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SERIES 50 REMOTE MOUNT IGNITION COILS

Series 50G engines produced prior to July 1996 used remote mount ignition coils. This system consists of a coil bracket, two coil packs, an ignition wire harness, an ignition wire bracket, a waste spark harness, an ignition coil harness, and four spark plugs. Each coil mounts to coil bracket by three 1/4 20 x 2.5 in. screws. The coil bracket mounts to the cylinder head by two M12 x 1.75 x 30 metric bolts. See Figure 27336 . ‪

1. Nut ‪

5. Right Coil Label ‪

2. Lockwasher (1/4) ‪

6. Ignition Coil Pack (2) ‪

3. Ignition Coil Mounting Bracket ‪

7. Bolts (1/4 20 x 2.5 in.) ‪

4. Left Coil Label ‪

8. Bolt (M12 x 1.75 x 30 in.) ‪

Remote Mount Ignition Coils

Removal of Ignition Coil Bracket

Remove the ignition coil bracket as follows: ‪

  1. Unplug the ignition wire harness connectors from the ignition coil packs.
  2. Unplug the waste wire harness connectors from the ignition coil packs.
  3. Disconnect the ignition coil harness from the ignition coil packs.
  4. Remove the two M12 x 1.75 x 30 mounting bolts.
  5. Inspect the coil bracket. Refer to Section .
Inspection of Coil Bracket

Inspect the coil assembly as follows: ‪

  1. Visually check the coils for damage.
    1. If damage is found. replace coils as necessary. Refer to Section .
    2. If no damage is found, reuse the coils. Refer to Section .
  2. Visually check the coil towers and electrical connectors for dirt, debris, and oil.
    1. If contamination is found, clean as necessary and apply a light film of dielectric grease on the inside lip of each ignition wire and waste gate wire connector. Reuse component. Refer to Section .
    2. If no contamination is found, reuse and apply a light film of dielectric grease on the inside lip of each ignition wire and waste gate wire connector. Reuse component. Refer to Section .
  3. Visually check the coil bracket for damage.
    1. If damage is found, replace the bracket. Refer to Section .
    2. If no damage is found, reuse the bracket. Refer to Section .

Installation of Coil Brackets

Install the coil bracket as follows: ‪

  1. Install the bracket to the cylinder head with two M12 x 1.75 x 30 mounting bolts. Torque to 100-126 Nm (74-93 lbft). See Figure 27336 .
  2. Press the ignition wire harness connectors on the coil towers corresponding to the cylinder positions indicated on the label. See Figure 27337 .

    1. Left Label ‪

    3. Right Label ‪

    2. Ignition Coil Packs ‪

    4. Coil Towers ‪

    Ignition Coil Pack Label Location

    Note: Ensure that each connector is fully seated on the coil tower.

  3. Press the waste wire harness connectors on the coil towers corresponding to the letter "G" (indicating a ground position). Position the longest lead of the harness on the left most ground tower, and the remaining leads in order of their length.
  4. Press the ignition coil harness into the connectors in the ignition coil packs.

Removal of Ignition Coil Pack

Remove the ignition coil pack as follows: ‪

  1. Remove the ignition coil bracket. Refer to Section .
  2. Remove the three 1/4 20 x 2.5 in. bolts, nuts, and lockwashers per ignition coil packs.
Cleaning of Coil Packs

Clean the coil packs as follows: ‪

  1. Remove dirt, debris, and oil using clean fuel oil.

    EYE INJURY

    To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 40 psi (276 kPa) air pressure.

  2. Dry parts with compressed air.
  3. Inspect the coil packs. Refer to Section .
Inspection of Coil Pack

Inspect the coil packs as follows: ‪

  1. Visually check the coil packs for damage.
    1. If damage is found, replace as necessary. Refer to Section .
    2. If no damage is found, reuse the coil packs. Refer to Section .

Installation of Coil Packs

Install coil packs as follows: ‪

  1. Apply a light film of dielectric grease on the mounting face of the coil pack.
  2. Install the ignition coil pack on the coil bracket with three 1/4 20 x 2.5 in. bolts, nuts, and lockwashers per coil pack. Torque bolts to 9-12 Nm (7-9 lbft).
  3. Install the coil bracket to the cylinder head. Refer to Section .

    Note: If a new ignition coil pack is being installed. Attach either a left or right label on the new coil pack corresponding to the position of the coil pack on the engine. See Figure 27337 .

    1. Left Label ‪

    3. Right Label ‪

    2. Ignition Coil Packs ‪

    4. Coil Towers ‪

    Ignition Coil Pack Label Location