributor shaft over the Hall sensor.

4. Plug the Hall sensor into the socket. Secure the socket to the distributor body with its clip.

5. Install the lone spring clip and secure it and the Hall sensor with the appropriate screws.
Distributor Rebuilding Kit Application Chart

PART NUMBER APPLICATION SUPERSEDES TO

93-59-605 Rebuilding Kit
1982, 8-Valve

FIGURE 3 - POSITIONING THE STRAIGHT PIN.:

6. Hook the vacuum control unit on its pin. Secure it and the other spring clip With the appropriate screws.

7. Place the slotted rotor on the distributor shaft. Align the cutout in the rotor for the straight pin with the cutout for the pin in the shaft. Place the straight pin in the cutout with a pair of needle nose pliers as shown in Figure 3.

FIGURE 4 - INSTALLING THE STRAIGHT PIN.:

8. Use a drift and hammer to tap the pin into place (Figure 4).
9. Install the c-clip to secure the slotted rotor.

10. Install the lock ring and bearing cap, and secure with two screws.

11. Install the dust protection cover.


NOTE

The new rotor must be locked to the distributor shaft with Loctite 601 or equivalent.


12. Apply Loctite 601 to the distributor shaft and install the rotor.

13. Install the new seal ring on the distributor body.

14. Install the ignition distributor on the engine as shown in the Service Manual.


Warranty Information

Warranty policy requires that whenever possible the above distributor repair procedure be followed rather than replace the entire distributor assembly. For claims use Failure Coding 34272-60- 0-__-01. Labor allowance is Operation No. 34272 (1.6 hours).