We strongly recommend that you read through the entire installation procedure before installing your new EIS on your aircraft. The procedure listed below is an abridged version of the installation manual. Make sure that any questions you might have are answered before the actual installation. Also, make sure any extra components that you might need, e.g. cable ties, circuit breakers, switch terminations, etc., are all available. And above all else, use good common sense and judgment. An electronic ignition system is a high voltage device. If an EIS is improperly installed or miss-fired, you could cause severe damage to the EIS, your aircraft, or even yourself.

Please contact us if you have any questions during this installation process. Good luck and happy flying!!  

Installation of EIS

1. General overview and recommendations
• Read through the entire installation instructions before beginning the installation to make sure you understand each step. CALL US if you have any questions or there are items that are unclear.
• The installation of the EIS should take between 4-6 hours for 4-cylinder engines & 8-10 hours for 6-cylinder engines, depending on your skill set for working on the engine & ignition system.
• Review your own skill set. If this is the first time installing an ignition system of any kind, we recommend that you have some one available with some ignition experience in order to help you.
• If you are installing a Crank Shaft Timing Wheel (CSTW), we strongly recommend that you have help in this procedure. There are instances where two sets of hands are useful. And we also recommend that one of the installers be familiar with removing and installing components on engines.
• Always use good safety and work practices. Use appropriate safety equipment (glasses, etc.) and precautions. The EIS is a high voltage system and if installed or tested incorrectly can cause substantial damage to both the system and YOU.

2. Removal of old ignition components
   
The obvious first step requires that you remove the right hand magneto and harness. Before beginning this step: Verify that the master switch is off and battery is disconnected. Keep necessary parts for later use.
3. Set-up & Installation of Mag Timing Housing (MTH); 4-cylinder ONLY
   
This step covers the installation of the Electroair Mag Timing Housing. The MTH is where engine rpm information is picked up and transmitted to the EIS Controller. For a 4-cylinder engine, the MTH is already pre-set to TDC and is as easy to install as any magneto (even easier because you won’t be installing a spark plug harness). The MTH makes setting up the ignition timing for the engine very close to ‘plug-n-play’. Note: the MTH is mounted using magneto holder clips, if you do not have these (typical when replacing a Bendix mag); they are available from us under kit p/n EA-015.
4. Set-up and installation of Crank-Shaft Timing Wheel (CSTW); 6-cylinder only
   
This procedure outlines the set-up of the Crank-Shaft Timing wheel for 6-cylinder engines (See the figure below). This procedure requires more work than the MTH as listed above, but because of the RPM difference between the magneto hole and actual engine speed (mag spins 1-1/2 times faster than the engine), this is the best solution at the moment (we are working on refining our MTH for 6-cylinders).

6-Cylinder Installation


5. Installation of EIS Controller and Coil Pack
   Select appropriate locations for the EIS Controller and Coil Pack to be mounted and install using standard AN hardware. We recommend the controller be installed on the cockpit side of the firewall and the coil pack be mounted on the engine side of the firewall. The biggest consideration when mounting these parts is harness runs from the controller to the coil pack and the coil pack to the spark plugs. Grounding considerations are also important. The installation manual details many suggestions for ideal mounting locations.




6. Installation of MAP Sensor and connection of vacuum line
   The EIS comes with a manifold pressure (MAP) sensor and is used to optimize the spark advance based on altitude conditions (atmospherics). Installation of the MAP Sensor is optional, but recommended in order to achieve optimum performance. Installation simply requires ‘teeing’ in to the vacuum line which currently drives your MAP gauge. Additionally, Electroair offers a hardware kit (p/n EA-013) with the necessary parts for completing this connection. A wire connection is then made from the EIS Controller to the MAP Sensor.

If you do not have a MAP gauge (and hence a vacuum line) installed, the installation manual outlines several options for installing a vacuum line. Depending on your skill level, we recommend reviewing the addition of a vacuum line with an engine maintenance professional before proceeding.
7. Spark Plugs and Spark Plug Wire Harness
   We recommend that you use new, aircraft spark plugs with the massive electrodes. If you are re-using the old spark plugs, make sure that they are clean. Gap the spark plugs to 0.030”-0.035”. We suggest using the REM37BY (or UREM37BY) spark plug because they are the easiest to gap. Check the engine application data to verify that these plugs can be used in your engine.

CAUTION: Be careful when not using an REM37BY (UREM37BY) plug when gapping because the outer electrode can become over-stressed and break. If you have any problems with plug selection, please give us a call.

Your kit will come with spark plug wire assemblies (two assemblies for a 4-cylinder engine & three assemblies for a 6-cylinder engine). Each assembly will make two spark plug wires. CAUTION: Since each assembly makes two spark plug wires, be careful when determining spark plug wire length. Route the spark plug wire from the coil pack to the correct cylinder (see chart below for correct firing order) to determine the spark plug wire length. Make sure to keep spark plug wire routings away from exhaust pipes and do not run two wires parallel to each other without a minimum of ¼” of separation between the wires. Terminate the spark plug ends as indicated in the drawing below. The installation manual comes with a Spark Plug Wire Hook-Up Chart for the correct firing order. MAKE SURE THE CORRECT FIRING ORDER IS USED – THE SYSTEM WILL NOT WORK PROPERLY WHEN SPARK PLUG WIRES ARE INCORRECTLY INSTALLED.


8. Wiring Hook-Up
   Verify that the master switch is off and battery is disconnected. The electrical connections that will be made are as follows: 1. Grounds; 2. Spark Plugs; 3. Timing Pick-Up; 4. Coil Pack; 5. Power switch (or key switch). The harness that came with the EIS Controller is bundled and labeled for each of these connections. Some of the connections require a termination (ring terminal or Molex type), other bundles are already terminated. Keep handy a bundle of tie-wraps for finishing the wiring.

CAUTION: The Coil Pack MUST be grounded. Failure to ground the Coil Pack may result in SEVERE ELECTRICAL SHOCK! Also, a poorly grounded Coil Pack may result in poor engine performance and can cause ENGINE DAMAGE.

Please let your Electroair representative know if you will be using the key-switch option (p/n EA-014) so the appropriate upgrade can be installed before shipping.

The installation manual comes with a complete wiring overview. Do not hesitate to call if any sections of the wiring hook-up are unclear or if you have any questions.

9. Final Installation Steps
   Your unit has been pre-set at the factory based on the information you gave when you placed your order and should not need any adjustment in the field. Please contact us if you feel that your unit is not performing optimally. Otherwise, re-attach and reinstall any connections or components that were removed or loosened during this installation. Secure all new wires, harness, connections and lines to prevent failures due to vibration. Connect battery connections and close any open circuit breakers. Recover all tools that may have been used (you don’t want any tools ‘floating’ around inside the airplane). Proceed to the operational section and perform a test run-up before flying.

Not as hard as you might have thought. Thank you for considering Electroair and Happy Flying!!

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