How do I install the ignition module? - Motorcycles

IGNITION SWITCH REPLACEMENT
REMOVAL PROCEDURE
1.Remove the instrument panel (IP) cluster.
2.Remove the knee bolster.
3.Remove the I/P center trim panel.
4.Remove the ignition switch wire harness connector.
5.Remove the theft deterrent control module wire harness connector.
6.Remove the ignition switch lock cylinder.
7.Disconnect the park lock cable at the ignition switch.
8. Remove the ignition switch at the IP screws.
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9. Remove the ignition switch assembly.
10.Remove the ignition switch bracket screws.
11.Remove the theft deterrent control module.
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12.Remove the ignition switch bracket.
INSTALLATION PROCEDURE
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1.Install the ignition switch bracket.
2.Install the theft deterrent control module.
3.Install the ignition switch bracket screws.
NOTE: Refer to Fastener Notice in Service Precautions.
Tighten the screws to 5 Nm (44 lb in).
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4.Install the ignition switch .
5.Tighten the ignition switch screws.
Tighten the screws to 2.5 Nm (22 lb in).
6.Connect the park lock cable at the ignition switch.
7.Install the theft deterrent control module wire harness connector.
S. Install the ignition switch wire harness connector.
9. Install the ignition switch lock cylinder.
10.Install the I P center trim panel.
11.Install the knee bolster.
12.Install the I P cluster.
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take the negative cable off the battery,unplug the plugs relaled to the ignition module.remove the ignition wire from the coils ;remember where they were removed from so that you don't cross the wires. once that you've done that remove each coil and the ignition module will be cler and available for you to remove the screws that holds the module in place. install the new module, be sure to follow all directions and repeat the removable instruction in reverse to install new module.

Sometimes the coil packs are numbered from the factory --- Firing Order 1-6-5-4-3-2
Ignition Coil Removal & Installation To Remove:
Ignition Coils

1. Before servicing the vehicle, refer to the service precautions in the beginning of this section
2. Disconnect the spark plug wires from the coils
3. Remove the fasteners securing the coil(s)
4. Remove the coil(s) from the ignition control module

To Install:

1. Install the coil(s) to the ignition module
2. Install the coil fasteners
   • Torque to 40 in-lbs (4.5 Nm)
3. Connect the spark plug wires to coil assemblies

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Ignition Module Removal & Installation To Remove:
Ignition Coils

1. Before servicing the vehicle, refer to the service precautions in the beginning of this section
2. Turn the ignition OFF
3. Disconnect the 14-way connector from the ignition module
4. Note the position of the spark plug wires and disconnect from the coils
5. Remove the fasteners securing the coil(s)
6. Remove the coils and the Ignition module from the bracket

To Install:

1. Install the coils and the ignition module to the bracket
2. Install the fasteners that retain the ignition coils to the ignition module
   • Torque the fasteners to 40 in-lbs (4.5 Nm)
3. Install the nuts and washers that retain the ignition module to the bracket
   • Torque the screws to 70 in-lbs (8 Nm)
4. Connect the spark plug wires to the coils assemblies
5. Connect the 14-way connector to the ignition module
   • Torque the screw to 19 in-lbs (2.1 Nm)

That sounds like a malfunction with the ignition module inside of the distributor, and you can remove the ignition module and have it tested for free at most auto part stores.

If you do purchase a new ignition module be sure that it does come with a silicone grease or a die-electric compound because it is a heat sink and the ignition module will burn up without it.

To install the new ignition module first clean out the mounting surface inside of the distributor. Then completely coat the metal contact surface under the ignition module with the silicone grease or die-electric compound and do not leave any of the metal contact surface of the ignition module un-coated with the silicone grease or die-electric compound, and be very careful not to over-tighten the ignition module.

That problem is most likely the ignition module inside of the distributor, and you can remove it and have it tested for free at most auto part stores.

The ignition module could also have been damaged by a faulty ignition coil or a damaged distributor cap that allowed secondary voltage to flow over the ignition module, or a shorted pick-up coil inside of the distributor could also have caused the ignition module to malfunction, and in that case you should replace the distributor. (if the ignition module does test out to be alright then the pick-up coil is the next likely culprit)

Be sure that if you purchase a new ignition module that it does come with either a silicone grease, or a die-electric compound, and be very certain that you completely cover the metal mounting contact area under the ignition module with that silicone grease or die-electric compound because it is a heat sink and the ignition module will overheat without it, and be very careful that you do not over-tighten the ignition module or it will be damaged.

Be sure that you also clean off the mounting surface for the ignition module on the inside of the distributor very well before you install the ignition module, and if installing the old module back into the distributor be sure to obtain either silicone grease or a die-electric compound for it.

REMOVAL

1. Disable SIR system. (Refer to "SIR Disable/Enable Procedure (For Frontal and Curtain Inflators)".
2. Disconnect negative battery cable.
3. Remove lock cylinder bezel from steering column shroud by carefully prying with thin blade screwdriver.
4. Remove shroud fasteners and remove steering column upper and lower shroud panels.
5. Insert key into ignition lock cylinder and rotate to RUN position. Then rotate ignition cylinder back to ACC position.
6. Depress locking button on side of ignition module assembly with a thin pick-type tool. Slide lock cylinder assembly from ignition module.

INSTALLATION

IMPORTANT: Actuator blade within ignition module housing must be in ACC position to install lock cylinder assembly. If rotated, replace it to ACC position, using needle nose pliers.

1. Insert key into ignition lock cylinder and install into ignition module.
2. Install steering column upper and lower shrouds and shroud fasteners.
3. Install lock cylinder bezel.
4. Connect negative battery cable.
5. Enable the SIR system. (Refer to "SIR Disable/Enable Procedure (For Frontal and Curtain Inflators)".

Each ignition control module (ICM) has the following circuits:
An ignition 1 voltage circuit A chassis ground An ignition control circuit for each cylinder A low reference circuit
The PCM controls spark by pulsing the ignition control circuits to the ICM to trigger the coils and fire the spark plugs. The PCM and ICM are internally protected against shorts to power and ground on the ignition control circuits.

The spark plugs are connected to each coil by a short boot. The boot contains a spring that conducts the spark energy from the coil to the spark plug. The spark plugs are tipped with platinum for long wear and higher efficiency.


Ignition Control Module (ICM) Connectors



Fig. Ignition coil locations 2001-2004 4.8L, 5.3L, 6.0L Engines



Removal & Installation
2.2L (L61) Engine

1. Turn OFF the ignition.
2. Remove the accelerator cable from the bracket.
3. Remove the accelerator cable bracket bolt.
4. Remove the accelerator cable bracket.
5. Disconnect the ignition control module (ICM) harness connector.
6. Remove the ICM retaining screws.
7. Remove the ICM from the ignition coil housing.
   

To install:

1. Install the ignition control module in the ignition coil housing.
2. Install the ICM retaining screws. Tighten the retaining screws.
3. Connect the ICM harness connector.
4. Install the accelerator cable bracket.
5. Install the accelerator cable bracket bolt. Tighten the retaining screws.
6. Install the accelerator cable to the bracket.

2.2L (Ln2) Engine

1. Remove the air cleaner outlet from the air cleaner.
2. Remove the ICM electrical connectors (1) and spark plug wires (2).
3. Remove the ignition coils bolts (3).
4. Remove the ignition coils and ICM assembly.
5. Installation is the reverse of the removal procedure.
   

2.4L Engine

1. Disconnect the negative battery cable.
2. Remove the accelerator cable from the hold down clip.
3. Remove the cruise control cable, if applicable.
4. Remove the bolt from the fuel line retaining clip.
5. Disconnect the 11-pin harness connector for the ignition control module (ICM).
6. Remove the bolts from the ignition coil and the ICM assembly-to-camshaft housing.
7. Remove the ignition coil and ICM assembly from the engine.
8. Remove the screws that retain the housing to the cover.
9. Disconnect the coil harness connector from the ICM.
   CAUTION When removing the housing from the cover, make sure the ground strap stays in place.
   
10. Remove the housing from the cover.
11. Remove the screws that retain the ICM to the cover.
12. Remove the ICM from the cover.
    
    
    Fig. Removing the ICM from the camshaft cover
    

To install:

CAUTION DO NOT wipe grease from the module or coil if the same module is to be replaced. If a new module is to be installed, a package of silicone grease will be included with the module. Spread the grease on the metal face of the module and on the cover where the module seats. This grease is necessary for module cooling.

1. Install the ICM to the cover.
2. Install the screws that retain the ICM to the cover.
3. Install the ground strap, if necessary.
4. Connect the ignition coils connector to the ICM.
   CAUTION When installing the housing to the cover, make sure the ground strap stays in place.
5. Install the housing to the cover.
6. Install the screws that retain the housing to the cover.
7. Install the spark plug boots and the retainers to the housing, if necessary.
8. Install the ICM assembly to the engine while carefully aligning the spark boots to the spark plug terminals.
   CAUTION The ICM cover bolts must be installed using isolator washers with the rubber side facing down.
   
9. Install the bolts that retain the ICM assembly to the camshaft housing after coating the bolt threads with LOCTITE, or equivalent. Tighten the bolts to 16 ft. lbs. (22 Nm).
10. Connect the ICM 11 pin harness connector.
11. Install the bolt to the fuel line retainer clip.
12. Install the accelerator cable into the hold down clip.
13. Install the cruise control cable, if applicable. Connect the negative battery cable.

Hope this help (remember comment and rated this).

1. Easy job and should have no problems here some help
   Disconnect the negative battery cable.
2. Detach the engine control sensor wiring connector from the ignition control module by pressing down on the locking tab where it is stamped PUSH, and remove the connector.
3. Remove the ignition module and the module bracket from the front fender apron.
4. Unfasten the two ignition module retaining screws, then remove the ignition module form the module bracket.

To install:


Fig. Fig. 2: The ignition module on 1994-95 vehicles is mounted on the front fender apron

1. Install the ignition module onto the module bracket. Tighten the retaining screws to 24-33 inch lbs. (2.7-3.7 Nm).
2. Position the ignition module and bracket assembly onto the front fender apron. Secure with the retaining bolt and tighten to 35-50 inch lbs. (4-5.6 Nm).
3. Attach the engine control sensor wiring connector to the ignition module.
4. Connect the negative battery cable.
   

Unscrew the ignition coil(s) from on top of the module...(leave plug wires attached)....and set aside noting coil position on module....unplug module and replace with a known working module.If there is grease under old module...transfer it to new module.Replace coil(s) and start her up.
TIP. While you are there,why not also change the crank sensor (if it not new).....it is THE trouble maker on these engines.

Removal Procedure

1. Remove all the electrical connectors at the ignition control module.
2. Note position of spark plug wires for installation
3. Remove the spark plug wires from ignition coils.
4. Remove the screws securing coil assemblies to ignition control module.
5. Disconnect coils from ignition control module. Installation Procedure
   
   1. Install the coils to ignition control module.
   2. Install the screws and tighten to 4-5 Nm (36-44 lb. in.) .
   3. Install the fasteners securing assembly to engine and tighten to 8 Nm (70 lb. in.) .
   4. Install the spark plug wires as noted during removal.
   5. Install the electrical connectors to the ignition control module
6. Hope this Helps !