Mechanical Gas Fuel System G5.9, G8.3 – 013-043   Ignition Generator

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

• Disconnect the battery cables and connections.
  Refer to Procedure 013-009 in Section 13.

WARNING  The ignition system produces very high voltages. To reduce the possibility of personal injury from electrical shock, do not touch any ignition wires or components while the engine is operating, unless using suitably insulated tools.

WARNING  The engine must not be running and the ignition or key switch must be in the OFF position when installing or removing the ignition generator To reduce the possibility of personal injury or equipment damage, do not touch the pins on the ignition generator unless using suitably insulated tools.

Bar the engine until the timing marks on the accessory drive pulley align with the timing pointer at the prescribed ignition timing value.
Refer to Procedure 018-016 in Section V.

Check the alignment of the indicator on the rear of the ignition generator. The marks
must be near alignment on the
counterclockwise (CWW) mark for the G/GTA28 and the
clockwise (CW) mark for all other engine models.

If the marks are approximately 180 degrees out of alignment, rotate the engine an additional 360 degrees and check the rear alignment of the ignition generator again.

Disconnect the wiring harness.

Remove the two mounting capscrews on the ignition generator.

Remove the generator.

Inspect the coupling.
Refer to Procedure 013-046 in Section 13 for reuse guidelines.

Remove the four mounting capscrews (1) and chassis ground (2).

Remove the wiring harness connectors from the module (3).

WARNING  The ignition system produces very high voltages. To reduce the possibility of personal injury from electrical shock, do not touch any ignition wires or components while the engine is operating, unless using suitably insulated tools.

WARNING  The engine must not be running and the ignition or key switch must be in the OFF position when installing or removing the ignition generator To reduce the possibility of personal injury or equipment damage, do not touch the pins on the ignition generator unless using suitably insulated tools.

Bar the engine so the left bank, cylinder number 1 for the GTA28, and the right bank, cylinder number 1 for all other engine models, is at the desired firing point on the compression stroke.
Refer to Procedure 018-016 in Section V.

Use number 1 cylinder on the left bank for G/GTA28 engines as viewed from the front of the engine. See illustration.

Align the timing mark on the back cover shaft with the stationary rotation mark
counterclockwise (CWW) on the back cover for the GTA28 and
clockwise (CW) on the back cover for all other engine models.

Install the gasket onto the ignition generator.

Install the intermediate coupling before mounting the ignition generator onto the engine. Using two mounting capscrews, install the ignition generator on the engine, keeping the two red lines aligned as closely as possible.

If the two lines do
not meet, loosen the back cover by removing the four fastening screws and carefully tilt the top of the cover away from the unit, keeping the internal plug connected. Rotate the distributor shaft until the marks are aligned. Install the cover and securely tighten the four fastening the screws.

Tighten the capscrews and connect the wiring harness. Start the engine and verify timing is at the correct specification.
Refer to Procedure 013-042 in Section 13.

Install the chassis ground (2) and replace the four mounting capscrews (1).
Refer to Procedure 018-016 in Section V.

Install the wiring harness connectors (3).

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

• Connect the battery cables and connections.
  Refer to Procedure 013-009 in Section 13.
• Operate the engine and check for proper operation.