How to install the Kbox distributor rebuild kit?

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How to install the Kbox distributor rebuild kit?

Postby drscam » Mon Jan 12, 2004 12:17 am

posted by ITA-MR2
Well . . ..

To start with, turn the engine to top dead center (always do this to pull the distributor). You do that by making sure the "0" timing mark on the pulley lines up with the marker pin. Then look down in the oil filler hole. You should see a dimple in the intake cam. The dimple should be split by the "straight edge" of the oil filler.

Remove the distributor cap. Then undo the two 12mm bolts that hold the distributor in. Then you unplug the electrical connections and remove the distributor. (It may take a bit of a tug to get it started on the way out.)

You will see the external O-ring on the base of the shaft. It is fairly obvious how to replace it. Just roll it off - then lightly lubricate the new one and roll it back on.

(Note: If you don't lubricate the O-rings, you will have wasted your time, because they will not only be hard to reinsert, but you will damage them, and the new ones will leak as badly as the old ones and then you'll be pissed at Jody for selling a defective product when in fact it was your own damn fault!)

Now - look inside the distributor where the electrical parts and rotor are. Is it oily, or is it nice and clean. If it's nice and clean - skip to the reinstall phase.
.................................

If it is not clean - icky with dirty oil and such - the inner O-ring needs to be replaced. You will need to drill, and then drive out the pin that locates the gear on the shaft. I recommend mounting the distributor in a vise and using a drill bit that is about 1.5 mm smaller in diameter than the pin. Mark the position of the gear on the shaft with a sharpie or a scratch awl. When you have a hole through the center of the pin, or at least about half way through, you can use a drift the size of the pin to drive it out.

Once you get the pin out remove the gear (you marked it, didn't you.) then you are set to pull out the shaft. Hold the diostributor with the cap end facing up (so you pull "up" on the shaft).
Make sure when you pull the shaft out that NOTHING gets disturbed on the top end - those little field pickups are VERY picky about where they are.

Once the shaft is out, you can roll the inner O-ring off, and then lubricate and roll the new one back on. Then CAREFULLY reinsert the shaft into the housing. Once the shaft seats, you can replace the gear (align the marks) and drive the roll pin (provided in the kit) in to hold it in place. You are ready to reinstall it.
.......................................

Make sure the distributor shaft turns freely, and has no excessive free-play. There is a dimple in the distributor shaft (near the pin) and one on the housing. Line those marks up. Holding the rotor stationary (very important), turn the distributor to where the rotor is pointing at the ground. Insert the distributor - and still holding the rotor stationary with respect to the housing slide it in. As you do, it will rotate about 60* clockwise. Again, make sure the rotor doesn't turn with respect to the housing (it will turn with respect to the motor). Once it is in, check to see if the bolt holes line up. If they do, you're almost done. If they don't note how much they are off and pull it out and try agian, adjusting for the amount of error. (Note: If you do this part right, you should have no problem starting the engine and re-timing it. In fact, if you mark base with respect to one of the bolts before you loosen it, and line everything back up right, you shouldn't even have to set the timing.)

When you've done this insert the bolts and tighten them just past finger tight. Reconnect the electrical plugs. Look at the bottom of the distributor cap, there should be another large O-ring around the base - where it sits on the distributor. If there is, replace it - if there isn't put the new one from the kit in there. Then reinstall the distributor cap (or - it might be a good time to think about replacing it).

Start the car. Time it. Torque the distributor hold-down bolts. Clean up the area and close the engine cover. Have a beer. ;)


[quote]posted by kbox
[b]We are changing the solid pin to a spring tension pin to ease the install procedure for customers.

I have the pins in stock, and David (Two's R Us) will have his next week.




If you have any questions, feel free to email Jody (Kbox) directly info@kbox.ca or post.
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Postby Mantle » Mon Jan 12, 2004 12:49 am

Just a note: apparently the "green plug o-ring" is an optional part depending on the year of the car. I had the ring left over after I got the kit installed and asked Jody about it and he said the distributors went through a design change.
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Postby Narfy » Thu Jul 29, 2004 10:45 pm

i believe the bolts that hold the distributor down are 12mm, not 10mm...

the bolts that hold the distributor cap down to the distributor body are 8mm..
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Postby camshaft » Tue Oct 09, 2007 9:35 pm

Revamped

Highly suggest you do with with the engine COLD

Please remember that this is a very important that you be careful with the steps.
As incorrect install of any one of the parts can cause distributor failure. Can cause oil to excessively leak out the housing onto the exhaust cause a fire.
Or cause your car not to start or run incorrectly with incorrect timing.
Or engine damage...

To start with, turn the engine to top dead center (always do this to pull the distributor). You do that by making sure the "0" timing mark on the pulley lines up with the marker pin. Then look down in the oil filler hole. You should see a dimple in the intake cam. The dimple should be split by the "straight edge" of the oil filler.

Remove the distributor cap. Then undo the two 10mm bolts that hold the distributor in. Then you unplug the electrical connections and remove the distributor. (It may take a bit of a tug to get it started on the way out.)
Recommend put a couple rags down as oil will come out of the cylinder head.

You will see the external O-ring on the base of the shaft. It is fairly obvious how to replace it. Just roll it off
Most likely it will just snap because of engine heat. - then lightly lubricate the new one and roll it back on.

(Note: If you don't lubricate the O-rings, you will have wasted your time, because they will not only be hard to reinsert, but you will damage them, and the new ones will leak as badly as the old ones and then you'll be pissed at Jody for selling a defective product when in fact it was your own damn fault!)

Now - look inside the distributor where the electrical parts and rotor are. Is it oily, or is it nice and clean. If it's nice and clean - skip to the reinstall phase.
.................................

If it is not clean - icky with dirty oil and such - the inner seal needs to be replaced. You will need to drill, and then drive out the pin that locates the gear on the shaft. I recommend mounting the distributor in a vise and using a drill bit that is about 1.5 mm smaller in diameter than the pin. Mark the position of the gear on the shaft with a sharpie or a scratch awl. When you have a hole through the center of the pin, or at least about half way through, you can use a drift the size of the pin to drive it out.

Once you get the pin out remove the gear (you marked it, didn't you.) then you are set to pull out the shaft.
You need to measure the distance from the sensor reluctor to the distributor housing. The vertical distance so further on when you reinstall the bearing you know how far it needs to be installed on the shaft.
Looking down into the distributor you should see two metal tabs 180 apart from each other. With one screw holding the tab into the distributor housing. And the other part of the tab sticking out onto the shaft bearing.
Remove these two screws and tabs
Hold the distributor with the cap end facing up (so you pull "up" on the shaft).
Depending on the age of the car and how many km's or hours it has been running will effect it coming apart. Some times the shaft and bearing come out in one unit other times you need to use force. Please remember not to hammer on machined surfaces. If you have to use brass, rubber or wood to stop damage to the item.
Make sure when you pull the shaft out that NOTHING gets disturbed on the top end - those little field pickups are VERY picky about where they are.

At this point you many have the bearing still in the distributor housing or on the distributor shaft.



Once the shaft is out..
You are going to have to find a drift or a long screw driver that you can extract the inner shaft seal. Most times this seal is going to be rock hard and just break off in pieces. Full remove seal and any little pieces left over.
Lube new seal lip area with white grease, rubber grease, assembly lube.
Find a socket or tool that is just smaller then the seals outer edge. And install the new seal down into the distributor housing.

Replace bearing in housing or distributor shaft.. where the bearing is on the shaft is VERY important.

. Then CAREFULLY reinsert the shaft into the housing. Once the shaft
seats,
Reinstall tabs that hold bearing in place
you can replace the gear (align the marks) and drive the roll pin (provided in the kit) in to hold it in place. You are ready to reinstall it.
.......................................

Make sure the distributor shaft turns freely, and has no excessive free-play. There is a dimple in the distributor shaft (near the pin) and one on the housing. Line those marks up. Holding the rotor stationary (very important), turn the distributor to where the rotor is pointing at the ground. Insert the distributor - and still holding the rotor stationary with respect to the housing slide it in. As you do, it will rotate about 60* clockwise. Again, make sure the rotor doesn't turn with respect to the housing (it will turn with respect to the motor). Once it is in, check to see if the bolt holes line up. If they do, you're almost done. If they don't note how much they are off and pull it out and try agian, adjusting for the amount of error. (Note: If you do this part right, you should have no problem starting the engine and re-timing it. In fact, if you mark base with respect to one of the bolts before you loosen it, and line everything back up right, you shouldn't even have to set the timing.)

When you've done this insert the bolts and tighten them just past finger tight. Reconnect the electrical plugs. Look at the bottom of the distributor cap, there should be another large O-ring around the base - where it sits on the distributor. If there is, replace it - if there isn't put the new one from the kit in there. Then reinstall the distributor cap (or - it might be a good time to think about replacing it).

www.bcmr2.com recommends that you have a mechanic install this kit.
This is only a guide and bcmr2.com shall not be held responsible for any damages for DYI installs.
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