Did you pull the pump relay before cranking for the spark test?

Before sending the CDI module for replacement, did you look in the Bentley and follow the steps for checking the unit?
The first thing is to ensure power on pin #15 and go from there.

If you don't get power to the CDI, even a new one isn't going to work.
Or if the "green" signal wire is frazzled at the distributor, a new unit isn't going to work.
Why not do the easy things first as explained in the Bentley?

Here's the deal....

1.) PO must have dropped the engine and mechanic forgot to plug the voltage regulator back up. Alt. was sending too much power to the battery, which caused the failure in the CDI unit. Purchased a new voltage regulator and installed

2.) Checked power to the CDI Unit, all is good here

3.) Purchased a re-furbed CDI unit and installed

4.) Purchased new Red Relay and installed

5.) Buddy figured that getting new magnacor'es was a good idea, so we installed those as well

7.) Turned the key on, heard the whine from the new CDI unit, & she fired up without hesitation.

Car is running like a champ. Thanks for all that helped. Until next time!

Curry

Still an issue.....
 

My buddy drove his car to charlotte, nc and the distinct smell of boiling acid started back again (about 1.5 hours into the drive).....:confused: Pulled over, open the hood, battery hot to the touch, & acid boiling.... Couldn't go two weeks without another failure...

The Good News; this time there was no crazy windshield wipers and the car did not die on him....he shut it off well in advance in order to prevent any damage to the electrical system....this never happens with short drives around town, only during longer drives lasting longer than 1-2 hrs...how long does it usually take for an faulty alt. to overcharge a battery??

As a recap, we have competed the following from the last effect of the boiling battery, which shorted out the CDI unit:

*checked ground strap, brown wires by the battery
*ran spark and fuel test (fuel good, confirmed CDI unit is bad)
*replaced red relay (needed to do anyways)
*replaced voltage regulator
*replaced CDI Unit (had to get the car running again)

Will double check voltage from the battery with the car on and off to see if the alt. is overcharging, now that the regulator has been replaced....will report back soon.

In the interim, anyone else had experience with this issue and if so, was it the alt. or a short somewhere in the electrical system? Perhaps its not that black and white, just curious which is more common. Are their any common grounding points that generally go bad? I have a Haynes Manual that came with the car, which I will reference.