Transcript Powerpoint File

Installation Instructions
Original distributor, coil, and plug wires- old, inefficient 70s technology.
Your PinzSSI kit will contain these items.
Packing List
Coil/Relay assembly
Mounting L bracket
Spark Plugs (4)
Spark Plug Wires (4)
Module
¼” Wire loom (6’)
Manual/Parts CD
Parts package
Printed Instructions
Spark Plug Wire Spacers
Parts package includes:
1. Butt sleeves (6)
2. Spade connectors (6)
3. Boot grease
4. Vacuum plug
5. Heat shrink
6. Colored wire for battery
7. Battery connector (red or black)
8. Cable ties
Be sure to use the correct tool for crimping the butt sleeves and spade connectors.
Otherwise, the connection may eventually fail. Don’t use pliers. This is very
important! Use heat shrink on all connections.
Crimp here
This heat gun and crimping tool can both be purchased at Harbor Freight Tools
if you want to properly install connectors and heat shrink. Around $21 total.
The heart of the system is the wiring harness and power module, which are
permanently connected.
Cut ignition feed here
Begin by removing the coil and bracket, suppressor, and distributor.
Cut off the ignition power source wire at the suppressor connection.
Plug vacuum port
Remove spark plugs and wires. Remove vacuum line and block
the port with the provided plug. Remove the pinch clamp from
the distributor and save for use on the new ignition module.
Remove the bolt near the top of the driver’s side coil spring. This holds the
heater hose clamp in place as shown.
Using the longer provided bolt, install the mounting L-bracket.
Bolt the coil/relay pack onto the mounting L-bracket using the provided
nut, washers, and bolt.
It is important to line up the notches correctly before installing the module in block.
The small spring should be visible inside the block. The pinch clamp should be in
place and the module shaft should be lightly oiled. When the module is fully seated,
install the 13 mm bolt and tighten. The module can then be rotated to preference.
24v ignition wire splice
Connect
ground
Yellow ignition wire
Connect the yellow wire from the harness to the white 24v ignition wire that was cut off
earlier. Install heat shrink. Route over the engine. Work the slack towards the coil/relay pack.
Secure the wiring into place using wire ties.
Connect the black wire to the chassis, using the screw that holds the Molex connector to
the alternator for example.
Harness
Route the harness over the top of the engine in the vicinity of where
the spark plug wires used to run, and secure with wire ties.
On the driver’s side, tie to the vacuum line and keep clear of the throttle rod.
Battery box hole
12 volt feed
Route the power feed from the battery box by either 1) using the existing hole as shown
or 2) drilling a hole. The photo shows using the existing hole (from under the vehicle), the
same hole that the other battery cables use. The fit is tight! Leave enough slack to reach
the battery terminal as shown, but do not connect at this time. The PinzSSI system works
on 12 volts. Be sure to verify voltage as there are several possible battery configurations.
The photo shown is just one possibility, which reflects the original factory set-up.
Do not use the ignition switch wire to power the module. This will damage the module and
void the warranty! The 24 volts from the ignition powers the relay solenoid only.
Use provided wire loom to cover the all wire after installation.
2) 12 volt feed
from the battery
1) 24 volt ignition feed (yellow)
3) 12 volt feed to the new harness (red)
This also feeds tach voltage if applicable.
At the relay make the following 3 connections- 1) 24 volt feed from the ignition
switch, 2) 12 volt feed from the battery, and 3) 12 volt feed to the new harness (red).
Leave the harness unplugged from the coil pack until after the timing is set!
Jumper wire
Reconnect the battery with the new power feed. Be sure it is a 12 connection!
The red or black battery connector can connect to either battery post that
the large jumper wire connects to.
Here is a simple schematic of the interconnections between the battery,
relay, ignition key, and the new wiring harness.
The module draws just 660 mA, not enough to interfere with the charging
system or shorten the life of either battery.
Note- 24v to 12v DC converters have been tested to replace the battery 12v
connection. All converters failed except for the more expensive versions,
as they do not produce a smooth enough voltage for the module to operate.
The module is a computer which takes readings from the optical sensor and sends the info
to the CPU. This includes RPM and rate of engine acceleration/deceleration. The CPU adjusts
the ignition timing based on the input information.
The timing is 0 degrees BTDC while the engine cranks, and jumps to normal advance at about
300 RPM. From there the maximum total advance reaches 38 degrees at about 3500 RPM.
It is important to set the static timing (timing set with engine not running) at 0 degrees, or
TDC, because this is the reference point that the computer uses for the rest of the curve.
The spark plugs fire 3 times every time the piston is at TDC, which is why you can set the
timing at either the compression or exhaust stroke. Unlike other ignition systems that must
fire at the top of the compression stroke, the PinzSSI fires every time. Plugs in cylinders 1 and 4
fire simultaneously, cylinders 2 and 3 do the same. In fact, one plug is actually the return path
for the other, with the engine block acting as the electrical path!
This schematic shows the
path that voltage takes to
jump 2 plugs every time that
pistons are at TDC in cylinders
1-4 and 2-3. Each plug
fires 3 times to ensure
complete combustion.
The firing order is normally
1-2-4-3 every 720 degrees
of crankshaft revolution using
the stock Bosch system.
With PinzSSI, the plug firing
alternates between cylinders
1-4 and 2-3 every 180 degrees
of crankshaft revolution.
This is a typical 4-cylinder OHC engine. The 1 and 4 pistons are at TDC
while pistons 2 and 3 are at BDC. This design keeps vibration to a minimum.
If this were a Pinzgauer engine, the plugs in 1 and 4 cylinders would be firing,
regardless of which cylinder is at the beginning the of the power stroke.
Optical pickup
#1 timing mark
Red timing LED
The optical pickup should be towards the rear of the vehicle, the harness should be towards
the front. The #1 cylinder timing mark and the red timing LED are indicated by arrows. The
timing disc rotates clockwise when the engine is running. LED location and appearance may
vary! The physical rotational position of the module can vary due to preference.
Note- When setting the timing, your only concern is lining up the pulley notch correctly. Do
not be concerned which cylinder you are on, as the notch placement is based on the #1 piston
position at TDC on either the compression OR exhaust stroke. This photo shows the module
before it has been rotated to the final position.
Begin by rotating the engine CW using a 27mm socket on the fan nut until the timing mark on
the pulley lines up with the pointer, which is at 0 degrees (or TDC). Turn on the key. Loosen
the screw that holds the slotted disc, and rotate the disc until the red LED turns on. Tighten
the screw, but do not over-tighten. Rotate the engine twice until the pointer and mark on the
pulley line up again, the red light should come on. If it doesn’t, slowly rotate the module until
the red LED lights. Snug the pinch clamp, and rotate the engine 2 times again until the pulley
mark arrives again at TDC. The LED should light. If it doesn’t, adjust again, being careful not to
rotate the engine backwards. Repeat this process until you can rotate the engine twice with
the LED lighting at the correct position of TDC. Tighten pinch clamp and plug the harness into
the coil pack. Turn the key off for now, the timing is set.
Here is another view of the pointer lining up with the notch on the pulley,
but at a slight angle. It does not matter if the piston is at TDC of the exhaust
or compression stroke when setting the timing. Cylinders 1 and 4 are at TDC.
#4 cyl.
Longest
wire
Cylinder number (4)
Install the spark plugs (.032” gap) and torque. Grease plug wire boots and install the wires.
The corresponding cylinder numbers are on the coil pack, and the wires are cut to specific
lengths for the intended plugs. #1 wire is shortest, #2 is second, etc. Install wire spacers that
keep the wires apart and away from metal. Run the engine for a minute, and re-check the
timing with harness plug disconnected. If the timing is correct, you are done-plug it back in.
The new PinzSSI ignition system is ready for a road test!
Testing jumper
Grounding jumper
Grounding screw
There is a possibility that the relay may not work properly due to improperly
grounding of the coil pack plate. It is recommended that a grounding jumper
be connected to a new grounding screw that has been installed on the chassis. To
test for this, run a testing jumper from the relay screw to the engine with the key
on. If the relay clicks when this temporary connection is made, install a grounding
jumper. It is recommended that this be done anyway to prevent future problems.
3
2
1
4
Troubleshooting the PinzSSI is easy. All voltage checks are made at the relay.
1- Voltage should always be 12 volts. Check battery connection if it is 0.
2- Voltage should be 0 with the key off, 12 volts with the key on.
3- Voltage should be 0 with the key off, 24 volts with the key on.
4- Ground terminal for the relay. If you get 0 volts at 2 and 3 with the key
on, push the test button on the relay, which is below the 1 and 2 terminals.
If this results in voltage at 2/3, then 4 is not grounding to the chassis properly.
Run a permanent jumper from 4 to the vehicle frame for a better ground.
CAUTION
NGK BPR6ES resistor spark plugs included with the kit MUST
be used at all times, along with resistor plug wires. Always
replace the spark plugs/wires with the same resistor type.
Failure to do so could damage the module or result in poor
performance. Or both!
Replacement wires need to be 800 ohms/ft. PinzSSI has
individual replacement wires in stock.
Also, never crank the engine with any spark plug wires
disconnected, unless you have the harness unplugged from
the ignition coil pack. Failure to do so could also damage the
ignition coil/module.
Questions? Comments? Need parts? Then contact us at
www.pinzssi.com or call 760-775-5160. We promptly return all
calls if you leave a message.