MSD 62153 Installation

MSD DIS-2 Plus HO

PN 62113

DIS-4 Plus HO

PN 62153

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The MSD Digital DIS-2 Plus HO Ignition can be used on 4-cylinder engines equipped with two dual output coils. The DIS-4 Plus HO Ignition can be used on 4, 6 or 8-cylinder engines equipped with up to four dual output coils. The Ignitions will accept trigger inputs from electronic distributorless type ignition systems.

Parts Included:

1 - MSD DIS Ignition 12 - Connectors, Butt Splice 1 - Cable Assembly 1 - Bypass Plug

Parts not included but may be needed:

Ignition Adapter(s) PN 8912, PN 89121, PN 8917 Coil Interface Modules, PN 8870 for GM DIS Applications Coil Interface Modules, PN 8879 for Saturn Applications Cam Sync Adapter, PN 8914 for Saturn Applications

NOTE: It is recommended that you have the Service Manual and wiring diagram for your vehicle

before beginning the installation of the MSD DIS Ignition.

WARNING: Before installing the Ignition, disconnect the battery cables. When disconnecting

the battery cables, always remove the Negative (-) cable ﬁrst and install it last.

NOTES: 1. Solid Core spark plug wires cannot be used with an MSD DIS Ignition.

2. Vehicles originally equipped with a CD ignition cannot use an MSD DIS Ignition.

3. This ignition should be used for RACING ONLY, not for street use.

IMPORTANT

Read these instructions before attempting this installation!

TECHNICAL FEATURES - DIGITAL DIS-2 PLUS HO

Operating Voltage: 12-18 volts (neg. ground) Operating Current: 5.3 Amperes @ 10,000 RPM RPM Capability: 14,000 RPM - 4-Cyl. @ 14 volts Ignition Inputs: 2 - DIS Type Ignition Outputs: 2 - DIS Type LED Indicator: Ign. trigger, low battery voltage Tach Output: (+) 12 volt square wave, 40° Duration Rev Limiter: High RPM - Adjustable Low RPM - Adjustable Spark Duration: 20°- 4-Cyl. Max Sparks - 12 Energy Output Max: 165-175 milliJoules per spark. 2100 milliJoules per sequence. Output Voltage: Primary (Into Coil): 460-480 volts Secondary: (w/stock coil) 43,000 volts Weight & Size: 3 lbs., 9.5"L x 4.5"W x 2.2"H

TECHNICAL FEATURES - DIGITAL DIS-4 PLUS HO

Operating Voltage: 12-18 volts (neg. ground) Operating Current: 10 Amperes @ 10,000 RPM RPM Capability: 14,000 RPM - 4, 6, 8-Cyl. @ 14 volts Ignition Inputs: 2, 3, 4 - DIS Type Ignition Outputs: 2, 3, 4 - DIS Type LED Indicator: Ign. trigger, low battery voltage Tach Output: (+) 12 volt square wave, 40° Duration Rev Limiter: High RPM - Adjustable Low RPM - Adjustable Spark Duration: 20°- 4, 6, 8-Cyl. Max Sparks - 12 Energy Output Max: 165-175 milliJoules per spark. 2100 milliJoules per sequence. Output Voltage: Primary (Into Coil): 460-480 volts Secondary: (w/stock coil) 43,000 volts Weight & Size: 3 lbs., 9.5"L x 4.5"W x 2.2"H

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2 INSTALLATION INSTRUCTIONS

THEORY OF OPERATION

CAPACITIVE DISCHARGE

The MSD Digital DIS Series Ignitions feature a capacitive discharge ignition design. The majority of stock ignitions are inductive ignitions. In an inductive ignition, the coil must store and step up the voltage to maximum strength in between each ﬁring. At higher rpm, since there is less time to charge the coil to full capacity, the voltage falls short of reaching maximum energy which results in a loss of power or top end miss. The MSD Ignition features a capacitor which is quickly charged to 460-480 volts and stores it until the ignition is triggered. With the CD design, the voltage sent to the coil is always at full power even at high rpm.

MULTIPLE SPARKS

The MSD Digital DIS Series Ignition produces full power multiple sparks for each ﬁring of the spark plug. The number of sparks that occur decreases as rpm increases, however the spark series always lasts for 20° of crankshaft rotation. Above 3,000 rpm there is simply not enough time to ﬁre the spark plug more than once, so there is only one powerful spark.

REV LIMITER

The MSD DIS-2 and 4 Ignitions are equipped with a built-in adjustable Soft Touch Rev Control. This rev limit feature can be adjusted in 100 rpm increments using the program switches on the ignition's end panel. The Soft Touch circuitry provides a smooth and accurate rev limit by dropping the spark to individual cylinders. The Soft Touch produces a load-free rev limit that is accurate to within 10 rpm of the selected rpm.

GENERAL INFORMATION

BATTERY

An MSD Digital DIS Series Ignition will operate on any negative ground, 12 volt electrical system without a distributor. The MSD can be used with a 16 volt battery and can withstand a momentary 24 volts in case of a jump start. The ignition will deliver full voltage with a supply of 12 - 18 volts and will operate with a supply voltage as low as 8 volts. If your application does not use an alternator, allow at least 15 amp/hour for every half hour of operation. If the engine is cranked with the same battery or other accessories such as an electric fuel pump, fan or water pump are used, the amp/hour rating of the battery must be increased.

COILS

The MSD Digital DIS Ignitions can be used with most stock coils and most aftermarket coils that are designed to replace the stock coils. If you have any questions concerning coils, contact our MSD Customer Service Department at (915) 855-7123. Due to the increased energy driving the stock coils, this ignition should not be used for street use.

TACHOMETERS/FUEL INJECTION

The MSD Digital Series Ignitions feature a Tach Output Terminal on the side of the unit. This terminal provides a trigger signal for tachometers, fuel injection, a shift light or other add-on devices that require a 12 volt square wave rpm signal with a 20° duration. Some vehicles may require an Ignition Adapter to operate properly with the MSD. For more information on tachometers and MSD Ignition Adapters, refer to page 13.

NOTE: If you plan on welding on your vehicle, to avoid possible damage to the ignition, always

disconnect both MSD Heavy Power cables from the battery. It is also recommended that the tach ground wire be disconnected.

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INSTALLATION INSTRUCTIONS 3

SPARK PLUGS AND WIRES

Spark plug wires are very important to the operation of the DIS Series Ignition. A good quality, helically wound wire and proper routing are required to obtain the best performance from the ignition. MSD recommends using a helically wound suppression type wire such as the MSD 8mm Heli-Core or 8.5mm Super Conductor Spark Plug Wire. This type of wire provides a good path for the spark to follow while keeping Electro Magnetic Interference (EMI) to a minimum. Excessive EMI, such as the amount that is produced by solid core spark plug wires, will interfere with the operation of the MSD or other electronics on the vehicle.

NOTE: Solid Core spark plug wires cannot be used with an MSD Ignition.

Routing: Correct routing of the plug wires is also important to performance. Wires should be routed

away from sharp edges and engine heat sources. If there are two wires that are next to each other in the engine's ﬁring order, the wires should be routed away from each other to avoid inducing a spark into the other wire. To add more heat protection to the wires, MSD offers Pro Heat Guard, PN 3411. This is a glass woven and silicone coated protective sleeve that can be slid over the plug wires. For extra protection to the spark plug boots, MSD also offers Pro-Boot Guard, PN 3412.

Spark Plugs: Choosing the correct spark plug design and heat range is important when trying to get the best performance possible. Since there are so many engine combinations and manufacturers, MSD does not recommend which plug or gap is exactly right for your application. Platinum style spark plugs are not recommended. MSD suggests that you follow the engine builder or manufacturer’s speciﬁcation for spark plugs. With that, you can then experiment with the plug gap to obtain the best performance. The gap of the plugs can be opened in 0.005” increments, then tested until the best performance is obtained. MSD judges the plug gap by compression and other variables. Every application is different and should be tested and tuned.

MOUNTING

The MSD Ignition may be mounted in any location except on the engine or near the exhaust manifold. Excessive heat at these locations may cause damage to the ignition. It is not recommended to mount the unit in an enclosed area such as the glovebox. When selecting a mounting location, make sure the cable harness will reach the battery and coils and the programming dial are accessible. When a suitable location is found, hold the ignition in place and mark the location of the mounting holes. Using a 13/64” drill bit, drill a hole in each of the locations marked and use the supplied hardware screws to mount the ignition unit (Figure 1).

Figure 1 Mounting the DIS Ignition.

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4 INSTALLATION INSTRUCTIONS

WIRING

GENERAL WIRING INFORMATION

Wire Length: All of the wires of the MSD Ignition may be shortened as long as quality connectors are used or soldered in place. To lengthen the wires, use one size bigger gauge wire (12 gauge for the power leads and 16 gauge for all other wires) with proper connections. All connections must be soldered and sealed.

Grounds: A poor ground connection can cause many frustrating problems. When a wire is speciﬁed to go to ground, it should be connected to the battery negative terminal, engine block or chassis. There should always be a ground strap between the engine and the chassis. Always securely connect the ground wire to a clean, paint free metal surface.

ROUTING WIRES

The MSD wires should be routed away from direct heat such as the exhaust manifolds/headers and any sharp edges. The trigger wires should be routed separate from the other wires and spark plug wires. It is best if they are routed along a ground plane such as the block or ﬁrewall as an electrical shield.

Power Leads

These are the two heavy guage wires (14 guage) and are responsible for getting direct battery voltage to the ignition.

Heavy Red

Heavy

This wire connects directly to the battery positive (+) terminal, to a positive battery junction or the positive side of the starter solenoid. NOTE: Do not connect to alternator.

This wire connects to a good ground, either at the battery negative (-) terminal or to the engine.

Black

Red

Connects to a switched 12 volte source, such as the ignition key or switch.

Coil Wires

Brown/ Orange

Brown/ White

Brown/ Green

Brown/ Yellow

Brown/ Violet

There are two Brown/Orange wires. Connects to the positive (+) terminal/wire of the coil. NOTE: This is the only wire that makes electrical contact with coil positive (+).

Connects to the negative (-) terminal/wire of the coil (Channel 1). NOTE: This is the only wire that makes electrical contact with channel 1 coil negative (-).

Connects to the negative (-) terminal/wire of the coil (Channel 2). NOTE: This is the only wire that makes electrical contact with channel 2 coil negative (-).

Connects to the negative (-) terminal/wire of the coil, (Channel 3 available on DIS-4 only). NOTE: This is the only wire that makes electrical contact with channel 3 coil negative (-).

Connects to the negative (-) terminal/wire of the coil, (Channel 4 available on DIS-4 only).

NOTE: This is the only wire that makes electrical contact with channel 4 coil negative (-).

Trigger Wires

There are two or more circuits that can be used to trigger the MSD Ignition; from the electronic ampliﬁer.

White Green Yellow Violet

This wire is used to connect to the electronic ignition ampliﬁer output of channel 1. This wire is used to connect to the electronic ignition ampliﬁer output of channel 2. This wire is used to connect to the electronic ignition ampliﬁer output of channel 3. This wire is used to connect to the electronic ignition ampliﬁer output of channel 4.

Accessory Wires

Brown Blue Pink

Ignition interrupt/theft deterrent. To activate, connect this wire to ground through a switch. Two Step feature. To activate low rpm limit, connect this wire to 12 volts. Step Retard. To activate the step retard connect this wire to 12 volts.

WARNING: High Voltage is present on the coil terminals. Do not touch the coil terminals or wiring when the engine is cranking or running.

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INSTALLATION INSTRUCTIONS 5

WIRING

NOTE: The factory rev limiter and all timing functions will still

function as normal with the MSD Digital DIS-Ignition installed.

1. Locate the ignition coils and identify which wire leading to the coil(s) has 12 volts on it with the ignition key in the On position. If available, refer to the vehicle's service manual wiring diagram to assist you in identifying the 12 volt wire(s).

NOTE: On some vehicles the starter must be engaged to provide

+12 volts to the positive wire leading to the coils. If none of the wires indicate 12 volts, have someone engage the starter while testing each of the wires.

If a service manual is not available, follow this procedure

A. Disconnect all wires leading to the coil(s). NOTE: On some applications it may require that the

harness leading to the coil be cut to access the wires.

B. Turn the ignition switch On. Using a voltmeter, probe each of the wires on the harness to

determine which wire has 12 volts on it. NOTE: Make sure the wires do not contact any engine components.

C. The wire that shows 12 volts is the positive feed to the coil. Turn the ignition switch Off and

connect the DIS Red wires to the harness and the DIS Brown/Orange wires to the positive (+) side of the coil.

D. The remaining wires on the harness are the trigger wires. On a 4-cylinder you should have two,

on a 6-cylinder three, and on a 8-cylinder there should be four. Each of these wires needs to be connected to one of the trigger input wires of the DIS Ignition. Using Figure 3 and 4 as a guide, connect the DIS trigger input and coil (-) wires as follows.

1. Connect the DIS White wire, Channel 1, to the ﬁrst factory trigger wire and then connect the DIS Brown/White Coil (-) wire to the corresponding wire on the coil.

2. Connect the DIS Green wire, Channel 2, to the second factory trigger wire and then connect the DIS Brown/Green Coil (-) wire to the corresponding wire on the coil.

3. Connect the DIS Yellow wire, Channel 3, (available on the DIS-4 only) to the third factory trigger wire and then connect the DIS Brown/Yellow Coil (-) wire to the corresponding wire on the coil.

4. Connect the DIS Violet wire, Channel 4, (available on the DIS-4 only) to the fourth factory trigger wire and then connect the DIS Brown/Violet Coil (-) wire to the corresponding wire on the coil.

Figure 2 Locating 12 Volts at the coil.

IMPORTANT: If you are using the DIS-4 HO on a 4 or 6-cylinder application where all the DIS channels

are not used, you must ground the unused trigger input wires. On a 6-cylinder application, ground the DIS Violet wire and on a 4-cylinder, ground the DIS Violet and Yellow wires.

At this point all the DIS harness wires should be connected. Review your wiring and make any corrections if required. To verify that all wires are connected to their proper locations, plug the supplied bypass plug into the DIS harness and then start the vehicle. If the vehicle does not start then the harness was not installed properly. Check all your connections to ensure that they are secure and connected in the proper order. The only wires that should be connected directly to the coil are the BRN/ORG, BRN/WHT, BRN/GRN, BRN/YEL and the BRN/VIO. Do not hook any other wires to the coil. The Red wires should be connected to a switched 12 volt source, allowing the ignition to be switched On and Off by the vehicles ignition switch.

In most applications, when the vehicle starts, that indicates that the harness is correctly installed. Connect the DIS heavy Red wire to the positive (+) battery terminal and the heavy Black wire to the negative (-) battery terminal. Remove the bypass plug from the harness and plug the DIS Ignition into the harness. Start the vehicle to veriﬁy that all functions are operating.

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