Installation Instructions

Original distributor, coil, and plug wires- old, inefficient 70s technology.

Your PinzSSI kit will contain these items.

Packing List

Coil/Relay assemblyMounting L bracketSpark Plugs (4)Spark Plug Wires (4)Module¼” Wire loom (6’)Manual/Parts CDParts packagePrinted InstructionsSpark Plug Wire Spacers

Parts package includes:1.Butt sleeves (6)2.Spade connectors (6)3.Boot grease4.Vacuum plug5.Heat shrink6.Colored wire for battery7. Battery connector (red or black)8. Cable ties

Be sure to use the correct tool for crimping the butt sleeves and spade connectors.Otherwise, the connection may eventually fail. Don’t use pliers. This is very important! Use heat shrink on all connections.

This heat gun and crimping tool can both be purchased at Harbor Freight Toolsif you want to properly install connectors and heat shrink. Around $21 total.

Crimp here

The heart of the system is the wiring harness and power module, which arepermanently connected.

Begin by removing the coil and bracket, suppressor, and distributor. Cut off the ignition power source wire at the suppressor connection.

Cut ignition feed here

Remove spark plugs and wires. Remove vacuum line and block the port with the provided plug. Remove the pinch clamp from the distributor and save for use on the new ignition module.

Plug vacuum port

Remove the bolt near the top of the driver’s side coil spring. This holds the heater hose clamp in place as shown.

Using the longer provided bolt, install the mounting L-bracket.

Bolt the coil/relay pack onto the mounting L-bracket using the providednut, washers, and bolt.

It is important to line up the notches correctly before installing the module in block.The small spring should be visible inside the block. The pinch clamp should be inplace and the module shaft should be lightly oiled. When the module is fully seated,install the 13 mm bolt and tighten. The module can then be rotated to preference.

Connect the yellow wire from the harness to the white 24v ignition wire that was cut off earlier. Install heat shrink. Route over the engine. Work the slack towards the coil/relay pack. Secure the wiring into place using wire ties.Connect the black wire to the chassis, using the screw that holds the Molex connector tothe alternator for example.

Yellow ignition wire

24v ignition wire splice

Connectground

Route the harness over the top of the engine in the vicinity of wherethe spark plug wires used to run, and secure with wire ties. On the driver’s side, tie to the vacuum line and keep clear of the throttle rod.

Harness

Route the power feed from the battery box by either 1) using the existing hole as shownor 2) drilling a hole. The photo shows using the existing hole (from under the vehicle), thesame hole that the other battery cables use. The fit is tight! Leave enough slack to reachthe battery terminal as shown, but do not connect at this time. The PinzSSI system workson 12 volts. Be sure to verify voltage as there are several possible battery configurations. The photo shown is just one possibility, which reflects the original factory set-up.Do not use the ignition switch wire to power the module. This will damage the module andvoid the warranty! The 24 volts from the ignition powers the relay solenoid only.Use provided wire loom to cover the all wire after installation.

12 volt feed

Battery box hole

At the relay make the following 3 connections- 1) 24 volt feed from the ignitionswitch, 2) 12 volt feed from the battery, and 3) 12 volt feed to the new harness (red).Leave the harness unplugged from the coil pack until after the timing is set!

1) 24 volt ignition feed (yellow)2) 12 volt feedfrom the battery

3) 12 volt feed to the new harness (red)This also feeds tach voltage if applicable.

Reconnect the battery with the new power feed. Be sure it is a 12 connection!The red or black battery connector can connect to either battery post that the large jumper wire connects to.

Jumper wire

Here is a simple schematic of the interconnections between the battery, relay, ignition key, and the new wiring harness.The module draws just 660 mA, not enough to interfere with the charging system or shorten the life of either battery. Note- 24v to 12v DC converters have been tested to replace the battery 12v connection. All converters failed except for the more expensive versions,as they do not produce a smooth enough voltage for the module to operate.

The module is a computer which takes readings from the optical sensor and sends the info to the CPU. This includes RPM and rate of engine acceleration/deceleration. The CPU adjuststhe ignition timing based on the input information.The timing is 0 degrees BTDC while the engine cranks, and jumps to normal advance at about300 RPM. From there the maximum total advance reaches 38 degrees at about 3500 RPM.It is important to set the static timing (timing set with engine not running) at 0 degrees, orTDC, because this is the reference point that the computer uses for the rest of the curve.The spark plugs fire 3 times every time the piston is at TDC, which is why you can set thetiming at either the compression or exhaust stroke. Unlike other ignition systems that must fire at the top of the compression stroke, the PinzSSI fires every time. Plugs in cylinders 1 and 4 fire simultaneously, cylinders 2 and 3 do the same. In fact, one plug is actually the return path for the other, with the engine block acting as the electrical path!

This schematic shows thepath that voltage takes to jump 2 plugs every time that pistons are at TDC in cylinders1-4 and 2-3. Each plugfires 3 times to ensurecomplete combustion.The firing order is normally1-2-4-3 every 720 degreesof crankshaft revolution using the stock Bosch system. With PinzSSI, the plug firing alternates between cylinders 1-4 and 2-3 every 180 degreesof crankshaft revolution.

This is a typical 4-cylinder OHC engine. The 1 and 4 pistons are at TDC while pistons 2 and 3 are at BDC. This design keeps vibration to a minimum.If this were a Pinzgauer engine, the plugs in 1 and 4 cylinders would be firing,regardless of which cylinder is at the beginning the of the power stroke.

The optical pickup should be towards the rear of the vehicle, the harness should be towards the front. The #1 cylinder timing mark and the red timing LED are indicated by arrows. The timing disc rotates clockwise when the engine is running. LED location and appearance may vary! The physical rotational position of the module can vary due to preference.Note- When setting the timing, your only concern is lining up the pulley notch correctly. Donot be concerned which cylinder you are on, as the notch placement is based on the #1 pistonposition at TDC on either the compression OR exhaust stroke. This photo shows the modulebefore it has been rotated to the final position.

#1 timing markRed timing LED

Optical pickup

Begin by rotating the engine CW using a 27mm socket on the fan nut until the timing mark on the pulley lines up with the pointer, which is at 0 degrees (or TDC). Turn on the key. Loosen the screw that holds the slotted disc, and rotate the disc until the red LED turns on. Tighten the screw, but do not over-tighten. Rotate the engine twice until the pointer and mark on the pulley line up again, the red light should come on. If it doesn’t, slowly rotate the module until the red LED lights. Snug the pinch clamp, and rotate the engine 2 times again until the pulley mark arrives again at TDC. The LED should light. If it doesn’t, adjust again, being careful not to rotate the engine backwards. Repeat this process until you can rotate the engine twice with the LED lighting at the correct position of TDC. Tighten pinch clamp and plug the harness into the coil pack. Turn the key off for now, the timing is set.

Here is another view of the pointer lining up with the notch on the pulley,but at a slight angle. It does not matter if the piston is at TDC of the exhaustor compression stroke when setting the timing. Cylinders 1 and 4 are at TDC.

Install the spark plugs (.032” gap) and torque. Grease plug wire boots and install the wires.The corresponding cylinder numbers are on the coil pack, and the wires are cut to specific lengths for the intended plugs. #1 wire is shortest, #2 is second, etc. Install wire spacers that keep the wires apart and away from metal. Run the engine for a minute, and re-check the timing with harness plug disconnected. If the timing is correct, you are done-plug it back in. The new PinzSSI ignition system is ready for a road test!

Cylinder number (4)

#4 cyl.

Longest wire

Grounding jumper

Grounding screw

Testing jumper

There is a possibility that the relay may not work properly due to improperlygrounding of the coil pack plate. It is recommended that a grounding jumperbe connected to a new grounding screw that has been installed on the chassis. Totest for this, run a testing jumper from the relay screw to the engine with the keyon. If the relay clicks when this temporary connection is made, install a groundingjumper. It is recommended that this be done anyway to prevent future problems.

Troubleshooting the PinzSSI is easy. All voltage checks are made at the relay.1- Voltage should always be 12 volts. Check battery connection if it is 0.2- Voltage should be 0 with the key off, 12 volts with the key on.3- Voltage should be 0 with the key off, 24 volts with the key on.4- Ground terminal for the relay. If you get 0 volts at 2 and 3 with the keyon, push the test button on the relay, which is below the 1 and 2 terminals.If this results in voltage at 2/3, then 4 is not grounding to the chassis properly.Run a permanent jumper from 4 to the vehicle frame for a better ground.

12

3

4

CAUTION NGK BPR6ES resistor spark plugs included with the kit MUST be used at all times, along with resistor plug wires. Always replace the spark plugs/wires with the same resistor type. Failure to do so could damage the module or result in poor performance. Or both!

Replacement wires need to be 800 ohms/ft. PinzSSI has individual replacement wires in stock. Also, never crank the engine with any spark plug wires disconnected, unless you have the harness unplugged from the ignition coil pack. Failure to do so could also damage the ignition coil/module.

Questions? Comments? Need parts? Then contact us at www.pinzssi.com or call 760-775-5160. We promptly return all calls if you leave a message.