96 LT1 Opti replacement problems
Thread Starter
6th Gear
Joined: Apr 2005
Posts: 6
Likes: 0
96 LT1 Opti replacement problems
Hi, I have a 96 collector's edition LT1 engine and I'm getting really frustrated with the Opti change. I pulled the water pump out, crank pulley and got the old Opti out, now I pretty much trashed the old one while removing it.
I ended up picking up a reman Opti from a local parts place, along with a new cap (trying to save a few bucks staying away from the dealer). Now after assembling the new opti and installing it on the cam, it seems like it's sticking out a few millimeters from the block where it bolts down. It seems like it's on there and I was able to tighten the bolts just fine, but when I went to plug in the connector for the Opti, I can't get it to click in.
I went so far as taking it all apart again and tried plugging the wires in without the distributor installed, still doesn't snap in. I then took the Opti apart all the way and tried plugging in the wires directly to the opti sensor, it plugs in fine, but when I put on the white plastic peice where the plug is supposed to lock on, it won't fit, it goes almost all the way, but then stops before it gets to the lock. Can anyone help me out with this?? Thanks in advance.
I ended up picking up a reman Opti from a local parts place, along with a new cap (trying to save a few bucks staying away from the dealer). Now after assembling the new opti and installing it on the cam, it seems like it's sticking out a few millimeters from the block where it bolts down. It seems like it's on there and I was able to tighten the bolts just fine, but when I went to plug in the connector for the Opti, I can't get it to click in.
I went so far as taking it all apart again and tried plugging the wires in without the distributor installed, still doesn't snap in. I then took the Opti apart all the way and tried plugging in the wires directly to the opti sensor, it plugs in fine, but when I put on the white plastic peice where the plug is supposed to lock on, it won't fit, it goes almost all the way, but then stops before it gets to the lock. Can anyone help me out with this?? Thanks in advance.
Melting Slicks
Joined: Mar 1999
Posts: 2,535
Likes: 2
From: Rochester NY
I spent about $600 for the Delteq. I will never have to replace the opti crap again. Take a break and slow down. Go over everything. Remenber, it will only going one way. If it does not go in don't force it. Perhaps thing is not line up.
Melting Slicks
Joined: Oct 2004
Posts: 2,510
Likes: 4
From: Austin Texas
Wow!!! STOP what you are doing NOW!! It sounds like you do not have your Optispark "keyed" correctly. You need to line up the index groove(see pic) to the steel pin sticking out of the cam. You should have NO PLAY whatsoever once you have mated your Opti properly to the front of your engine. Stick your head in the engine bay to see the relative position of the pin on the cam, then turn the Opti shaft to get the indexed groove to be in the relative position of the cam pin. Then take the Opti and carefully mount. If you don't get a flush seating, remove the Opti and turn the shaft a little to reposition the index groove. You may have to do this 3 or 4 times before you get the cam pin to seat into the index groove. But when you get the Opti seated correctly, you will know it. I hope you didn't tighten the 3 Opti bolts too tight, as this could cause the aluminum housing to get deformed!!!??????
As far as the connectors, you may have broken the little lock clips, so you won't get a "click" sound when you install. You should be OK if the connectors mate tightly...If not you may have to buy new connectors and cut the old ones off and splice the new ones on... But I doubt you will have any problems with the connectors the way they are.....
As far as the connectors, you may have broken the little lock clips, so you won't get a "click" sound when you install. You should be OK if the connectors mate tightly...If not you may have to buy new connectors and cut the old ones off and splice the new ones on... But I doubt you will have any problems with the connectors the way they are.....
Last edited by MikeC4; May 7, 2005 at 06:33 PM.
Thread Starter
6th Gear
Joined: Apr 2005
Posts: 6
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Well, when putting on the connector, it doesn't lock in, and the lock is still there, it won't go on far enough to lock it down. And, if let it sit where it's at in the connector, it just pops out by itself. I'm so frustrated with it that I'm ready to take a hammer to it to get it to seat further down in there 
I'm going to try seating the distributor to cam without the dizzy cap on so i can rotate the rotor to line it up better.
I'm going to try seating the distributor to cam without the dizzy cap on so i can rotate the rotor to line it up better.
Melting Slicks
Joined: Oct 2004
Posts: 2,510
Likes: 4
From: Austin Texas
Originally Posted by mstolars22
Well, when putting on the connector, it doesn't lock in, and the lock is still there, it won't go on far enough to lock it down. And, if let it sit where it's at in the connector, it just pops out by itself. I'm so frustrated with it that I'm ready to take a hammer to it to get it to seat further down in there I'm going to try seating the distributor to cam without the dizzy cap on so i can rotate the rotor to line it up better.
I'm going to try seating the distributor to cam without the dizzy cap on so i can rotate the rotor to line it up better.As far as alignment of the Opti index groove and the cam pin, you just need to excersise a little more patience...If you do install it with the dist. cap off, be careful not to get any gunk on the rotor, and keep an eye on the rubber gasket, making sure it stays firmly seated.....I assume you have the proper inverse torx bit for the 4 screws that attach the dist. to the Opti unit.....
Le Mans Master
Joined: Dec 2004
Posts: 5,789
Likes: 8
From: Myrtle Beach SC
St. Jude Donor '05-'06
You think yours is tough try a 93 with our geared spline wit a 2 tooth key to match up.Paitence is a virtue here. When you get it right it will "pop" onto the timing cover and be flush with it keep at it you will get it.
Try some Die electric grease in the plug. You should always use a little when working with Opti plugs and plug wires.
Try some Die electric grease in the plug. You should always use a little when working with Opti plugs and plug wires.
Last edited by Redeasysport; May 8, 2005 at 12:33 AM.
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Thread Starter
6th Gear
Joined: Apr 2005
Posts: 6
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Pins are fine, like i said in the first post, if i take the distributor all apart i can plug the wires directly onto the pins, but when I put the white outer part on the distributor the connector won't lock in, it's like the plug is too long or something. Also, the old distributor got trashed from trying to get the crank pulley off with 2 pry bars between the distributor and the pulley.
Racer
Joined: Apr 2002
Posts: 342
Likes: 0
From: new orleans La
I know what your going through. I had the same problem a few years ago when I changed an opti. It can be a PITA sometimes to get the cam pin lined up properly. It should fit perfectly flush against the timing cover. Goodluck
Race Director
Joined: Feb 2003
Posts: 11,672
Likes: 20
From: Lake Wylie SC
Originally Posted by mstolars22
Also, the old distributor got trashed from trying to get the crank pulley off with 2 pry bars between the distributor and the pulley.
Thread Starter
6th Gear
Joined: Apr 2005
Posts: 6
Likes: 0
AHHHH! I did all that stuff allready, all I can't do now is plug in the wires for the opti sensor. Thanks for all the help and all, but I keep reading the same posts and it's driving me crazy 
Please don't take offense to that, but after trying to put that plug in for over 3 days, I'm in another world and ready to just sell the car so I don't have to worry about it anymore.
Please don't take offense to that, but after trying to put that plug in for over 3 days, I'm in another world and ready to just sell the car so I don't have to worry about it anymore.
Burning Brakes
Joined: Jun 2002
Posts: 1,159
Likes: 0
From: royal palm beach florida
Iam spending the money for the Deltag system.I think my ignition worries will be over.I have read many posts on the opti and the remanafactured is not the way to go.I have also seen a opti go out in 8000 miles. 
Melting Slicks
Joined: Aug 1999
Posts: 2,240
Likes: 42
From: Baltimore, MD USA
Originally Posted by Bruce
I spent about $600 for the Delteq. I will never have to replace the opti crap again.
Doesn't the Delteq unit use/need the Low resolution signal from the Optispark?
Thread Starter
6th Gear
Joined: Apr 2005
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Hmm, this Delteq system has me intrigued. I wonder, is there a way to do away with the actual optispark distributor and use some other sensor in its place?? It seems that you still have to use the optispark distributor when you install the delteq. So, if the waterpump decides to take a dive again, the optispark will go out again, and it won't matter if you have the delteq.
Le Mans Master
Joined: Dec 2004
Posts: 5,789
Likes: 8
From: Myrtle Beach SC
St. Jude Donor '05-'06
Mod your water pump like I did and it will never dump on the opti look in my gallery for a pic.
You should be able to peel the opti layers off and use your old ring with the plug in it as long as it is not totally carbon traced you can clean it with electrical cleaner.It also pays at this point to use some RTV Hitemp and seal each layer of the opti as you re assemble but you wont be able to take it back if you do this I believe(mabey not?).
If it still won't go on take it back it is junk. So try pluggin it in before sealing the Opti. As was already stated above some things on a vette you can get for cheap others it pays to stay with OEM or better and remans are prone to failure on this item. So good luck with the opti.
You should be able to peel the opti layers off and use your old ring with the plug in it as long as it is not totally carbon traced you can clean it with electrical cleaner.It also pays at this point to use some RTV Hitemp and seal each layer of the opti as you re assemble but you wont be able to take it back if you do this I believe(mabey not?).
If it still won't go on take it back it is junk. So try pluggin it in before sealing the Opti. As was already stated above some things on a vette you can get for cheap others it pays to stay with OEM or better and remans are prone to failure on this item. So good luck with the opti.
Last edited by Redeasysport; May 8, 2005 at 08:09 PM.
Instructor
Joined: Sep 2004
Posts: 165
Likes: 0
From: Middleburg Florida
Originally Posted by mstolars22
So, if the waterpump decides to take a dive again, the optispark will go out again, and it won't matter if you have the delteq.
