Installing HEI Ignition on 3PG Carts
 

Hi, All:

I decided to put together a short summary of my HEI conversion on my 3PG gasser. I found it frustrating searching thru threads and pulling bits of information from several places, and not really knowing if what I assembled was correct. So, without further adieu, here's what I did:

HEI Conversion on 3PG Cart

- Purchase an ignition coil and matchiing ignitor from a 1977 Chevy
Nova 4.1L I6 I got mine from Advance Auto for about $60.
See pics #1 and #2 below.

- Remove the stock ignitor from the cart and mount the new ignitor in it's
place. Be sure to apply conduction grease supplied with ignotor on the
backside to improve cooling. The ignitor can get HOT!
See pic #3 below.

- Remove the stock coil from the cart.

- Mount new coil. I chose to mount it close enough to the engine so I could
still use my stock spark plug wire. You can mount the coil sideways like I
did since it is not oil filled. I just drilled two holes on the cross member and
used long bolts to secure it.
See pic #4 below.

- Go to NAPA and get a spark plug connector and boot for the blunt end of
your stock plug wire and install them so your plug wire will plug onto your
new coil.

- Refer to attached wiring diagram that I found on this site. Note, the wires
from the pulsar to the ignitor needed to be reversed on my cart, or it would
not run!!!! See pic #5 below.

- Connect the BLUE wire from the pulsar
to the "G" terminal on the ignitor.
- Connect the RED wire from the pulsar
to the "W" terminal on the ignitor
- Connect the B terminal on the ignitor
to the "YELLOW/RED" wire on the solenoid.
- Connect the C terminal on the ignitor
to the "- TERMINAL" on the coil.
- Connect the + TERMINAL on the coil
to the "GREEN" wire on the solenoid.

Your cart should now run like a champ!!!

Re: Installing HEI Ignition on 3PG Carts
 

One other thing, see pic below from 1989Marathon showing polarity on the coil. He figured it out and posted the pic.

Kudo's to 1989Marathon for coming up with the 1977 Chevy ignition retrofit and to whoever modified the factory wiring diagram for the HEI connections.

Re: Installing HEI Ignition on 3PG Carts
 

Very nicely done Ron, perhaps an Administrator could pick this up and dump it in the stickies section.

Dave

Re: Installing HEI Ignition on 3PG Carts
 

One other thing that I forgot. You need to trim two small "feet" from the backside of the new ignitor or it won't sit flat. This is important for heat transfer from the ignitor to the metal plate you're mounting it to. See pics below.

Re: Installing HEI Ignition on 3PG Carts
 

Thanks Dave!! :notworthy:
Certainly not the level of your workmanship, but it works!!

I tried to post this in the stickies section but learned that I don't have write authority there.

Re: Installing HEI Ignition on 3PG Carts
 

Great job Ron, you just saved me alot of time digging through the threads. Will get the parts tomorrow at work and hopefully get them on by this weekend and see what happens then. Donald Oh by the way $ on the carb ?

Re: Installing HEI Ignition on 3PG Carts
 

Nice job that should work on the 244 cc too...might do this to my two carts a 88 and 82 ezgo

Re: Installing HEI Ignition on 3PG Carts
 

What does 2pg mean vs 3 pg?

Re: Installing HEI Ignition on 3PG Carts
 

Bifferd, A short history of the PG engine, enjoy.

-In 1976 the so-called '2pg'--a 244cc, Fuji Heavy Industries/Robin Engine--with an internal starter generator (st/gen), became standard. Repair parts are still available except for the crankshaft assembly, the voltage regulator/starter relay and the internal st/gen stator & field.

-In 1980, an external, Hitachi brand starter generator was introduced and the engine was modified. The crank bearings, drive clutch, point set & condenser, voltage regulator and the engine frame all changed.

-1981 ushered in an electronic ignition system, which did away with the golf carts point set & condenser altogether, and the point activator lobe on the crankshaft soon went away too. Except for the addition of an oil injection system, this engine went virually unchanged until 1989 when the 3pg golf cart engine replaced it. Although the two engines are similar, many parts are very different.

-1983 was the oddball year for the 2pg engine. The muffler was placed behind the engine and it layed down instead of standing up. The '83 golf cart had a different engine frame, muffler & exhaust stack. It only lasted one year though...lots of problems.

In '84 the E-Z-GO golf cart went back to the old exhaust system & stand-up muffler on the driver side of the car.

1988 was the last full year of the 2pg engine. A larger golf cart carburetor and another change to the muffler & exhaust system were implemented trying to get more power for the car. The st/gen bracket also went through several changes as the increased power caused the original bracket to break apart.

In mid-year 1989, (early '89 models had the 2pg engine) E-Z-GO changed to the '3pg' engine, leaving the old 2pg to history. The '3pg' engine has the spark plug turned upward, and the whole engine is rotated such that both clutches face the driver side of the golf cart. This rotation allowed for the differential to be changed from a hypoid gearing to a more efficient helical gear design, a change that persists to this day. The lay-down style golf cart muffler for the '3pg' engine is in front of, and slightly above the engine. The piston is about the only part that works in either engine. The crankshaft & clutches, the exhaust system, the carburetor, air intake & control cables all changed.

1992 is the generally accepted date that the twin-cylider 4-cycle engine became the standard power plant but in fact the 3pg engine can be found in golf carts as late as 1994.

Re: Installing HEI Ignition on 3PG Carts
 

Can someone describe to me and maybe others what this comment Dave said.

The underlined is what I am more confused about.

EDIT:
What does the HEI stand for ??


In mid-year 1989, (early '89 models had the 2pg engine) E-Z-GO changed to the '3pg' engine, leaving the old 2pg to history. The '3pg' engine has the spark plug turned upward, and the whole engine is rotated such that both clutches face the driver side of the golf cart. This rotation allowed for the differential to be changed from a hypoid gearing to a more efficient helical gear design,

Re: Installing HEI Ignition on 3PG Carts
 

Donald:

Thank you!! If you have any questions, just PM me. As for the carb, I paid $124 for it. Got it two weeks ago. I'll take $100 plus shipping.

Ron

Re: Installing HEI Ignition on 3PG Carts
 

Cool!! I have to say, the more modern ignition really works well. All along, my starting problem over the last two years was just an old worn-out ignition coil with a poor connection for the spark plug wire.

My understanding is 2PG is the engine code for 2 stroke carts built perhaps from the beginning of time until early '89. Late in '89, EZGO went to a new engine design called the 3PG which was a little more powerful, and was used up to maybe '94. The 3PG was turned in the chassis so that they could hook up to a more reliable rear differential. 2PG has a muffler that sits vertical and the 3PG has a muffler that sits parallel. That's about all I know...

Re: Installing HEI Ignition on 3PG Carts
 

I'll take this part anyway... HEI Stands for High Energy Ignition. A generic term for various modern ignition systems in cars.

Re: Installing HEI Ignition on 3PG Carts
 

Thank you for the nice history lesson on these carts. That quite fascinating ....

Re: Installing HEI Ignition on 3PG Carts
 

I agree Thanks for the history lesson, :thumbup:

Re: Installing HEI Ignition on 3PG Carts
 

And such is the beauty of this forum. When we all pool our knowledge and research we are all enriched. Or as Bernard of Chartres used to say, we are like dwarfs on the shoulders of giants, so that we can see more than they, and things at a greater distance, not by virtue of any sharpness of sight on our part, or any physical distinction, but because we are carried high and raised up by their giant size.

Dave

Re: Installing HEI Ignition on 3PG Carts
 

Now who'd ever imagine that golf cart repair could parallel deep philosophy? Good stuff Dave!!

Re: Installing HEI Ignition on 3PG Carts
 

But I like it on the bottom.

OH GEEZ.
I just had to say it.:shock:

Re: Installing HEI Ignition on 3PG Carts
 

High Efficiency Ignition. Copied from the Mallory Ignitions that were being installed in drag cars. Did away with points. with points, they pitted and since they were controlled by lobes, the firing was always set to #1 cylinder. I still have a unit that was used to check the firing of all 8 cylinders. It spun the distributor and you had to file each lobe to make them at the exact degree from #1. It used a neon strobe and was quite accurate. you used the firing order for the engine, plugged in the wires and watched a wheel that was about 10 inches in diameter and a strobe for each cylinder. Each lobe was either filled or brass was added to the lobe and then filled. Been building race car engines since 1950. Curtis Turner, Ronnie Sox, and many more.

Re: Installing HEI Ignition on 3PG Carts
 

High Energy Ignition

Re: Installing HEI Ignition on 3PG Carts
 

Thanks Dave for the lesson I'm New to the cart world but with all the lessons you guys give it helps us new guys figure out things alot fast.

Re: Installing HEI Ignition on 3PG Carts
 

Comment on the 2pg / 3pg and a little history. The 2PG was built by Robin. EZ-GO decided that they could do better and designed the 3PG. It had more power and the engine placement was necessary because of the new rear ends that were available. Finally EX-GO gave up on the 2-cycle concept and change to the 4 stroke engine that was compatible with the rear ends they were using. Of note, During this time frame, the rear ends used by Yamaha and EZ-GO were self adjusting. Took Club Car forever to catch on that self adjusting brakes were a good idea. Why they took so long is still a mystery.

Re: Installing HEI Ignition on 3PG Carts
 

Geat write up and cured my irratic spark like a charm!!!!!

Re: Installing HEI Ignition on 3PG Carts
 

Thank you!! Glad it worked out for you. I think half the improvement is the new connector end on the plug wire. Electrically, it's just a far better solution than the old-school screw post inside the stock coil.

Re: Installing HEI Ignition on 3PG Carts
 

Ron Man, I just put the HEI on my 87 marathon, runs great Thanks a Bunch!!! Got the coil & ignitor from Auto Zone for $46.00, man i just can't get over it , that son of a gun runs better than it ever has.

Re: Installing HEI Ignition on 3PG Carts
 

Yes siree!!! They sure do run great with HEI!! Glad it worked out for you too!!

Re: Installing HEI Ignition on 3PG Carts
 

Here is another way to install the coil that would survive the rough life my carts enjoy. It is on a 89 3PG Truckster. BTW the black wire on the electrical diagram does go to the ground screw on the ignition module - that is not clearly described previously.

Re: Installing HEI Ignition on 3PG Carts
 

Nice!! Not sure my utility body would clear the coil in that location though.

Re: Installing HEI Ignition on 3PG Carts
 

i'ts actually below the top of frame rail by 1/4"..... may be tough to service though....

Re: Installing HEI Ignition on 3PG Carts
 

Changed over the igniter as above but getting low to intermittement spark, any non factory ideas for igniter assy to control the spark that i might be able to locate in the provinces of Philippines, ie: mostly salvage parts from toyota cars available.

Re: Installing HEI Ignition on 3PG Carts
 

wow that is sweet, what about a voltage regulatur is there one that would work besides buyimg an ezgo one

Re: Installing HEI Ignition on 3PG Carts
 

regulator sorry

Re: Installing HEI Ignition on 3PG Carts
 

No idea. Perhaps a topic for a separate thread where others might see it.

Re: Installing HEI Ignition on 3PG Carts
 

Re: Installing HEI Ignition on 3PG Carts
 

Can this be done to the Robin 295 2 cyl. engine also? I have eratic spark issues I am chasing....

Re: Installing HEI Ignition on 3PG Carts
 

Since your conversion references a 1 plug wire coil is it safe to say that is for a 2 cycle? I would like to do the HEI conversion on my cart with a 350 4 cycle but I don' know how to connect 1 coil wire to 2 spark plugs - please advise.
Thankyou

Re: Installing HEI Ignition on 3PG Carts
 

I've got a 97 ezgo 2 cyl. Is there any benefit in doing the HEI conversion to it?

Re: Installing HEI Ignition on 3PG Carts
 

Re: Installing HEI Ignition on 3PG Carts
 

I figured it out, the orange/white wire coming from the old ignitor going to the solonoid is not used and you have to re-gap your plugs from .030 to .012 with that said you need to follow your wires from the coil and the pulsar coil because the white wire and the red go into the factory four wire plug comes out reversed in the connecting factory plug and you use your old 2 plug wire coil.

Re: Installing HEI Ignition on 3PG Carts
 

OKay I need help! I did everything and my cart will not run?