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View Full Version : HOW TO: AEM CDI Install (pics) AND COIL ON PLUG GENERAL SETUP



gt40
10-10-2004, 12:04 PM
CDI Install:

Not for electrically challenged- The AEM warnings should be taken seriously as you are dealing with 540 VOLTS!

1. Make bracket for the CDI to be mounted. Basically it is a piece of rectangular aluminum extending from both ends of the cdi with one side bent up for the mounting bolt and other side having holes for the power steering bolt holes:

http://www.socalevo.net/gallery/albums/uploads/gt40/cdi1.jpg

2. Mount the cdi, using the power steering fill tank bolts and the 3rd bolt on the other side.
http://www.socalevo.net/gallery/albums/uploads/gt40/normal_power_steering_mounting_bolts.jpg

3. Mount the DSM coils- I made a bracket and mounted them on the bottom of my strut tower brace:
http://www.socalevo.net/gallery/albums/uploads/gt40/normal_magnacor_wires.jpg

4. Connect red wire coming directly out of the cdi box(not harness) to the battery or primary 12v source and use the inline fuse supplied.

http://www.socalevo.net/gallery/albums/uploads/gt40/normal_power_and_ground.jpg

5.Â* Connect black wire coming directly out of the cdi box(not harness) to a good ground- ie direct to battery ground or engine/block and chassis

http://www.socalevo.net/gallery/albums/uploads/gt40/supplemental_ground.jpg

6. Leave the white tach wire coming directly out of the cdi unused unless you have an extra tach. The evo already picks up a tach signal without it.

7.Â* Connect white ignition trigger wire in from the cdi harness to the black/green trigger wire going to the stock coil.

http://www.socalevo.net/gallery/albums/uploads/gt40/normal_trigger_and_12v_switched_copy.jpg

8. Connect the yellowÂ* ign trigger wire in from the cdi harness to the other black/green trigger wire going to the other stock coil.

9. Leave the black wires from the stock coil unused and insulate:

http://www.socalevo.net/gallery/albums/uploads/gt40/normal_trigger_and_12v_switched_001.jpg

Almost home...

The DSM coil packs are wired together with a 3 prong plug.Â* I wired in a weatherpack connector in place as i didn't have the other side of the dsm plug.

11.Â* The black/white wire is the positive and is connected to the tan wire from the cdi.Â* This wire carries the 540v into the plugs.Â*

12. Wire the red wire(trigger1) from the coil pack to trigger 1 dark brown wire from cdi harness

13. Wire the white wire from the coil pack(trigger 2) to the blue trigger 2 wire from cdi harness

http://archive.socalevo.net/gallery/albums/gt40/coil_pack_wiring.sized.jpg
14. Flip dip switch #2 on the cdi box to the on position.

15. Double check all connections

16. Run new plug wires from the dsm coils to the sparkplugs.Â* I used dsm magnacore wires and trimmed the boot with a knife so they fit properly. one coil feeds 1 and 4 and the other coil feeds spark 2 and 3.Â* The firing order is listed on the trigger one coil: 4123
http://archive.socalevo.net/gallery/albums/gt40/magnacor_wires.sized.jpg


Be sure to insulate the pink wire from the cdi(540v!) and all unused wires from cdi.

START THE CAR...

If you followed the aem diagram and these pics, it should work.Â* If so, shut the car off and put everything in splitloom tubing and wrap well to make everything safe, protected and tidy.Â*

Clean up and encase the wiring in split loom after you have verified it works properly or you will make troubleshooting a real pain.

Thanks to MikeW from RRE and Dr. Gray for their help on the phone...

gt40
10-10-2004, 11:16 PM
I did some pulls and my ignition problems are gone. Before I would misfire at 6700 rpm or more and now it pulls fine through 8500. Power up top is much more solid too and starts/idles a tad better with the upgrade.