Distributor: Service and Repair

REMOVAL
1. Disconnect distributor from engine control sensor wiring.
2. Mark position of No. 1 cylinder distributor cap wire tower on distributor housing for reference when installing distributor.
3. Loosen distributor cap hold-down screws. Remove distributor cap straight off distributor to prevent damage to distributor rotor blade and spring. Position distributor cap with ignition wires aside so as not to interfere with distributor removal.
4. Remove distributor rotor by pulling upward to remove distributor rotor from the distributor shaft and armature.
5. Remove hold-down clamp and retainer bolt. Remove distributor by pulling upward.
6. Cover distributor opening in the cylinder block or engine front cover (depending upon application) with a clean shop towel to prevent the entry of foreign material or dirt into the engine.

INSTALLATION

NOTE: Visually inspect distributor before installing. Inspect the O-ring. O-ring should fit tightly and be free of cuts. The distributor drive gear should be free of nicks, cracks, and excessive wear. Rotate distributor shaft. It should move freely, without binding.

NOTE: To install distributor correctly, No. 1 piston must be at Top Dead Center (TDC) of compression stroke.

1. Remove No. 1 cylinder spark plug and rotate crankshaft clockwise until No. 1 piston is on the compression stroke, align timing pointer with TDC mark on the crankshaft damper.
2. Align locating boss on distributor rotor with hole on armature. Fully seat distributor rotor on distributor shaft.
3. Rotate distributor shaft so blade on distributor rotor is pointing toward mark on distributor housing made in Step 2 of the Removal procedure.

CAUTION: When replacing the distributor, coat the entire distributor drive gear with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A prior to installation of the distributor.

NOTE: Prior to installation of the distributor, coat the camshaft distributor gear with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A through the distributor hole.

4. While installing, continue rotating distributor rotor slightly so leading edge of the armature vane is centered in distributor stator.
5. Rotate distributor in engine to align leading edge of vane and distributor stator. Verify distributor rotor is pointing at mark on distributor housing.

NOTE: If vane and distributor stator cannot be aligned by rotating distributor in engine, remove distributor just enough to disengage distributor gear from camshaft gear. Rotate distributor rotor enough to engage distributor gear on another tooth of camshaft gear. Repeat Step 1 if necessary.

6. Install hold-down clamp and bolt. Tighten bolt, but leave it loose enough to rotate distributor.
7. Install No. 1 spark plug and ignition wires. Check that ignition wires are securely connected to the distributor cap and spark plugs. Tighten distributor cap hold-down screws to 2.0-2.6 Nm (18-23 in lb).
8. Reconnect distributor to engine control sensor wiring.
9. Set initial engine ignition timing.
10. After engine ignition timing is set, tighten distributor hold-down bolt to 20-30 Nm (15-22 ft lb).
11. Recheck initial engine ignition timing. Adjust if necessary.