ACCEL 120328 Distributor Cap Instruction Manual

1. Product Overview

The ACCEL 120328 Distributor Cap is a performance replacement component engineered for 3.9L V6 Dodge Magnum engines. It is designed to provide an impenetrable barrier against arc-through and crossfire, ensuring optimal ignition performance.

Key features of this distributor cap include:

• Engineered specifically for 3.9L V6 Dodge Magnum engines.
• Delivers unrestricted spark energy flow, maximum energy transfer, and more power.
• Prevents arc-through and crossfire.
• Stress-relieved immediately after molding to ensure dimensional stability.
• Features highly conductive, corrosion-resistant brass inserts and stainless steel rotor springs.

Figure 1: Front view of the ACCEL 120328 Distributor Cap, showcasing its black housing and brass terminals.

2. Specifications

3. Setup and Installation

Proper installation of the distributor cap is crucial for engine performance and safety. If you are unsure about any step, consult a qualified automotive technician.

Required Tools:

• Screwdriver (Phillips or flathead, depending on cap screws)
• Wrench (if bolts are used)
• Dielectric grease (optional, for spark plug wire boots)
• Marker or tape (for labeling spark plug wires)

Installation Steps:

1. Safety First: Ensure the engine is off and cool. Disconnect the negative terminal of the vehicle's battery to prevent accidental starting or electrical shorts.
2. Identify and Label Wires: Before removing any components, carefully label each spark plug wire with its corresponding cylinder number. This is critical for correct reinstallation and proper engine firing order. You can use tape and a marker for this.
3. Remove Old Cap and Wires: Disconnect the spark plug wires from the old distributor cap. Then, unfasten the retaining clips or screws that hold the old distributor cap in place and carefully remove it.
4. Inspect Rotor: While the cap is off, inspect the distributor rotor for wear, cracks, or carbon buildup. Replace the rotor if necessary (rotor not included with this cap).
5. Install New Cap: Position the new ACCEL 120328 Distributor Cap onto the distributor housing, ensuring it seats correctly. The cap is designed to fit in only one orientation. Secure it with the retaining clips or screws. Do not overtighten.
6. Connect Spark Plug Wires: Reconnect the spark plug wires to the new distributor cap according to the labels you made in Step 2. Ensure each wire clicks securely into place. A small amount of dielectric grease can be applied inside the boots for easier installation and moisture protection.
7. Reconnect Battery: Reconnect the negative battery terminal.
8. Test Engine: Start the engine and listen for any misfires or unusual noises. If the engine runs rough, recheck the spark plug wire connections and firing order.

Figure 2: Interior view of the ACCEL 120328 Distributor Cap, showing the brass contacts and internal structure.

4. Operation

The distributor cap is a critical component of a vehicle's ignition system. Its primary function is to distribute high voltage from the ignition coil to the correct spark plug at the precise moment for combustion.

• The central terminal of the distributor cap receives high voltage from the ignition coil via the coil wire.
• Inside the cap, a rotor (not included with this cap) spins, making contact with the brass terminals for each cylinder.
• As the rotor aligns with a terminal, the high voltage is directed through that terminal and its corresponding spark plug wire to the spark plug, creating a spark that ignites the air-fuel mixture in the cylinder.
• The ACCEL 120328 cap's design, with brass inserts and stainless steel rotor springs, ensures efficient and consistent spark energy transfer, contributing to optimal engine performance.

Figure 3: Top view of the ACCEL 120328 Distributor Cap, showing the arrangement of the spark plug wire terminals.

5. Maintenance

Regular inspection and maintenance of your ignition system components, including the distributor cap, can help ensure reliable engine operation.

• Visual Inspection: Periodically inspect the distributor cap for cracks, carbon tracks (burn marks), corrosion on terminals, or excessive wear. These can indicate a failing cap.
• Cleanliness: Keep the exterior of the distributor cap clean and free from oil, dirt, and moisture. Contaminants can create paths for spark energy to escape, leading to misfires.
• Spark Plug Wires: Ensure spark plug wires are securely connected and free from damage. Damaged wires can lead to poor performance and premature cap wear.
• Rotor Inspection: When inspecting the cap, also check the rotor for wear or damage. A worn rotor can cause misfires.
• Replacement Interval: Follow your vehicle manufacturer's recommended service intervals for ignition components. While this is a performance part, regular checks are still advised.

Figure 4: Side view of the ACCEL 120328 Distributor Cap, showing the overall shape and terminal placement.

6. Troubleshooting

If you experience issues after installing the ACCEL 120328 Distributor Cap, consider the following common troubleshooting steps:

• Engine Misfires or Rough Idling:
  • Check Wire Order: The most common cause is incorrect spark plug wire routing. Double-check that each wire is connected to the correct terminal on the cap and the correct spark plug on the engine, following the vehicle's firing order.
  • Secure Connections: Ensure all spark plug wires are fully seated on both the cap and the spark plugs.
  • Damaged Wires: Inspect spark plug wires for cuts, cracks, or signs of arcing. Replace any damaged wires.
• No Start Condition:
  • Cap Seating: Verify the distributor cap is fully seated and secured to the distributor housing.
  • Rotor Position: Ensure the rotor is correctly installed and not damaged.
  • Coil Wire: Check that the coil wire is securely connected to the center terminal of the distributor cap and the ignition coil.
• Visible Arcing or Spark Leakage:
  • Cracked Cap: Although unlikely with a new cap, inspect for any hairline cracks that could allow spark to escape.
  • Moisture/Contaminants: Ensure the cap and surrounding area are dry and clean.

7. Warranty and Support

For specific warranty information regarding your ACCEL 120328 Distributor Cap, please refer to the documentation provided with your purchase or visit the official ACCEL website. Warranty terms and conditions may vary.

If you require technical assistance or have questions about the product, please contact ACCEL customer support through their official channels.

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