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Ok Guys here's the scoop. Took the car down to Rathman (pronounced rip-off) Chevrolet. They said that they think (think?) it's the opti-spark, wires, and maybe the ecm module. All this to the tune of $1675. I asked if they do any diagnosis on the opti to tell what's going on. They said that they don't do any repairs or diag to the unit, just R&R. Boy, that's an expensive way to find out if what they "think" is right. So, I told them to give me the keys and the car and I took it home.
I took the opti-spark out and opened it up. Found that the metal contact on the rotor was coming loose from the rotor body and had gouged the cap across two terminals (lots of carbon arching). So, cleaned out the rest of the unit, replaced the cap & rotor and am ready to re-install.
Now, my question: When I try and put the unit back it stops short of going all the way in by about 3/16". The rotor is lined up with the cam, the cam pin is inserted into the correct slot on the rotor, and the opti-spark slides into the oil seal ok. I don't know if the unit is supposed to easily slide into the seal and mate right up to the block, or if it's a very tight fit and tightening the mounting bolts will bring the unit up against the block. After all of this I sure don't want to force the unit and break a flange off the housing and have to do this job over again!
So, would appreciate any advice from someone that's had this much fun and done this job before. Thanks for the help.
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