Mallory Ignition 61003M User Manual
E-SPARK™ CONVERSION PART NO. 61003M
PARTS INCLUDED IN THIS KIT
1 E-Spark™Module 1 Cable Tie
1 Rotor/Shutter Wheel 1 Capsule, Silicone Grease
1 Distributor Wire Harness 2 Screws, 6-32 x 3/16
1 Female Connector 1 Grommet
1 Mounting Plate
IMPORTANT: Before installing the E-Spark™ Ignition System, make sure that your vehicle is equipped with an ignition ballast resistor (or loom resistance
wire) in the wire between the ignition switch and the coil (+) terminal. One easy way to find the ignition ballast resistor is to check the service manual for
your vehicle. You can test your stock ignition system voltage while the engine is a t idle at the coil (+) terminal. If the measur ed voltage is within 1-volt
of battery voltage, an ignition ballast resistor must be installed in the wire from the ignition s witch. In general, all vehicles equipped with the Delco point
ignition were equipped with an ignition ballast resistor.If you find your vehicle is not equipped with an ignition ballast resistor ,install a Mallory Ignition Ballast
Resistor Part No. 700 in series in the wire from the ignition switch. Failure to use an ignition ballast resistor will result in the eventual destruction of the
E-Spark™ Ignition Module.
Exceptions: 1)Using one of Mallory's 3 specially matched coils eliminate the need for a ballast resistor or a resistance wire.These coils are:29219- Chrome
Canister Coil, 30450 PROMASTER e Coil and 29450 PROMASTER Classic Coil.
2) If your vehicle is equipped with a HyFire Electronic Ignition Control or similar aftermarket ignition control, use the wiring specified for the
particular controller,along with its matching coil, such as Mallory's 29440 or 30440.
NOTE: This kit can be installed in the distributor without removing the distributor from the engine if the distributor is easily accessible. However,
removal of the distributor from the engine is recommended.
GENERAL INFORMATION
Ignition Coils:
The E-Spark™ Ignition System is designed to work with most stock
ignition coils and aftermarket high performance ignition coils.For optimum
performance in systems without a HyFire or similar ignition control,use one
of Mallory's 3 specially matched coils eliminates the need for a ballast
resistor or a resistance wire.These coils are: 29219- Chrome Canister Coil,
30450 PROMASTER e Coil and 29450 PROMASTER Classic Coil.
Spark Plug Wires:
To prevent false triggering and the possibility of premature ignition failures,
use suppression type spark plug wire. We recommend spiral core ignition
wire, such as Mallory PRO SIDEWINDER
®
Ignition Wire.
Spark Plug Gaps:
For street applications, use your engine manufacturer’s specifications. For
racing applications, start with your engine manufacturer’s specifications,
then experiment with and closely monitor various gaps to achieve maximum performance.
Electric Welding:
Unplug the distributor wire harness before welding on the vehicle.
Optional Circuit Guard Part No.29371:
Voltage spikes (voltage transients, power surges) are associated with
“noisy” electrical systems from electrical defects such as worn alternator
brushes, corroded or oxidized electrical connections and similar electrical
problems. Voltage spikes damage the E-Spark™ Ignition Module. Voltage
spikes are clamped and regulated by the optional Circuit Guard from
damaging the E-Spark™Ignition Module.
FORM 1583M 2/04
INSTALLATION PROCEDURE
Step 1
Disconnect the point trigger wire from the coil (–) terminal.
Step 2
Locate the spark plug wire on the distributor cap that the engine timing is
set from. See a service manual for these locations. Mark the distributor
housing, in line with this spark plug wire position on the distributor cap.
Step 3
Turn the engine crankshaft until the timing mark lines up with the TDC (top
dead center) mark on the timing tab.See a service manual for these locations.
NOTE: Removing the spark plugs may make it easier to turn the crankshaft.
Step 4
Remove and set aside the distributor cap to allow clear access to distributor. Do not remove plug wires from cap. If it is not necessary to remove
distributor from engine to install E-Spark Kit, remember rotor location so
distributor can be reinstalled in engine with the rotor pointing to the same
location as when distributor was removed.
NOTE: Review Figure 1 for the parts that will be reused during
this conversion.
Step 5
Remove points, condenser, primary lead wire and rotor from distributor.
Step 6
Remove point plate assembly from distributor housing. This can be done
without removing vacuum diaphragm.
Step 7
With point plate assembly removed from distributor, disassemble upper
point plate from lower stationary base plate by removing spring clip located beneath base plate. Use caution when gently removing the spring clip
to avoid spring clip distortion.
Step 8
(See Figure 1)
Reassemble plate assembly using new module adapter plate supplied.
Step 9
Reinstall new plate assembly into distributor housing the same as original
point plate.
Be sure vacuum diaphragm arm is properly connected to removable plate.
Step 10
Apply a thin coat of white silicone grease to the bottom of the new module.
Install E-Spark module using the two 6-32 screws supplied.
MALLORY IGNITION
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1
INSTALLATION INSTRUCTIONS
Step 11
Push supplied rubber grommet into hole inside distributor housing. Be sure
flat on flange of rubber grommet is on the outside of the distributor
housing facing upward. Push wires of module through rubber grommet.
Step 12
Mount connector pins into plastic terminal pin housing supplied. Be sure
wires are shoved in to pin housing as shown in Figure 2. Shove pins into
pin housing until a definite click is heard. Install rotor-shutter onto cam
sleeve. Make sure that you press on the top of the rotor and not the
shutter assembly. Be sure it is seated all the way down onto cam sleeve.
Step 13
If distributor was removed from engine, install back into engine with the
rotor pointing to the same location from which it was originally removed.
Step 14
Install new distributor cap onto distributor housing. Holding original
distributor cap near new distributor cap, remove plug wires one at a time,
installing them into new distributor cap in the same connector sockets as
removed from original cap. Be sure to do this one at a time so as not to
change the firing order. Remove coil wire from original cap and install into
new cap.
WIRING PROCEDURE
(See Figures 3, 4 and 5)
Step 1
Make sure that your vehicle is equipped with an ignition ballast resistor (or
loom resistance wire) in the wire between the ignition switch and the coil
(+) terminal.If you find your vehicle is not equipped with an ignition ballast
resistor,install a Mallor y Ignition Ballast Resistor Part No. 700 in series in
the wire from the ignition switch. For optimum performance in systems
without a HyFire or similar ignition control,use one of Mallory's 3 specially
matched coils which eliminates the need for a ballast resistor or a
resistance wire. These coils are: 29219- Chrome Canister Coil, 30450
PROMASTER e Coil and 29450 PROMASTER Classic Coil.
DISTRIBUTOR TUNE–UP PARTS PART NO.
DISTRIBUTOR CAP 216
ROTOR 334
E-SPARK™ MODULE 6100M
DISTRIBUTOR WIRE HARNESS 29349
Step 2
There are three wires coming from the distributor wire harness:
RED WIRE:Connect to the coil (+) terminal.
GREEN WIRE: Connect to the coil (–) terminal.
BROWN WIRE: Connect to engine block ground.
Clean away any grease, oil and paint from the mounting surface before the
connection is made.
NOTE: If a HYFIRE®Electronic Ignition Control or any other aftermarket
ignition control is being used, connect the distributor wire harness
according to the instructions supplied with the ignition control.
STARTING THE ENGINE
CAUTION: Be sure all tools,wires and miscellaneous objects are clear
of moving engine parts and extreme heat before starting the engine.
Recheck all wires and connections to make sure they are correct. Check
and clean, or replace spark plugs. If replacing spark plugs, use types
recommended by the engine manufacturer.
Step 1
Connect a timing light.Find the area with the best view of the timing marks.
Step 2
Start engine. If it fails to start, rotate the distributor in small increments
clockwise or counterclockwise until engine starts.Do not exceed more than
ten degrees of distributor housing rotation in either direction.
Step 3
Set timing as recommended by engine manufacturer, then tighten
distributor hold down clamp.Make sure timing is still correct.If timing has
moved, repeat this procedure.
Step 4
Re-connect the vacuum hose between the vacuum chamber and
the carburetor.
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FIGURE 1
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