My Budget Won’t Buy a Free Lunch!

The continuous refrain we hear is, "I have no budget for equipment". If that is also your problem, HELP IS HERE!

 The first project is a General Motors Distributorless Ignition System. Part Numbers and suggestions for places to purchase will be listed -- try automobile recycling centers first (junk yards to us pre-pc oldsters). Also included will be fabrication drawings for parts you cannot purchase and applicable theory of electricity/electronics to help you understand the operation.

How the parts are mounted and what type of front panel display you have is up to you. In other words, I am going to give you information about the operational parts, etc. and you need to figure out the presentation.

For those of you who do not wish to or can not construct your own trainers, ATech will gladly sell you the very nice unit shown below

Direct Ignition System - Part I

IMPORTANT!!
All moving parts and high voltage areas should be shielded to prevent student contact.

The system we are going to build is a Direct Ignition System for these vehicles:

A good reference book for this system is available from General Motors STG as book #16020.05-3. It can be ordered through the General Motors Training Materials catalog.

Automotive parts that you will need to purchase from either a salvage yard, aftermarket dealer, or automotive dealership are:

Description, Part Number

• Four Cylinder Coil/Module Assy, D1927A

• Motor (Blower), 15-8110

• Plug Wire 16 in., 312F

• Plug Wire 18 in., 312G

• Plug Wire 22 in., 312J

• Plug Wire 26 in., 312M

• DIS Sensor, 213-148

• DIS Coil (Qty 2), D555

• Module Shield, 1989812

• Module Mounting Plate, 10496151

• Coil Screws (4 pk), 10498731

• Spark Plugs, R45TS

• Seal (part of D1927A), 1989579

• DIS Sensor Harness (Car Dealer Item), 10486180

Electronic Parts you will need to purchase, most are available at Radio Shack:

• 6 Amp Toggle Switch, 757-4888 (Allied Elect)

• 2N3055 Transistor, 858-7389 (Allied)

• Transistor Mica Insulator, 4651 (Allied)

• Transistor Heat Sink, HS110-3-ND (Digikey)

• 500 ohm Potentiometer, 753-1340 (Allied)

The Reluctor Trigger Wheel Assembly drawing is illustrated below. The dimensions, etc. are not critical and most school level machine-shops can manufacture the part. This rotating part should be shielded after assembly.

Reluctor Trigger Wheel Assembly

The Spark Plug "Rail" Assembly drawing is illustrated below. This is the appropriate size "rail" for the spark plugs listed in the parts list. If you are going to use different spark plugs, adjust the hole sizes accordingly.
IMPORTANT!!
Be sure to ground the spark plug "rail" to the system ground.

Spark Plug "Rail"