Sears 161.2161 User manual

owners manual
ENGINE ANALYZER
MODEL 161.2161
FOR 12 VOLT IGNITION
SYSTEMS
IMPORTANT
The information in this manual will serve as a general guide for engine
tune-up and charging system tests and adjustments.
CONSULT TH-E OWNERS MA~UAL OF TffE VEHrCtf BEI~ TtSTEDl"'"'oO;;-:1~:::;?-i'~~~--'
FOR SPECIFIC TUNE -UP INFORMATION AND TEST PROCEDURES.
THE MANUFACTURERIS SPECIFICATIONS AND TEST PROCEDURE FOR
ADJUSTING DWELL ANGLE, IDLE SPEED AND CHARGING SYSTEM
OUTPUT SHOULD BE FOLLOWED.
FOR SAFE OPERATION
Be careful when testing an operating engine -- stay away
from the fan blades, drive belts, high voltage spark 'plug
wires
and hot exhaust manifold. .
Operate the vehicle in a well ventilated area to avoid
• danger of carbon monoxide poisoning.
I
[ PRINTED IN U.S.A. _
• <
SEARS,ROEBUCK AND CO. U.S.A.
CHICAGO, ILLINOIS 60684
2-13370

-
I
ZERO ADJUSTER. Before the con-
nections are made, if the pointer is
not on zero, rotate adjuster slowly
with a screwdriver until pointer is
on zero.
1. Connect the RED clip to the bat e .
Positive (+) terminal.
2. Connect the BLACK clip t· the: ,t-
tery Negative (- termin
3. Connect the GREEN ell
tributor connection on t
coi
I.
For connections to Ford cars, Delco
High Energy Ignition, Ford transistor
ignition and Chrysler transistor
ignition, see Figs. 2, 3,.4, 5 and 6. I
~~.-"::::;;;~,.--- FUNCTION SELECTOR'
KNOB
FIGURE 1
AMPS SHUNT
Not used for these
tests -See
page 6
for amp test con-
nections.
COIL
CONNECTIONS FOR RPM, DWELL, VOLT AND POINTS TESTS
SLIDE SWITCH KNOB TO -
"OTHER TESTS
"
POSITION
TACHOMETER CONNECTION TO GENERAL MOTORS CARS WITH
DIAGNOSTIC CONNECTOR AND DELCO HEI
TACHOMETER CONNECTIONS
FOR GENERAL MOTORS CARS
WITH
DIAGNOSTIC CONNECTORS
To make RPM tests, locate the Engine Elec-
trical Diagnosis Connector (usually near the
left front fender) open the cover and insert a
spade terminal in socket No.6.
Connect the GREEN clip to the spade terminal.
The RED clip must be connected to battery POS.
(+) and the BLACK clip to battery NEG. (-).
DELCO HIGH ENERGY IGNITION
4 CYL, AND IN-LINE 6 CYL. HEI
GR~EN" ~
CL~
HEI ADAPTER
INCLUDED
01
---~
~-~
',,~ ...
v - a ENGINE HEI
FIGURE 3.
CONNECT GREEN
CLIP TO THIS TERMINAL
On 4 cylinder ond in-line 6 cylinder
engines with 0 separote coi I, connect
the GREEN clip to the open TACH ter-
minal as indicated. :I ~ " :: ,0
On the integ,ol coil v-a HEI, slide the • ~ I" 1/1 l' .-
odapterontothe TACHterminalasshown. ~L t 1: At [7
Then connect the GREEN clip to the • - "'" I • cl
adapter. The RED and aLACK clips ore ...... :';::~ '/
connected to the battery Positive and 1'/
Negative os shown in FIGURE 1 '/'/
,.- '/
GREEN
CLIP
FIGURE
2.
1

TACHOMETER CONNECTION TO FORD AND CHRYSLER TRANSISTOR
IGNITION SYSTEMS AND LATE MODEL FORD STANDARD IGNITION
On Ford cars, Ii ft the dis-
tributor terminal and slide
the Ford Adopter
clip in
place as shown, then push
the terminal down on
it.
Remove when the tests are
finished.
Connect the GREEN lead to the negative ter-
minal of the ignition coi I.
Connect the RED and BLACK clips to the battery
Positive and Negative as shown in FIGURE 1.
CHRYSLER IGNITION
GREEN
CLIP
I
FORD IGNITION
Connect the RED and BLACK clips to the bat-
tery Positive and Negative as shown in
FIGURE" 1.
On 1974 Ford transistor ignition, use the Ford
adapter as shown in FIGURE 6.
On 1975 Ford transistor ignition, connect the
GREEN clip to the wire terminal on the DEC
side of the coi I as shown be low.
FIGURE 4
..
FIGURE 5
COIL
FIGURE 6
POINT .RESISTANCE TEST-CONVENTIONAL IGNITION SYSTEMS ONLY
Points are O. K. Turn the ignition key
OFF. Proceed to next TEST.
5. TEST RESULTS
POII'JTS
POINTS
POINTS
POINTS
During engine tune-up, this test should be per-
formed first.
1. The engine must be OFF. The test leads must
be connected as shown in FIG. 1.
• Se-t the slide swi.-tch knob to-OTHER TESl-S
and the Function Selector Knob to POI NTS.
NOTE: Remove
the distributor cap and
inspect the contact points. If
they are blued, blackened, or
pitted, they should be replaced.
Normal used contact points are
light gray in color. If the con-
tact points pass the visual in-
spection, proceed as follows:
3. Replace the distributor cap and REMOVE THE
HIGH TENSION LEAD FROM THE CENTER OF
THE DISTRIBUTOR CAP AND GROUND IT BY
PLACING THE LOOSE END SO IT TOUCHES
THE ENGINE OR FRAME.
NOTE: When
testing a vehicle with dual
points, alternately block one set
of points open with a piece of in-
sulating material while the other
set is being tested.
4. TURN THE IGNITION KEY ON. If the
meter reads near full scale right, the points
are open. Crank the engine with the igni-
tion key or an external starting switch a
fraction of a revolution at a time until the
meter reads in the left hand area of the
scale. The points are now closed.
The points may be defective or the following
faults may exist:
Poor distributor ground.
Poor connection on the primary
lead from the distributor to the
ignition coil.
Defective distributor lead.
Misaligned points.
Correct the defect, and repeat the test.
2

POINTS-DWELL TEST AND ADJUSTMENT
15 20 25 30
~V:~~:"~~
10 \ l IILI I I 50 5
o aCYL 0 30 50 70 60 aCYL 0
E 6CYL ~'\I"111"111j1ll1~ 6CYL 'E
L 4CYL 4CYL L
1/8" ALLEN
WRENCH
B. Raise the metal window and turn the
point adjusting screw with an 1/8" Allen
wrench until the dwell reading is the
same as specified by the manufacturer.
(FIGURE 7 )
On engines that have non-window type distri-
butors, adjust dwell as follows:
1. Remove coil wire from center tower of dis-
tributor cap and ground the wire by p!acing tne
loose end so it touches the engine or frame.
2. Remove the distributor cap and rot~.
5. To adjust dwell, loosen the locking screw (s)
slightly and adjust the point gap according to
the procedure outlined in the vehicle's service
manual. There are anumber of mechanical
methods for adjusting breaker points. Two
typical methods are shown in FIGURE 8. Tighten
locking screw, and recheck dwell while crank-
ing engine. Repeat procedure if necessary.
6. Reassemble distributor and recheck dwell read-
ing with engine operating at idle speed. Repeat
4 and 5 if necessary.
3. Connect a remote starter switch to test
vehicle or have an assistant crank the engine
for you.
4. With ignition switch on and engine cranking,
observe reading on the Dwell..:s:..;:c:.;:a.:le,:;.:.:- _
Check the owners manual or
engine compartment decal.
Follow instructions regarding
vacuum line or advance-
retard solenoid connections.
Vacuum line must be discon- r:...~'\~"
nected from distributor. ~) ),., '
~
~"II'I
~ §!;, 11l1ii~~\1
1111
11
"\\
PLUG END OF
VACUUM LINE
Connect the tester as s own in FIGURE or 6.
Set the slide switch knob to OTHER TESTS and
the Function Selector Knob to DWELL.
Operate the engine at idling speed and observe
the Dwell reading on the scale that corresponds
to the number of cylinders in the engine being
tested.
If the dwell reading is higher or lower than the
manufacturer's specification:
1. On Delco-Remy distributors with a sliding
metal window in the cap:
A. Operate the engine at idle RPM.
NOTE: This test and adjustment is performed
on cars with conventional ignition systems and
breaker-point transistor ignition systems. It is
not used on cars equipped with electroni c igni-
tion systems that do not have breaker points.
SLOTTED HOLE
FIGURE
8.
ADJUSTMENT
LOC
KING SCREW--_-..::::;6Z..I
TYPICAL
DISTRIBUTOR
BREAKER
POINT
CONSTRUCTION
3
NOTE: It is important to recheck the ignition timing every time the points are adjusted.

DWEll VARIATION TEST
Check the owners manual or engine compartment
decal. Follow instructions regarding vacuum line
or advance-retard solenoid connections. Vacuum
line must be disconneded from distributor.
Increase the engine speed from idle to aminimum
of 1500 RPM and then reduce it back to idle.
Watch the dwell reading during this procedure.
If the dwell variation is more than 3 degrees, check
for wear in the breaker plate or wear in the distri-
butor shaft or bushings •
IDLING SPEED AND CARBURETOR ADJUSTMENT
Start the engine and turn the idle speed screw
unti I specified idling speed is indicated.
x100
14
(See owners manua I).
On engines without exhaust emmission control sys-
tems, turn the idle mixture screw in (lean) unti I
the idling speed starts to decrease, then turn it
back out (rich) just until the idling speed reaches
amaximum. Further richening past this point will
only-wos-te ftte~. lh-ts--s-heul~done slewly to al
low eng i ne speed to stab iii ze •
NOTE: On multi-barrel carburetors, repeat this
procedure on each idle mixture screw until the
highest idling speed and smoothest operation is
obtained. If the engine idle speed is now higher
than the manufacturer's specification, turn the
throttle idling adjustment screw unti I the speci-
fied idling speed is indicated and readjust the
mixture screws with the above procedure.
TYPICAL CARBURETORS
10 12
B
o
RPM
x100
SOLIO
Connect the test leads as shown in FIGURE 1. Set
the slide switch knob to aT HER TESTS and the
Function Selector Knob to the RPM position that
corresponds to the number of cylinders in the
engine being tested.
.---0 serve-tne test readings onthe RPM x100
scale.
The engine should be at normal operating temper-
ature for this test. Many cars built in 1970 and
later have idle mixture screw limiter caps that
restri ct adjustment. On these cars the carburetor
should be adjusted according to the procedure in
the manufacturer's service manual.
NOTE: On engines equipped
with exhaust emission control
systems, air injection pumps
and positive crankcase ventila-
tion, refer to the decal in
the engine compartment or the
owners manual for idle adjust-
ment specifications.
IDLE MIXTURE SCREWS
IDLE SPEED SCREW
... ---------- ..... --------------------4

VOLTS -PRELIMINARY CHECKS
The VOLTS position is used to test the cranking and charging systems in the vehicle.
CONSULT THE OPERATING MANUAL
OF THE VEHICLE BEING TESTED FOR
SPECIFIC VOLTAGES
AND TEST
PROCEDURES:
The following information
will serve as a
general guide for making charging system
tests.
Before making VOLTS tests:
Check the fan belt--it should be tensioned
according to the manufacturer's specifications.
Check the generator or alternator pu IIey and
mounting bolts. They should be tight.
CRANKING va TS TEST
1. Remove the high tension lead from the
center of the distributor cap and ground it by
placing the loose end so it touches the engine
or frame.
2. Connect the test leads as shown in Fig. 1.
Set the slide switch knob to OTHER TESTS and
the Function Selector Knob to VOLTS.
3. Operate the starter for 10 seconds and ob-
serve the cranking voltage on the 0-16 Volts
scale. A steady reading of more than 9.6 volts
indicates that the battery, cables, and starter
system are in good condition.
CHARGING SYSTEM VOLTS TEST
. 1. Connect the test leads as shown in Fig. 1.
Set the slide switch knob to OTHER TESTS and
the Function Selector Knob to VOLTS.
Start the engine. Allow it to run afew
minutes
at 1500 to 2000 RPM. Observe
the reading on the 0 - 16 volt scale.
The pointer should be between 13.2 and
15.2 volts with or without headlights and
5
Make sure that the charging system wiring and
the battery cables are in good condition and
that connections are tight. Make sure the
battery is clean and that the liquid level in
each cell is above the plates.
The engine and all parts of the charging system
should be
at normal operating temperature be-
fore making any electrical tests. If the engine
is cold, operate the engine at idle speed for at
least 15 minutes before making any tests.
4. A reading below 9.6 volts could be caused by ~
a battery that is defective or not fully charged.
Fully charge the battery and repeat the test. If
the reading is sti" below 9.6 volts, either the
battery or starter is defective.
5. A fluctuating voltage reading is indicative
of a defect in the starter or battery or in the
battery-starter wiring circuit. Refer to page
6 (POINTS-LOW VOLTAGE SCALE) for trouble
shooting voltage drops in the battery-starter
wiring circuit.
Replace or repair any defective parts as required ~
to restore cranking system to proper operation.
6. Replace the high tension lead in the center
of the distributor cap.
blower motor on. Readings lower than
13.2 indicate either aworn out battery,
defective generator or alternator, defec-
tive or improperly adjusted voltage regu-
lator.
Readings above 15.2 are indicative of a
defective or improperly adjusted voltage
regulator.
Replace, repair or adjust the defective
part as required.

AMPS TEST
(ALTERNATOR OUTPUT)
REVERSE CONNECTIONS
IF METER READS BACKWARDS
OUTPUT
on the alternator. Reconnect the Negative cable
to the battery.
4. Turn off all lights and accessories. Start the
engine and rev it to about 2000 RPM. If the read-
ing observed on the 0-160 AMP scale corresponds
to the alternator output specified in the vehicle
service manual, the alternator is O.K. and the
trouble, if any, is in the regulator.
5. =-If the outptJt j.s-be low-ra-t-ifl , cheek fer I-eese
fan belt, defect in the alternator windings or
diodes or higher than normal resistance in the
cables or connections in the charging circuit.
6. As a safety precaution, remove the battery
Negative cable before you remove the shunt.
Attach the alternator output cable to the output
terminal and then re-connect the battery Nega-
tive cable.
The alternator output should be checked if the vo;tage reading was below 13.2 in the CHARGING
SYSTEM TEST on page 5, or if the battery requires frequent charging with a portable charger.
Set the slide switch knob to AMPS. The Function Selector Knob can be at any position. Observe
the test reading on the 0-160 AMPS scale.
1. Consult the vehicle service manual for the
correct method of disconnecting the regulator in
order to check the alternator output without the
regulator in the circuit. When the regulator is
disconnected, the circuit must be bypassed in
order to observe alternator output. Consult the
vehicle service manual for correct method of
bypassing the regulator circuit.
2. Remove the Negative cable connection on the
-.battery is wiII-e Ii mi nate-t-he danger of-shoF-t-i-Ag
the battery with the tooIused to perform Step 3.
3. Consult the service manual for the vehicle
being tested for the location of the alternator
output terminal and remove the cable from the
output terminal. Connect the shunt between
the cable and terminal as shown. Be sure these
connections are tight. The slotted side of the
shunt should be connected to the Positive terminal
POINTS- LOW VOLTAGE SCALE
The POINTS scale is also a 0-1.0 volt scale.
This scale is useful for checking voltage drops
in
the vehicle's electrical system.
POINTS
NOTE: USE GREEN AND BLACK
CLIPS· FOR THIS TEST
POINTS
Set the slide switch knob to OTHER TESTS and
the Function Se lector Knob to POI NTS. Use
the GREEN and BLACK clips for these tests.
The RED clip is not used.
Corroded or loose connections and frayed or bro-
ken cables can cause excessive voltage drops in
the starting
circuit which can cause hard starting.
To test for these conditions, connect the clips be-
tween 1 and 2, 2 and 3, 4and 5, 5and 6, 6and
7, 7 and 8with the starter turning. During this
test, no reading should be higher than .1 volt.
If areading higher than. 1 volt is observed during
any of these tests, check the cable or connections
involved, clean and tighten the connections and
replace the cables or solenoid when necessary. If
the meter reads to the
right of zero during any of
the above tests, reverse the position of the clips.
6

REPLACEMENT PARTS
PART NO.
DESCRIPTION DESCRIPTION
400-444
Case, Bottom
600-181
HEI Adapter
450-444 Knob, Selector 38-331 Cable Assembly, Green C
Ii P
38-329 Cable Assembly, Red and Black Clip 1000-221
AMP Shunt
38-330 Cable Assembly,
AMP Shunt 270-118 Screw, Case
Se If-Tap. #6-20 x 7/8 (2)
290-102 Nut, Hex 3/8-32 x 1/2 x 3/32 thk. 270-119 Screw, Case Self-Tap. #6-20 x 1-3/8 (2)
210-104 Lockwasher, 3/8 in.
400-467
Feet, Rubber (4)
2-1337 Instruction Manual 180-300
Ford Adapter
(>00-217 GM DiagnosticConnector Adapter
ISears I
owners
manual
ENGINE ANALYZER
Now that you have purchased your (E NG I NE
ANALYZER),should aneed ever exist for repair
parts or
service, simply contact your nearest
Sears store or service
center. Be sure to provide
all pertinent facts when you call or visit.
The model number of your ENGINE ANALYZER
lo---I----------lI--I--wfV+tt-"h u,e-~ocate on front decaIunder meter. !
MODEL NO.
161.2161
A II parts listed herein may be ordered from any
Sears, Roebuck and Company or Simpsons-Sears
Limited store or service
center.
WHEN ORDERING REPAIR PARTS, ALWAYS
GIVE THE FOLLOWING INFORMATION:
1. PART NUMBER
2. MODEL NUMBER
161.2161
3. PART DESCRIPTION
4. NAME OF ITEM
ENGINE ANALYZER
HOW TO ORDER
REPAIR PARTS
If the parts you need are not stocked loco IIy,
your order
wi" be electronico IIy transmitted
to aSears Repair Parts Distribution Center
for expedited handling.
SEARS,ROEBUCK AND CO. U.S.A.
CHICAGO, ILLINOIS 60684