1. Introduction
This instruction manual provides detailed guidance for the proper installation, operation, and maintenance of your Pertronix D1202 Flame-Thrower HEI Distributor. Please read this manual thoroughly before attempting installation or operation to ensure optimal performance and safety. This distributor is designed to provide a high-energy ignition system for Pontiac Small Block and Big Block engines, enhancing spark delivery and combustion efficiency.
2. Safety Information
Always prioritize safety when working on automotive systems. Failure to follow these safety guidelines may result in personal injury or damage to the vehicle.
- Disconnect the vehicle's battery before beginning any installation or maintenance procedures to prevent electrical shock or accidental engine cranking.
- Wear appropriate personal protective equipment, including safety glasses and gloves.
- Ensure the engine is cool before working on ignition components.
- Keep all ignition components away from flammable materials.
- Consult a qualified automotive technician if you are unsure about any part of the installation process.
Proposition 65 Warning: This product may contain chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.
3. Package Contents
Verify that all components are present before beginning installation:
- Pertronix Flame-Thrower Street / Strip HEI Distributor (D1202)
4. Product Overview
The Pertronix D1202 Flame-Thrower HEI Distributor is engineered for enhanced ignition performance in Pontiac Small Block and Big Block engines. It features a robust design and advanced internal components to deliver a powerful and consistent spark.
Image 1: Pertronix D1202 Flame-Thrower HEI Distributor with blue cap. This image displays the complete distributor assembly, including the blue cap, aluminum housing, and drive gear.
Key features of this distributor include:
- New Lightweight Aluminum Alloy Housing: Provides durability and reduces overall weight.
- Aligned and Honed High Quality Bronze Sintered Bushings: Designed for reduced friction and extended operational life.
- Centerless Ground Corrosion Resistant Shaft: Ensures smooth, concentric operation and resistance to corrosion.
- Distributor Gear Ground to Exact Tolerances: Promotes a tighter mesh with the camshaft for reliable performance. A bronze distributor gear is also available separately.
- High Dielectric Strength Cap with Brass Terminals: Features a low resistance center coil brush for efficient spark delivery.
5. Setup and Installation
Proper installation is crucial for the performance of your HEI distributor. If you are not experienced with automotive ignition systems, professional installation is recommended.
5.1 Pre-Installation Steps
- Disconnect Battery: Always disconnect the negative terminal of the vehicle's battery before starting work.
- Mark Rotor Position: Before removing the old distributor, note the exact position of the rotor and the orientation of the distributor housing. This will aid in initial timing setup.
- Mark Cylinder #1: Identify the spark plug wire for cylinder #1 on the old distributor cap.
- Remove Old Distributor: Carefully remove the old distributor, noting any shims or gaskets.
5.2 Installation Procedure
- Prepare New Distributor: Ensure the new Pertronix D1202 distributor is clean and free of debris. Apply a small amount of engine oil to the distributor gear.
- Install Distributor: Carefully insert the new distributor into the engine block, aligning the gear with the camshaft gear. The rotor should point to the approximate position noted in step 5.1.2, or slightly before the #1 cylinder spark plug terminal on the cap.
- Engage Oil Pump Shaft: As the distributor drops into place, the oil pump shaft will engage. It may be necessary to rotate the engine slightly by hand (using a wrench on the crankshaft pulley bolt) to allow the distributor to fully seat.
- Secure Distributor: Once seated, install the distributor hold-down clamp and bolt, but do not fully tighten it yet.
- Connect Wiring: Connect the HEI distributor's wiring as per your vehicle's specific requirements. Typically, this involves a 12-volt switched power source. Refer to your vehicle's service manual for exact wiring diagrams if needed.
- Install Spark Plug Wires: Transfer the spark plug wires from the old cap to the new blue cap, ensuring correct firing order. Start with cylinder #1 and follow the engine's firing order clockwise or counter-clockwise as indicated on the cap or in your vehicle's manual.
- Reconnect Battery: Reconnect the negative terminal of the battery.
5.3 Initial Timing
After installation, the engine will need to be timed. This is a critical step for proper engine operation.
- Start Engine: Start the engine and allow it to reach operating temperature.
- Connect Timing Light: Connect a timing light to the #1 spark plug wire.
- Adjust Timing: Loosen the distributor hold-down bolt slightly. While the engine is running, rotate the distributor housing slowly until the timing marks align with the manufacturer's specifications (typically found on a sticker under the hood or in your service manual).
- Tighten Distributor: Once the correct timing is achieved, tighten the distributor hold-down bolt securely.
- Verify Timing: Re-check the timing to ensure it has not shifted while tightening the bolt.
6. Operation
The Pertronix Flame-Thrower HEI Distributor operates by generating a high-voltage spark to ignite the air-fuel mixture in each cylinder at the precise moment. Its advanced design ensures a strong, consistent spark across a wide RPM range, contributing to improved engine performance and fuel efficiency.
The integrated high-energy module and coil combination are designed to operate effectively at higher RPMs than many stock HEI units, providing a more robust ignition system for performance applications.
7. Maintenance
Regular maintenance helps ensure the longevity and optimal performance of your Pertronix HEI Distributor.
- Cap and Rotor Inspection: Periodically inspect the distributor cap and rotor for cracks, carbon tracking, or excessive wear on the terminals. Replace if necessary.
- Spark Plug Wires: Check spark plug wires for damage, fraying, or poor connections. Ensure they are securely seated on both the cap and spark plugs.
- Cleanliness: Keep the exterior of the distributor clean and free of oil, dirt, and moisture.
- Timing Check: Occasionally verify engine timing, especially if you notice a change in engine performance.
8. Troubleshooting
If you experience issues with your ignition system, consider the following basic troubleshooting steps:
- No Spark:
- Check all electrical connections to the distributor for looseness or corrosion.
- Verify that the distributor is receiving 12-volt power.
- Inspect the distributor cap and rotor for damage.
- Ensure spark plug wires are correctly installed and not damaged.
- Engine Misfire or Rough Idle:
- Check spark plug wires for proper routing and secure connections.
- Inspect spark plugs for wear or fouling.
- Verify engine timing is set correctly.
- Check for vacuum leaks.
- Engine Cranks but Does Not Start:
- Confirm the distributor is fully seated and the hold-down clamp is secure.
- Re-check rotor position and spark plug wire routing.
- Ensure fuel delivery is adequate.
If these steps do not resolve the issue, it is recommended to consult a professional automotive technician or contact Pertronix technical support.
9. Specifications
| Specification | Value |
|---|---|
| Model Number | D1202 |
| Brand | Pertronix |
| Material | Aluminum |
| Exterior Finish | Bronze (Gear) |
| Item Weight | 6.7 pounds |
| Product Dimensions (L x W x H) | 16.5 x 9.6 x 6.5 inches |
| UPC | 694342009038 |
10. Warranty and Support
For information regarding the product warranty, please refer to the official Pertronix website or contact their customer support directly. Keep your purchase receipt as proof of purchase for any warranty claims.
For technical assistance or further inquiries, please visit the Pertronix support page or contact their customer service department.
