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Distributor

REMOVAL AND INSTALLATION

Fig. 1: Distributor assembly -- Millenia 2.5L (KLD) engines

Fig. 2: Aim the timing light in the appropriate position

1993-94 323 1.6L (B6E) and Protege 1.8L (BPD and BPE) Engines
  1. Disconnect the negative battery cable.
  2. Remove the distributor cap and position it aside, leaving the ignition wires connected.
  3. On SOHC engines, remove the air intake hose from it's position next to the distributor.
  4. Disconnect the distributor electrical connector(s) from the side of the distributor.
  5. Using a wrench on the crankshaft pulley, rotate the crankshaft to position the No. 1 piston on Top Dead Center (TDC) of the compression stroke; the crankshaft pulley mark should align with the timing indicator.
  6. Using chalk or paint, mark the position of the distributor housing on the cylinder head. Also mark the position of the distributor rotor in relation to the distributor housing.
  7. Remove the distributor hold-down bolt(s) and remove the distributor.
  8. Inspect the O-ring on the distributor housing and replace it, if it is damaged or worn.

    To install:

Timing Not Disturbed
  1. Apply clean engine oil to a new O-ring and install it on the distributor.
  2. Install the distributor in the cylinder head. Make sure the distributor rotor is pointing toward the No. 1 spark plug tower position on the distributor cap.
  3. Install the distributor mounting bolts. Align the marks made on the distributor housing and cylinder head during removal and loosely tighten the bolts.
  4. Connect the distributor wiring and, if equipped, vacuum hoses.
  5. Install the distributor cap and secure the screws.
  6. Connect the spark plug wires to the distributor cap in their original locations.
  7. Connect the negative battery cable. Check and adjust the ignition timing.
Timing Disturbed
  1. Disconnect the spark plug wire and remove the spark plug from the No. 1 cylinder. Place a finger over the spark plug hole.
  2. Turn the crankshaft pulley in the normal direction of rotation until compression is felt; the piston is approaching TDC on the compression stroke. Continue rotating the crankshaft pulley until the pulley mark aligns with the mark on the timing belt cover.
  3. Apply clean engine oil to a new O-ring and install it on the distributor.
  4. Install the distributor in the cylinder head. Make sure the distributor rotor is pointing toward the No. 1 spark plug tower position on the distributor cap.
  5. Install the distributor mounting bolts. Align the marks made on the distributor housing and cylinder head during removal and loosely tighten the bolts.
  6. Connect the distributor wiring and, if equipped, vacuum hoses.
  7. Install the distributor cap and secure the screws.
  8. Install the spark plug in the No. 1 cylinder and connect the spark plug wire.
  9. Connect the spark plug wires to the distributor cap in their original locations.
  10. Connect the negative battery cable. Check and adjust the ignition timing.
1995-97 Protege 1.5L (Z5D), 1.8L (BPD) and 1995 MX3 1.6L (B6-ZE) Engines

NOTE: The ignition coil and module are integral to the distributor. The assembly must be replaced as a whole.

  1. Disconnect the negative battery cable.
  2. Remove the air cleaner.
  3. Remove the distributor cap and position aside, leaving the spark plug wires connected. Before removing the distributor, mark the position of the No. 1 spark plug wire tower on the distributor cap.
  4. Disconnect the distributor electrical connectors.
  5. Using a wrench on the crankshaft pulley, rotate the crankshaft to position the No. 1 piston at TDC on the compression stroke. The crankshaft pulley notch should align with the timing plate indicator and the distributor rotor should be pointing to the No. 1 spark plug tower position on the distributor cap.
  6. Using chalk or paint, mark the position of the distributor housing on the cylinder head.
  7. Remove the distributor hold-down bolts and remove the distributor.
  8. Inspect the O-ring on the distributor housing and replace it if it is damaged or worn.

    To install:

Timing Not Disturbed
  1. Using clean engine oil, lubricate the distributor O-ring.
  2. Install the distributor. Make sure the distributor rotor aligns with the No. 1 spark plug tower position on the distributor cap and the distributor housing mark aligns with the cylinder head or cylinder block mark.

    NOTE: There are existing marks on the distributor shaft and housing, which when aligned, indicate the No. 1 spark plug wire tower position.

  3. Install and loosely tighten the distributor hold-down bolts.
  4. Connect the electrical connectors to their original locations. Install the distributor cap.
  5. Install the air cleaner.
  6. Connect the negative battery cable. Start the engine, and check or adjust the ignition timing.
Timing Disturbed
  1. Using clean engine oil, lubricate the distributor O-ring.
  2. Disconnect the spark plug wire from the No. 1 cylinder spark plug. Remove the spark plug from the No. 1 cylinder and press a thumb over the spark plug hole.
  3. Using a wrench on the crankshaft pulley, rotate the crankshaft until pressure is felt at the spark plug hole, indicating the piston is approaching TDC on the compression stroke. Continue rotating the crankshaft until the crankshaft pulley mark aligns with the timing cover indicator.
  4. Position the distributor rotor so it aligns with the No. 1 spark plug wire tower on the distributor cap.
  5. Install the distributor. Align the mark that was made on the distributor housing with the mark that was made on the cylinder block. Loosely tighten the distributor hold-down bolts.
  6. Connect the electrical connectors to their original locations. Install the distributor cap.
  7. Install the spark plug in the No. 1 cylinder and connect the spark plug wire.
  8. Install the air cleaner.
  9. Connect the negative battery cable. Start the engine, and check or adjust the ignition timing.
1995 MX3 1.8L (K8) Engines

NOTE: The ignition module and coil are both located in the distributor. Disassembly is required to examine or replace the components.

  1. Disconnect the negative battery cable.
  2. Remove the resonance air duct.
  3. Tag and disconnect the spark plug wires from the distributor cap. Disconnect the electrical connectors from the top of the distributor.
  4. Using chalk or paint, mark the position of the distributor housing on the cylinder head. Remove the distributor hold-down bolts and remove the distributor.
  5. To remove the ignition module or coil, remove the bolt from the cap, separate the distributor parts, and replace components as necessary. Reassemble the distributor, making sure that the packing is in position, and tighten the bolt to 9-17 inch lbs. (1-2 Nm).

    To install:

Timing Not Disturbed
  1. Align the distributor shaft with the camshaft end and install the distributor.

    NOTE: The tangs on the distributor shaft are different sizes, allowing the distributor to be installed in only one position.

  2. Install the distributor hold-down bolts. Align the mark that was made on the distributor housing with the mark that was made on the cylinder head and loosely tighten the bolts.
  3. Connect the electrical connectors to the distributor and the spark plug wires to the distributor cap.
  4. Install the resonance air duct.
  5. Connect the negative battery cable. Start the engine, and check or adjust the ignition timing.
Timing Disturbed
  1. Align the distributor shaft with the camshaft end and install the distributor.

    NOTE: The tangs on the distributor shaft are different sizes, allowing the distributor to be installed in only 1 position.

  2. Install the distributor hold-down bolts. Align the mark that was made on the distributor housing with the mark that was made on the cylinder head and loosely tighten the bolts.
  3. Connect the electrical connectors to the distributor and the spark plug wires to the distributor cap.
  4. Install the resonance air duct.
  5. Connect the negative battery cable. Start the engine and check or adjust the ignition timing.
1993-97 626 and MX6 2.0L (FS)
  1. Disconnect the negative battery cable.
  2. Remove the fresh air duct.
  3. Remove the distributor cap and position aside, leaving the spark plug wires connected. Before removing the distributor, mark the position of the No. 1 spark plug wire tower on the distributor cap.
  4. Disconnect the distributor electrical connector.
  5. Using a wrench on the crankshaft pulley, rotate the crankshaft to position the No. 1 piston at TDC on the compression stroke. The crankshaft pulley notch should align with the timing plate indicator and the distributor rotor should be pointing to the No. 1 spark plug tower position on the distributor cap.
  6. Using chalk or paint, mark the position of the distributor housing on the cylinder head.
  7. Remove the distributor hold-down bolt(s) and remove the distributor.
  8. Inspect the O-ring on the distributor housing and replace it if it is damaged or worn.

    To install:

Timing Not Disturbed
  1. Using clean engine oil, lubricate the distributor O-ring.
  2. Install the distributor. Make sure the distributor rotor aligns with the No. 1 spark plug tower position on the distributor cap and the distributor housing mark aligns with the cylinder head or cylinder block mark.

    NOTE: There are existing marks on the distributor shaft and housing, which when aligned, indicate the No. 1 spark plug wire tower position.

  3. Install and loosely tighten the distributor hold-down bolt(s).
  4. Connect the electrical connectors to their original locations. Install the distributor cap.
  5. Install the fresh air duct.
  6. Connect the negative battery cable. Start the engine and check or adjust the ignition timing.
Timing Disturbed
  1. Using clean engine oil, lubricate the distributor O-ring.
  2. Disconnect the spark plug wire from the No. 1 cylinder spark plug. Remove the spark plug from the No. 1 cylinder and press a thumb over the spark plug hole.
  3. Using a wrench on the crankshaft pulley, rotate the crankshaft until pressure is felt at the spark plug hole, indicating the piston is approaching TDC on the compression stroke. Continue rotating the crankshaft until the crankshaft pulley mark aligns with the timing cover indicator.
  4. Position the distributor rotor so it aligns with the No. 1 spark plug wire tower on the distributor cap.
  5. Install the distributor. Align the mark that was made on the distributor housing with the mark that was made on the cylinder block. Loosely tighten the distributor hold-down bolts.
  6. Connect the electrical connectors to their original locations. Install the distributor cap.
  7. Install the spark plug in the No. 1 cylinder and connect the spark plug wire.
  8. Install fresh air duct.
  9. Connect the negative battery cable. Start the engine and check or adjust the ignition timing.
1993-97 626 and MX6 2.5L (KL) Engines

NOTE: The ignition module and coil are both located in the distributor. Disassembly is required to examine or replace the components.

  1. Disconnect the negative battery cable.
  2. Remove the 2 fresh air duct nuts and 3 bolts. Loosen the spring clamp at the front of the air cleaner assembly and slide it forward. Remove the fresh air duct.
  3. Loosen the clamp on the front of the air flow meter and disconnect the air duct. Disconnect the air flow meter electrical connector at the left side of the air cleaner.
  4. Disconnect the evaporative canister hose from the routing clip on the front of the air cleaner. Remove the fuel pressure regulator control solenoid from the air cleaner and position aside.
  5. Remove the nuts and bolt and remove the air cleaner assembly.
  6. Tag and disconnect the spark plug wires from the distributor cap. Disconnect the electrical connectors from the top of the distributor.
  7. Using chalk or paint, mark the position of the distributor housing on the cylinder head. Remove the distributor hold-down bolts and remove the distributor.
  8. To remove the ignition module or coil, remove the bolt from the cap, separate the distributor parts, and replace components as necessary. Reassemble the distributor, making sure that the packing is in position, and tighten the bolt to 27-46 inch lbs. (3-5 Nm).

    To install:

Timing Not Disturbed
  1. Align the distributor shaft with the camshaft end and install the distributor.

    NOTE: The tangs on the distributor shaft are different sizes, allowing the distributor to be installed in only one position.

  2. Install the distributor hold-down bolts. Align the mark that was made on the distributor housing with the mark that was made on the cylinder head and loosely tighten the bolts.
  3. Connect the electrical connectors to the distributor and the spark plug wires to the distributor cap.
  4. Install the air cleaner assembly and tighten the nuts and bolt to 18 ft. lbs. (25 Nm).
  5. Install the fuel pressure regulator solenoid and connect the evaporative canister hose into the routing clip.
  6. Connect the air flow meter electrical connector. Connect the air duct and tighten the clamp.
  7. Align the fresh air duct and install the hose to the air cleaner assembly. Loosen the spring clamp and slide it into position. Install the fresh air duct nuts and bolts and tighten to 71-88 inch lbs. (8-10 Nm).
  8. Connect the negative battery cable. Start the engine, and check or adjust the ignition timing.
Timing Disturbed
  1. Align the distributor shaft with the camshaft end and install the distributor.

    NOTE: The tangs on the distributor shaft are different sizes, allowing the distributor to be installed in only 1 position.

  2. Install the distributor hold-down bolts. Align the mark that was made on the distributor housing with the mark that was made on the cylinder head and loosely tighten the bolts.
  3. Connect the electrical connectors to the distributor and the spark plug wires to the distributor cap.
  4. Install the air cleaner assembly and tighten the nuts and bolt to 18 ft. lbs. (25 Nm).
  5. Install the fuel pressure regulator solenoid and connect the evaporative canister hose into the routing clip.
  6. Connect the air flow meter electrical connector. Connect the air duct and tighten the clamp.
  7. Align the fresh air duct and install the hose to the air cleaner assembly. Loosen the spring clamp and slide it into position. Install the fresh air duct nuts and bolts and tighten to 71-88 inch lbs. (8-10 Nm).
  8. Connect the negative battery cable. Start the engine and check or adjust the ignition timing.
1993-95 929 3.0L (JE-ZE)
  1. Disconnect the negative battery cable.
  2. Turn the crankshaft pulley, in the normal direction of rotation, until the No. 1 cylinder piston is at Top Dead Center (TDC) on the compression stroke. The mark on the crankshaft pulley should be aligned with the T on the timing belt cover.
  3. Label and remove the spark plug wires from the distributor cap. Remove the distributor cap.
  4. Disconnect the wiring harness from the distributor.
  5. Mark the position of the distributor housing on the cylinder head.
  6. Remove the distributor mounting bolt and remove the distributor. Remove and discard the distributor O-ring.

    To install:

Timing Not Disturbed
  1. Apply clean engine oil to a new O-ring and install it on the distributor.
  2. Install the distributor in the cylinder head. Make sure the distributor rotor is pointing toward the No. 1 spark plug tower position on the distributor cap.
  3. Install the distributor mounting bolt. Align the marks made on the distributor housing and cylinder head during removal and loosely tighten the bolts.
  4. Connect the distributor wiring.
  5. Install the distributor cap and secure the screws.
  6. Connect the spark plug wires to the distributor cap in their original locations.
  7. Connect the negative battery cable. Check and adjust the ignition timing.
Timing Disturbed
  1. Disconnect the spark plug wire and remove the spark plug from the No. 1 cylinder. Place a finger over the spark plug hole.
  2. Turn the crankshaft pulley in the normal direction of rotation until compression is felt; the piston is approaching TDC on the compression stroke. Continue rotating the crankshaft pulley until the pulley mark aligns with the T mark on the timing belt cover.
  3. Apply clean engine oil to a new O-ring and install it on the distributor.
  4. Install the distributor in the cylinder head. Make sure the distributor rotor is pointing toward the No. 1 spark plug tower position on the distributor cap.
  5. Install the distributor mounting bolt. Align the marks made on the distributor housing and cylinder head during removal and loosely tighten the bolt.
  6. Connect the distributor wiring.
  7. Install the distributor cap and secure the screws.
  8. Install the spark plug in the No. 1 cylinder and connect the spark plug wire.
  9. Connect the spark plug wires to the distributor cap in their original locations.
  10. Connect the negative battery cable. Check and adjust the ignition timing.
Millenia

NOTE: The ignition module and coil are both located in the distributor. Disassembly is required to examine or replace the components.

  1. Disconnect the negative battery cable.
  2. Tag and disconnect the spark plug wires from the distributor cap. Disconnect the electrical connectors from the top of the distributor.
  3. Using chalk or paint, mark the position of the distributor housing on the cylinder head. Remove the distributor hold-down bolts and remove the distributor.
  4. To remove the ignition module or coil, remove the bolt from the cap, separate the distributor parts, and replace components as necessary. Reassemble the distributor, making sure that the packing is in position, and tighten the bolt to 27-46 inch lbs. (3-5 Nm).

    To install:

Timing Not Disturbed
  1. Align the distributor shaft with the camshaft end and install the distributor.

    NOTE: The tangs on the distributor shaft are different sizes, allowing the distributor to be installed in only one position.

  2. Install the distributor hold-down bolts. Align the mark that was made on the distributor housing with the mark that was made on the cylinder head and tighten the bolts to 14-18 ft. lbs. (19-25 Nm).
  3. Connect the electrical connectors to the distributor and the spark plug wires to the distributor cap.
  4. Connect the negative battery cable. Start the engine, and check or adjust the ignition timing.
Timing Disturbed
  1. Align the distributor shaft with the camshaft end and install the distributor.

    NOTE: The tangs on the distributor shaft are different sizes, allowing the distributor to be installed in only 1 position.

  2. Install the distributor hold-down bolts. Align the mark that was made on the distributor housing with the mark that was made on the cylinder head and tighten the bolts to 14-18 ft. lbs. (19-25 Nm).
  3. Connect the electrical connectors to the distributor and the spark plug wires to the distributor cap.
  4. Connect the negative battery cable. Start the engine and check or adjust the ignition timing.
 
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