No Spark, checked battery and coil, what next?

Theom

Cadet
Joined
Sep 12, 2019
Messages
20
I'm not getting any spark and I'm not sure what to trouble shoot next.

How I determined I have no spark: I took out the cylinder 2 plug, put it back into the spark plug wire, set the tip against the exhaust manifold riser bolt and turned over the engine.

My trouble shooting steps so far:
1) Wiggle, removed, and reinstalled kill switch.
2) Tested positive and negative cables at the battery posts and get 12.7V reading
3) Tested coil positive post. Turned key and battery on, put positive probe directly on top of coil positive post and negative probe on exhaust manifold riser bolt. 12.1V reading
4) Tested coil output. Attached 16 gauge wire to negative coil post, inserted spark plugs directly into plug end that normally attaches to the distributor, then rubbed the other end of the 16 gauge wire onto a manifold bolt and it resulted in the spark plug sparking. I'm led to believe this means my coil is ok.
5) Remove distributor cap to inspect. It's brand new, has no moisture or corrosion in it. The rotor turns when the engine is turned over.
6) Checked grounds from coil and distributor. Put positive probe on battery post and negative probe on coil negative post. Then put positive probe on battery post and negative probe on exhaust bolt that has distributor ground wire on it.

It seems my problem is at the distributor, but I don't know what's wrong with it or what to test on it. Through researching this I did realize I probably didn't line up my distributor correctly, so I'm working on finding compression TDC on cylinder #1 and getting that put in correctly, but even if my timing is off, it should still be getting spark when I turn it over from what I can tell. Any ideas on what to do next to get spark?

These are new plugs, new spark plug wires, and a new distributor cap. It's an old coil.

Engine: 7.4L, 454 CID, 330HP, Ser# 0C662618
https://www.mercruiserparts.com/7-4l-bravo-gm-454-v-8-1988-1991-0b7711
1989 Maxum 2300 SC, I/O
 
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Theom

Cadet
Joined
Sep 12, 2019
Messages
20
Also many instructions I've found online say to test the wires going into the distributor but they're buried in epoxy and not accessible without cutting.
 

Scott06

Admiral
Joined
Apr 20, 2014
Messages
6,514
Also many instructions I've found online say to test the wires going into the distributor but they're buried in epoxy and not accessible without cutting.
You will need to go through the thunderbolt troubleshooting https://forums.iboats.com/threads/how-mercruiser-thunderbolt-ignition-systems-work.676476/

there should be bullet connections for the distributor sensor which is the red and green striped wires. This is shown in the troubleshooting guide linked , if yours originally had the ring type connections someone may have spliced them. , not sure if thats what is under the shrink sleevesin the pictures.
there is a good connection between button in the cap and the rotor?
 
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2004 searay

Seaman Apprentice
Joined
Jun 30, 2023
Messages
44
this should help with your troubleshooting. as for the wires to the distributor, follow them from the dist to the ignition module, mounted on the riser. chances are the ignition switch, inside the distributor has gone bad, more likely than the module itself.
1735479569798.png
 

Theom

Cadet
Joined
Sep 12, 2019
Messages
20
I found the issue. I had the purple wires connected to the negative posts instead of the positive post. And the other wires on the coil were swapped too. I have spark now. One step closer to getting it fired up after the rebuild.
 

Theom

Cadet
Joined
Sep 12, 2019
Messages
20
this should help with your troubleshooting. as for the wires to the distributor, follow them from the dist to the ignition module, mounted on the riser. chances are the ignition switch, inside the distributor has gone bad, more likely than the module itself.
View attachment 404479
This description is helpful. I have the bullet connectors like this describes. I'll probably text these even though I have spark just to make everything has enough voltage
 
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