Mallory Ignition 8136 User Manual

FORM INS-59125 (Rev A) 01/12

INSTALLATION INSTRUCTIONS

ULTRA OPTI-SPARK II DISTRIBUTOR P/N 59125

ULTRA OPTI-SPARK II CAP & ROTOR KIT P/N 8136

GENERAL

First make sure your vehicle is equipped with an
Opti-Spark II type (pin drive – with positive vent
system) distributor. It is not necessary to remove
the distributor from the engine to determine if it is an
Opti-Spark II or not. Simply look for the intake
manifold vacuum hose line and air intake hose line
running to the distributor. The older Opti-Spark I
distributors are not vented and do not have these hose
connections. If the distributor is removed from the
engine, the Opti-Spark II unit will have a

non-splined pin shaft.

REMOVING/INSTALLING NEW OPTI-SPARK II
DISTRIBUTOR

NOTE: It is best to have a vehicle service manual for

detailed reference on removal and installation of
sensor and accessories.

1. Disconnect the negative side of the battery.

2. Drain coolant from cooling system.

3. Disconnect the mass air flow (MAF) and the intake air
temperature (IAT) sensors. Next, remove the air intake
elbow.

4. Remove upper radiator hose.

5. Remove serpentine belt. Remove the belt tensioner.

6. If necessary remove the cooling fans.

7. Remove the crankshaft pulley. Note: a balancer

removal tool may be required.

8. Position the crankshaft hub as in Figure 4

9. Disconnect and remove the air pump wires and hose’s
then remove the air pump.

10. Remove the air pump mounting bracket.

11. Disconnect the coolant temperature sensor (ECT) wire

harness from the water pump.

12. Remove the lower radiator and heater hoses from the

water pump.

13. Remove the water pump.

14. Be sure to mark the location of the spark plug wires

and then remove.

15. Remove vacuum lines and wire harness and coil wire

from existing Opt-Spark II.

16. Remove the 3 bolts holding the Opti-Spark II to the

engine.

17. Once the old distributor is removed, make sure that
both the old pin shaft drive seals are still in place on
the pin shaft drive assembly on the back side of the
distributor. If not, remove the seals from inside the
end of the cam shaft.

18. Important: DO NOT lube Opti-Spark hub or

timing cover seal, the seal MUST be installed dry
or it will leak oil.

19. When installing the ACCEL Ultra Opti-Spark II, be sure
to use the correct index on the pin drive shaft. See
Figures 1 & 2. This index is the only location that the
dowel pin on the camshaft
properly seats into.

20. Note: You will notice that if the correct index is not
used that the distributor will not seat properly and
rock against the engine see Figure 3.

DO NOT tighten the bolts down. Remove the ACCEL
Ultra Opti-Spark II and reinstall using the
correct index. Refer to Figures 1 & 2.

21. DO NOT force the electrical connector in. If

you have difficulties seating the connector remove
the connector and check the pins in the Opti­spark. If they are bent you can use a long flat
blade screwdriver and gently straighten the pins.

22. Reinstall accessories and sensors in reverse order to
complete installation.

NOTE: It is best to have a vehicle service manual for
detailed reference on removal and installation of sensor
and accessories.

REMOVING/INSTALLING NEW OPTI-SPARK II
CAP & ROTOR

Refer to the REMOVING/INSTALLING NEW
OPTI-SPARK II DISTRIBUTOR

1. Instructions above or a vehicle service manual for

instructions to provide access to the Opt-Spark II
distributor. Note: it is very easy to change the cap
and rotor with the Opti-spark unit on a work bench.
It can be done in the vehicle but will be very difficult.

2. Remove the 4 distributor cap retaining screws using

an E4 Reverse Torx socket.

ACCEL IGNITION www.accel-ignition.com

1

3. Carefully remove the distributor cap.

4. Remove the two rotor retaining screws using a T-8 Torx
socket and carefully remove the rotor. Make sure the
Stainless Steel trigger wheel is properly located on the
alignment pin.

5. Install the new rotor by first aligning the locator pin on the
bottom of the rotor with the mating hole in the distributor
hub assembly. Install the two new rotor retaining screws
and tighten to 6in/lbs to torque.

6. Make sure the new top seal is positioned correctly on the
cover assembly. The notch seats over top of the electrical
connector area.

7. Install the new distributor cap. Install the four new
distributor cap screws and tighten to 24in/lbs.

8. Reinstall the spark plug and coil leads along with the

vacuum line onto the distributor cap. Reinstall the wire
harness connector to the distributor.

9. Reinstall accessories and sensors in reverse order to
complete installation.

Align the Opti-Spark drive slot
with the camshaft drive pin

FIGURE 1

WARNING: Do NOT tighten the mounting
bolts if there is a gap between the
Opti-Spark and the timing cover

Align the camshaft dowel pin in this
slot only

FIGURE 2

Crankshaft hub positioning for
removal of the Opti-spark unit

Remove the Opti­Spark and realign the
drive hub with the
camshaft pin.

FIGURE 3

ACCEL IS A TRADEMARK OF PRESTOLITE PERFORMANCE
10601 MEMPHIS AVE. #12, CLEVELAND, OH 44144

216.688.8300 FAX [phone]

2 www.accel-ignition.com

FIGURE 4

FORM INS-59125

(Rev A) 01/12