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SERIES 50 WASTE WIRE HARNESS

The waste wire harness completes the high voltage electrical circuit for each ignition coil by grounding the towers that would otherwise be the waste spark side of an automotive DIS ignition system. The harness is subject to the same damage from contamination, abrasions on the insulation, and mishandling as the ignition wires. ‪

NOTICE:

Do not allow the spark plug wires to contact any engine or vehicle component which would cause rubbing on the insulation during engine operation. Contact with engine or vehicle can cause damage to the spark plug wires. ‪

NOTICE:

Do not allow spark wires to kink during handling. Kinking of spark plug wires can cause damage. ‪

NOTICE:

Do not allow spark plug boot or spark plug wire to come in contact with engine oil. Exposure to engine oil can cause damage. ‪

Removal of Waste Wire Harness

Remove the waste wire harness as follows: ‪

  1. Pull the waste wire harness connectors from the ignition coil at the coil towers.
  2. Remove the M8 x 1.25 x 14 bolt holding the harness terminal to the cylinder head.
  3. Inspect the waste wire harness. Refer to Section .
Inspection of Waste Wire Harness

Inspect the waste wire harness as follows: ‪

  1. Visually check the waste wire harness for cracks in the insulation or areas where the insulation has been damaged.
    1. If damage is found, replace as necessary.
    2. If no damage is found, reuse the waste wire harness.
  2. Visually check the waste wire harness for dirt, debris, and engine oil.
    1. If contamination is found, clean as necessary and apply a light coat of dielectric grease to the inside of the ignition wire connector. Refer to Section .
    2. If no contamination is found, reuse the waste wire harness and apply a light coat of dielectric grease to the inside of each waste wire connector. Refer to Section .

Installation of Waste Wire Harness

Install the waste wire harness as follows: ‪

  1. Press the waste wire harness connectors on the coil towers corresponding to the letter "G" (indicating a ground position). Install the longest lead of the harness on the left most ground wire, and the remaining leads in order of their length.
  2. Attach the waste wire terminal to the cylinder head with the M8 x 1.25 x 14 bolt. Include the ignition wire bracket if the right side ignition wire routing is used in this installation. Torque the M8 bolt to 30-38 Nm (22-28 lbft).