Service Procedure
1. Raise and support the hood.
2. Write down the owner's preset radio stations and such other memory functions that can be recorded and reset later; then, with the ignition in the "off" position, disconnect the negative battery cable from the battery. If a memory retention device, such as Kent-Moore tool KS295A, is used, it is not necessary to record memory functions.
3. Do NOT disconnect the 11 pin IDI harness connector.
4. Remove the four bolts, ignition system assembly to cam housing.
5. Remove the ignition system assembly from the engine, turn it upside down and lay it on the engine using two bolts as "locator pins" through the cover into the cam housing on the "rear side" of the engine to hold the ignition system assembly in place.
Figure 1:
Figure 2:
NOTICE: If boots adhere to spark plugs, use tool J 36011 to remove by first twisting and then pulling upward on retainers. Reinstall boots and retainers on IDI housing secondary terminals, making sure that the spark plug connectors (item 9 in Figure 1) are in place. Boots and retainers must be in place on IDI housing secondary terminals prior to ignition system assembly installation or ignition system damage may result.
6. Remove the four housing to cover screws (item 4 in Figure 1) and remove the ignition coil housing (item 7) from the cover (item 1).
7. Remove the coil harness connectors (item 5) from the coils.
8. Refer to Figure 2, and inspect the two ignition coils for color of electrical tab. Ignition coils with black electrical tabs are to be replaced with new coils having yellow electrical tabs (from kit P/N 10457062). Coils with yellow electrical tabs do not require replacement. It should be rare to find a campaign vehicle in which one or both coils already have yellow tabs.
9. If necessary to replace one or both coils, remove the "black tab" coil(s), the contacts(s), and the seal(s) from the cover (see Figure 1, item 6 and in View A, items 13 & 14).
10. Reinstall seal(s) (item 14 in Figure 1) to the housing.
11. Reinstall contact(s) (item 13) to the housing (use petroleum jelly to retain).
12. Install new "yellow tab" coil(s) to the cover, as required. Install coil harness connectors to both coils.
13. Reinstall the housing (item 7 in Figure 1) to the cover (item 1) with four screws (item 4); torque screws to 4 N-m (35 lb.in.).
14. Install the ignition system assembly to the engine while carefully aligning boots to the spark plug terminals.
15. Coat the four bolts, ignition system assembly to cam housing, with P/N 1052080 sealer (or equivalent). Install the bolts through the cover to the cam housing and torque to 20 N-m (15 lb.ft.).
NOTICE: If the above bolts are not coated with sealer prior to reinstallation, future removal of the bolts may strip the threads in the aluminum of the cam housings.
16. Reconnect the negative battery cable. In the interest of customer satisfaction, please reset (to the extent possible) all devices that lost their memory after the battery was disconnected (not required if a memory retention tool was used).
17. Install a Campaign Identification Label.