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INSTALLATION INSTRUCTIONS

XR-i IGNITIONPOINTS CONVERSION IGNITION SYSTEM

For more information, see www.cranecams.comCAUTION: READ INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.

OVERVIEW TheXR-ielectronicignitionmoduleisdesignedtoreplaceconventionalbreakerpointsonsmallblockChevroletandFordV8engineswithsinglepointdistributors.TheXR-irequiresballastresistancetolimitcoilcurrent.

TheXR-iignitionusesaHallEffectSensortodetectthelobesofthedistributorpointscam.DwelliscontrolledbythebatteryvoltageandengineRPMtoprovidemaximumignition energy and minimum component heating. Themechanicalandvacuumadvancemechanismsworkthesameaswiththeoriginalbreakerpoints.

IGNITION INSPECTION TheXR-i ignition requiresanOEspecificationdistribu-torcapandrotor toavoidclearanceproblemsandarc-ing.Youshouldreplacetherotorandcapwheninstallingthe new ignition system. For best results, you shouldalso replace the spark plugs, plug wires, and ignitioncoil.Carefullyinspectwiringtothecoilandreplaceanywornorfrayedsections.Formaximumperformance,useCranecoilsandFireWiresparkplugwires.

BALLAST RESISTANCE 1. AllvehicleswithOEbreakerpointsignitionarefac-

tory equippedwith ballast resistance.This canbeexternalresistanceintheformofaceramicballastresistor or a resistance wire between the ignitionkey and COIL+ terminal. Most Chevrolet vehicleshavearesistancewire.Ballastresistancecanalso

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be in the form ofinternal resis-tance within thecoil. Coils withinternal resis-tance will mea-sure 3 to 4 ohmsfrom COIL- toCOIL+terminals.

2. If you are chang-ing coils and yourvehicle has a ceramic ballast resistor or resistancewire, do not use any additional ballast resistor thatmaybeprovidedwiththecoil.

3. If yourOE coil had internal resistance and you arechangingtoanewcoilwithlowerresistance(suchasanaftermarketperformancecoil),youmustadda1.2to1.9ohmballastresistor.Ifaresistorisnotsuppliedwith thenewcoil, useaChrysler style two terminalballastresistorsuchasEchlinICR23orWellsCR107.ConnecttheballastresistorbetweentheCOIL+termi-nalandignitionswitch.

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Study the ballast resistance sections carefully. Most installation problems result from improper ballast resistance.

CAUTION: Disconnect the vehicle’s battery ground cable before continuing installation.

Quick Test for Ballast Resistance

You can determine if your vehicle has external ballast resistance with this simple test. Disconnect any wires going to COIL-. Reconnect battery. Turn the ignition key on but do not start the engine. Use a voltmeter as shown in Figure 2 and read voltage between COIL+ terminal and ground. It should be about 12 volts. Then momentarily jumper the COIL- terminal to ground. If voltage at COIL+ terminal drops below 8 volts, there is ballast resistance between the ignition key and COIL+ terminal. To determine if your coil has internal ballast resistance, use an ohm meter as shown in Figure 1. Coils with internal resistance will read 3 to 4 ohms. from COIL- to COIL+ terminals.

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doesnotrotatesmoothly,polishtheinnerdiameterof the top adapter platewithfineemeryclothuntilitdoesrotatesmoothly.

3. Press the four suppliednylon slides into the topplate from the bottomside.

4. Assemble the adapterplates and the centerring.Alignthetwosmallcutoutsinthetopplatewiththemountingholesinthebottomplate.Iftheydonotalign,flipthebottomplateover.

5. Placetheadapterplateassemblyintothedistributorandaligntheholesinthebottomplatewiththeholesinthedistributorbody.

6. Placethelargerringterminalofthejumperwireononeofthesupplied8-32screwswiththeflatsideoftheringterminalfacingawayfromtheheadofthescrew.

GM 8 CYLINDER DISTRIBUTOR 1. RefertoFigure3.Usethesuppliedhardware.Checkthe

orientationoftheadapterbracket,itwillonlyfitoneway.

2. Apply thermalgrease to thebottomsideof theXR-imodule.Installthe6-32hardwarebyhandtosecurethemodule to theadapterplate.Themodulewillbepositionedtoadjusttheairgaplater.

3. Apply thermal grease to the bottom of the adapterplate. Install the module and adapter plate in thelocation that thebreakerpointswere removed from.Firmly tighten the8-32suppliedhardware tosecuretheadapterplatetothedistributor.

4. Route thewiresasshown inFigure4.Besure thatthewiresdonot interferewith the vacuumadvancemechanism.

5. Install the supplied grommet over the wire harnessandinsertintothecableexitofthedistributor.Alubri-cantsuchasWD40 ishelpful in installing thegrom-met. Install the cable clamp as shown in Figure 4usingthesupplied8-32screw.

6. Loosenthe6-32hardwaretoallowtheXR-imoduletoslideontheadapterplate.Pushthemoduleascloseto the points cam as possible without touching thepointscamlobe.Tightenthehardwaretosecurethemoduleinplace.

FORD 8 CYLINDER DISTRIBUTORRemovedistributorfromvehicle.Forddistributorsrequireremovaloforiginalpointsplateassembly.RefertoFigure5toperformthefollowingsteps:

1. Removethee-clipholdingthevacuumlinkagearmtothepointsplatewithasmallscrewdriver.

2. Remove the 2 screws and the vacuummechanismfromthedistributorbodyandsetaside.

3. Carefullyremovethe2screwsholdingthepointsplateassemblytotheinsideofthedistributor.UseWD40orsimilarsolventtolubricatethesescrewtoavoiddam-agetothethreadsinthedistributorbody.

4. Removethepointsplateassemblyfromthedistribu-tor. This assembly should be saved since replace-mentsarenotavailable.

RefertoFigure6toperformthefollowingstepsforinstal-lationoftheadapterplatesandtheXR-iignition:

1. Pressthenyloncenterringintothebottomplateandensureitisfullyseated.

2. Testfit the topadapterplateon thecenter ring. If it

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7. Securetheadapterplateassemblytodistributorwiththe8-32screws,plasticwashers,andaluminumspacersasshown.Itisrecommendedtoapplyathreadlockcom-poundsuchasLocktite™tothescrewbeforeinstallingtheminthedistributor.

8. RoutetheXR-iwireharnessthroughtheholeinthedis-tributorasshown.

9. Installthesuppliedgrommetoverthewireharnessandinsert into the cable exit of the distributor.A lubricantsuchasWD40ishelpfulininstallingthegrommet.

10.Apply thermal grease to the bottom side of the XR-imodule. Install the 6-32 hardware but do not tighten.ThejumperwiremustbeinstalledontheXR-imountingearwiththemetalpad.TheflatsideoftheringterminalshouldcontacttheXR-imountingear.

11.Pushthemoduleasclosetothepointscamaspossiblewithouttouchingthepointscamlobe.Tightenthehard-waretosecurethemoduleinplace.

COMPLETING THE INSTALLATION 1. RefertoFigure7.Connecttheblack/yellowwireofthe

moduletotheCoil-terminalofthecoilwithoneofthering terminals, and connect the other ring terminal totheblack/redwireofthemoduleandconnectthistotheCOIL+terminaloftheCOIL.

2. Doublecheckallconnections.Reconnectthebatteryifyouhavenotalreadydoneso.Momentarilycrankengineandvisuallycheckforclearancearoundallparts.

3. Start your engine and set ignition timing according tomanufacturer’sspecifications.Note:Dwellmeter read-ingsaremeaninglesswithelectronicignitionsandshouldbeignored.

TROUBLESHOOTING TACH INOPERATIVE

1. MosttachsareconnectedtotheCOIL-terminal.Ifthetachisinoperative,traceoutthewire.Refertothevehi-cleservicemanualforfurtherinformation.

2. Ifthetachiserraticorreadshigh,youcanputaresistorinthetachwiretoreducethesignallevel.Startwitha10Kohm1/2watt.Youcangoaslowas1Kohm1/2watt.YoucanbuytheresistorsfromRadioShackorotherelectronicsuppliers. Solder into tachwire andwrapwith electricaltapeforprotection.Iftheresistorfixdoesnothelp,youmayrequireatachadapter.RefertoFigure8.

ENGINE WILL NOT START

1. Pullthehighvoltagecoilwireoutofthedistributorandcon-nectittoatestsparkplugorplacethewire3/8”awayfrom

ground.Cranktheengine.Ifsparksfire,theproblemisinthesecondarysystem.Possiblecauses:rotorleftout,rotor,cap,orsparkplugwiresdefective,ortimingisoff(distribu-torwasmoved,orplugwirefiringorderwaschanged).

2. Iftherearenosparks,connectatestlightbetweenCOIL-(negative)terminalandground.Cranktheengine.Ifthelightflashesonandoff,themoduleisokay,butthecoilmayhavefailed.Tryanothercoil.

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3. Ifthelightdoesnotflash,repeattestinstep2withaknowngoodcoil.Trydisconnecting any wires to COIL-otherthantheblack/yellowwirefromthe Crane module. The only extrawirenormallyconnectedtoCOIL- isthetachwire.Ifthelightstilldoesnotflash,themodulemayhavefailed.

4. Fuel injectedvehiclesonly.The fuelinjection system typically requires atrigger signal from the COIL- termi-nal.Refer tovehicleservicemanualfordetails.

CHECK ELECTRICAL CONNECTIONS

1. Checkgroundconnection.Verifycon-tinuity from the tin plated tab of themoduletochassisground.Ifthereisnocontinuity,removethe6-32screwandlockwasher,cleanwith isopropylalco-hol,andreinstall.

2. CheckvoltageatCOIL+(positive)ter-minalwhilecrankingengine.Readingshouldbeatleast9volts.Iflessthan9volts,checkbatteryandstartersystem.Ifthereadingisclosetozero,checkwiringbackto ignitionswitchandbattery.Someapplica-tionsuseastarterbypass tobypass theballast resistorwhilecranking.Thiswirecomesfromthestartersolenoid,relay,orignitionswitch.Checkyourwiringdiagram.

ROUGH OR INTERMITTENT OPERATION

1. Check for disconnected or cracked vacuum hoses,stuckPCVvalve,orcloggedfuelfilter.Theseproblemsmaycausesymptomssimilartoignitiontrouble.

2. Check electrical connections and optical trigger asexplained in the above sections. Check for loose orcorrodedconnectionsandbrokenwires.Tryadifferentgroundconnectionpointontheengineblockorchassis.Checkdistributorforlooseormisalignedpartsinopticaltriggerassemblyoradvancemechanism.

3. Replacesparkplugs.Checkforproperheatrangeandgapsize.Replacerotor,cap,sparkplugwires,andcoil.

REV LIMIT SETTING

TherevlimitoftheXR-iignitionisintendedtobeusedasasafetyfeaturetopreventenginedamageinoverrevvingsituationssuchasmissedshifts.Thepotentiometerrotates270degreeswithfullcounterclockwisepositionrepresent-ing4000RPMandfullclockwiserepresenting8000RPM.RefertoFigure9belowforadetailedviewoftherevlimitadjuster.TherevlimitinFigure9issetto6000RPM.