with thanks to andy (ineedalager)
Things you will need:
1. (2) water pump gaskets
2. New Opti-spark
3. bucket(s)
4. pliers
5. 5/16" socket or wrench
6. 11/32" socket
7. 9/16" socket AND wrench
8. 10mm socket
9. 13mm socket
10. 16mm wrench
11. breaker bar
12. extensions
13. razorblades
14. screw drivers
15. shop towels
16. Tape and a permanent marker
1.)
First get the car in the air. Get it up high enough to get your bucket or pan under it. Let the car cool down completely.
2.)
Use the 5/16" socket or wrench and remove the negative terminal from the battery.
3.)
Use a screwdriver to remove the air temp sensor, intake ducting, and MAF. Be sure to remove the plug from the back of the MAF before you pull it.
4.)
You should now remove the coil wire, Opti connection (pass side on top), and the water pump coolant sensor connection and wire clips. (front of water pump)
5.)
Under the car now, use the 13mm socket and breaker bar to pull the belt tensioner down and pull the belt off.
6.)
Use a 16mm socket to remove the 3 bolts from your pulley. A impact or breaker bar can really come in handy here.
7.)
Now you can remove the pulley (you may need a 3 toe pulley puller to remove it). I can pull or tap mine off with a hammer.
8.)
*Tip of the day* Save your self some frustration now and turn the crank shaft hub to the position shown. When you go to remove the Opti if one of the hub "arms" is up, you will never get it off.
9.)
Ok time to free up a little more room to work. First take your screwdriver and pop loose the Air pump connector, cooling fan connectors and wire looms.
10.)
Then use your 10mm socket to remove the 4 bolts in each fan. It might be easier to get the top ones from the top.
11.)
Remove the fans and set them aside. Now you should have plenty off room to get to the AIR pump, the bottom of the Opti and water pump.
12.)
(as you can see I already went !AIR) Then take your 10mm socket and remove the 3 screws that hold the AIR pump to the bracket, also remove the 11/32" bolt that holds it to the metal air tubing and remove the pump.
13.)
Now take your tape and permanent marker and label your plug wires. If you look on either side of the Opti it has #'s that correspond to the cylinders.
14.)
Ok, get your bucket and place it under the petcock valve on the passenger side of the radiator. Use pliers to open the valve, but be careful it's plastic and can break. Open the radiator cap and bleed screw by the thermostat housing. Sit back and let it drain.
15.)
Now you can start removing the lower hoses from the water pump and letting them drain. (have some shop towels ready) Do this one at a time, and let each one drain as much as possible, bounce the car if necessary to get out as much coolant as you can. This will save you a huge mess later.
16.)
Remove the upper hoses now, very little coolant should come out if you drained it well. After they are drained pull them back out of the way.
16.)
Use a 9/16" socket to remove the 6 bolts from the water pump. Now beware when doing this coolant will leak, out watch your eyes!
17.)
Now you can remove the Water pump. It maybe stuck on there, so you may have to tug and wiggle it a bit to get it loose. Also watch out for the sleeve on the back of the water pump, don't loose it.
18.)
You can see the sleeve here. (sticking out above the Opti) And now you have free access to the Opti. This is a good time to double check that your plug wires are labeled correctly.
*if you have a vented Opti remove the 2 hoses from the bottom of the Opti now.
19.)
Now remove the wires. Use a 10mm socket to remove the 3 bolts holding the Opti to the timing cover. Slide the Opti out, if you followed my tip from earlier you should be able to slide and twist it right out. You may have to turn the hub a little more one way or the other if it doesn't pop out.
20.)
Now you will want to take a razor blade and scrape off any remaining gasket material off the water pump and where it meets the block.
21.)
Here it the culprit in all it's glory! On the 93-94 style Opti, pay attention to the dowel that is either in the timing cover or on the Opti. There is a notch on the Opti that it lines up with it to reinstall. Make sure the new one goes on flush and it's not misaligned. DO NOT tighten the bolts to pull it on!!
22.)
Now it all goes back on in reverse. Double check all wires and connectors are properly connected. Fill the radiator up with a 50/50 mix of coolant and water. Start the car and let it idle, keeping an eye on the coolant level, open the bled screws until all the air is out of the system. Continue it fill the system to the proper level.
Check for leaks, and get your roll on!
Good Luck!
opti-spark replacement
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- POC Newbie
- Posts: 65
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- Membership No: 88-001
- Year: 1966
- Model: most of them
- Engine: 462
- Name: Robin Gray
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Re: opti-spark replacement
Did you do it then
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