Mallory Ignition 685, 6851 User Manual

FORM 1478 (REV. D) 09/2008

INSTALLATION INSTRUCTIONS

HYFIRE® VI SERIES OF ELECTRONIC

IGNITION CONTROLS

HYFIRE® VI Ignition System Part No. 685, Advanced

HYFIRE® VI Ignition System Part No. 6851, Basic

For applications triggered by points, Mallory Electronic Ignition Distributor (all models), original equipment electronic ignition ampliﬁ ers and magnetic trigger pulses (magnetic pickup distributor or crank trigger ignition). Optional adapters are available for easy connection to early model Delco/GM HEI Systems, late model GM HEI/EST Systems, Ford TFI Systems, and OEM magnetic pickup (non-computer; Ford DuraSpark, GM HEI and Mopar/Chrysler Electronic Systems).

This product is legal to sell, distribute or install on vehicles in California. C.A.R.B. Executive Order D-70-26.

NOTE: Mallory HYFIRE® VI Electronic Ignition Controls are not compatible with distributorless systems or positive ground applications. The RPM Limiter in the HYFIRE® VI (Part No. 685) will not work properly with odd-ﬁ re or semi-even ﬁ re V6 applications.

Parts included in this kit:

1 HYFIRE® VI Electronic Ignition Control - Part No. 685 or 6851 1 Ignition Control Harness - Part No. 29348 2 Terminal Connectors - Part No. 450 1 Bypass Connector 4 Cable Ties 2 Spade Terminals

8 Ring Terminals, 1/4” 1 Ring Terminal, 3/8” 5 Spade Receptacle Terminals 4 10-32 Screws 4 10-32 Nuts with Lockwashers

WARNING: DO NOT USE NON-SUPPRESSOR SPARK PLUG

WIRES WITH THE HYFIRE® VI IGNITION CONTROL.

KEEP ALL IGNITION SYSTEM WIRES AS FAR FROM SPARK PLUG WIRES AS POSSIBLE.

CONTENTS

General Information ...............................................................................2

Ignition Ballast Resistor/Loom Resistance Wire ............................2

Standard Ignition Bypass (Bypass Connector) ..............................2

Ignition Coils ....................................................................................2

Fuel Injection ....................................................................................2

Spark Plug Wires ..............................................................................2

Spark Plug Gaps ..............................................................................2

Electric Welding ...............................................................................2

External RPM Limiters

Mallory PRO TACH® I, IV and VI ......................................................2

Mounting Procedure ..............................................................................2

Mounting to a Flat Surface Without Brackets ................................2

Mounting to a Flat or Uneven Surface Using Brackets ................2

Mounting to a Flat Surface with Shock Mounts ............................2

Wiring Procedure ...................................................................................3

Wiring Method using Adapters and Harnesses ..............................3

GM HEI Systems/coil-in-cap with OEM module) ..................3-4

Late Model GM HEI/EST Systems (external coil) .................3-5

Ford TFI Systems .........................................................................3-4

Ford DuraSpark Systems (non-computer type,

without module) ......................................................................5-6

Early Model GM HEI Systems (non-computer type,

without module) .....................................................................6, 8

Mopar/Chrysler Corp. Electronic Systems

(non-computer type, without module) .................................6, 9

Wiring Method Without Adapters ..........................................................7

Breaker Point Systems ................................................................7, 9

Mallory Electronic Ignition, UNILITE® Distributors,

Magnetic Breakerless Distributors or Electronic

Advance Distributors (3-wire/red, brown, green) .............7, 10

For OEM Electronic Systems with modules/ampliﬁ ers

(Chrysler, Ford, and import) ...............................................7, 10

Magnetic Pickup Trigger Pulses (magnetic

pickup distributors or crank trigger ignition) .........................7, 10

Top Panel Operation and Features .................................................... 11

RPM Limiter Operation – HYFIRE® VI Ignition System

(PN 685 only) ..................................................................................11

Optional Ignition Accessories .............................................................11

Bypass Connector ...............................................................................12

Mounting Template ..............................................................................12

GENERAL INFORMATION

The HYFIRE® VI Ignition System Part Nos. 685 and 6851 are not for marine use.

The RPM limiter in the HYFIRE® VI is not recommended as an engine speed governor. The use of the RPM limiters is not recommended for applications equipped with a catalytic converter. Similarly, forcing engine RPM past the RPM limiter continuously for long sustained intervals can cause fuel build up in the exhaust system that may adversely affect your application. The RPM limiting systems will not work properly with odd-ﬁ re V6 applications.

Ignition Ballast Resistor / Loom Resistance Wire

The performance of the HYFIRE® VI is not affected by the presence of the factory ignition resistors or ignition ballast resistors in the wire from the ignition switch.

Standard Ignition Bypass (Bypass Connector)

The Bypass Connector (supplied) ﬁ ts into the Ignition Control Harness to convert back to stan- dard ignition. If you use the Bypass Connector, use ignition ballast resistors designed for your vehicle’s distributor and coil (see diagrams for more information). This bypass method does not work with magnetic pickup distributor or crank trigger ignition. Racing Applications: It is not necessary to install ignition ballast resistors. However, do not use the Bypass Connector until the ignition ballast resistors are installed in the wire from the ignition switch.

Ignition Coils

The HYFIRE® VI Electronic Ignition Controls are designed to work with most original equipment ignition coils. For optimum performance use the Mallory PROMASTER® Coil Part No. 29440 (up to 7,500 RPM) or Part No. 29625 (up to 10,000 RPM).

Fuel Injection

Some fuel injection systems need a voltage spike signal from the ignition coil before they will operate properly. This signal changes once HYFIRE® VI Electronic Ignition Controls are installed. The Mallory Fuel Injection and Tachometer Adapters Part Nos. 29074 and 29078 supply the proper signal to the vehicle computer to operate the fuel injection system. Installation procedure and diagrams are supplied with these adapters.

Spark Plug Wires

YOU MUST USE suppression type (carbon core, spiral core, suppression core) spark plug wire. We recommend spiral core ignition wire, such as Mallory PRO SIDEWINDER® Ignition Wire. Suppression type spark plug wires prevent false triggering and possible premature ignition or accessory failures. DO NOT USE solid core (copper core; stainless steel core)

spark plug wire with any electronic ignition system or accessory.

Spark Plug Gaps

For street applications, use your engine manufacturer’s speciﬁ cations. For racing applications, start with your engine manufacturer’s speciﬁ cations, then experiment with, and closely monitor, various gaps to achieve maximum performance.

Electric Welding

Unplug the Ignition Control Harness from the HYFIRE® VI Electronic Ignition Control and unplug any distributor harnesses (if possible) before any welding is done on the vehicle.

External RPM Limiters

Mallory Proportional RPM Limiter Part Nos. 641-4, 641-6, 641-8, 642, 643 and 644 WILL NOT function with the HYFIRE® VI Electronic Ignition Controls.

Mallory PRO TACH® I, IV and VI

The RPM needle and shift light will work with the HYFIRE® VI. However, the tach’s proportional controller that limits RPM WILL NOT function with the HYFIRE® VI. Turn the LIMIT RPM knob slightly past 11,000 to prevent the limiter from interfering with the tach’s other functions. See Optional Ignition Accessories for more information.

MOUNTING PROCEDURE

Step 1

Disconnect the battery (–) cable to cut power to the system. Computerized vehicles: Disconnect the battery (–) cable and let the vehicle sit overnight before proceeding. This allows the computer to calibrate for the new ignition.

Step 2

Select a convenient location to mount the HYFIRE® VI Electronic Ignition Control. Keep the unit away from hot engine components or extreme heat such as the exhaust system and manifolds. Also, keep it away from moving devices, such as fans, belts and linkages. The location must be dry. Moisture will damage components inside the unit.

Step 3

Choose one mounting method listed below for mounting the HYFIRE® VI Electronic Ignition Control (3a, 3b, or 3c).

(3a) Mounting to a ﬂ at surface

• Center punch the mounting pattern on the mounting surface using the housing holes to mark locations for drilling mounting holes. Drill holes using a 7/32” drill bit.

• Hold the HYFIRE® VI Electronic Ignition Control in position over the mounting holes.

• From the backside of the mounting surface, insert the 10-32 screws with lock washers through the mounting holes and attach with the 10-32 nuts supplied.

(3c) Mounting to a ﬂ at surface with shock mounts (available separately, PN

29069)

• Center punch the mounting pattern on the mounting surface using the housing holes to mark locations for drilling mounting holes. Drill holes using a 7/32” drill bit.

• Install the shock mounts into the side ﬂ anges of the HYFIRE® VI and tighten nuts. Hold the unit in position where it will be mounted.

• From the backside of the mounting surface, insert the 10-32 nuts with lock washers onto the shock mount studs. Tighten each nut until snug.

FIGURE 1

BASIC WIRING PROCEDURE

BLA

BRO

Step 1

Refer to Figure 2

Ensure that your vehicle is equipped with a ground cable between the engine block and ﬁ rewall (10 gauge or larger is required). Locate the harness with the LONG RED WIRE and one LONG BLACK WIRE at the end plate of the HYFIRE® VI Electronic Ignition Control.

• Connect the LONG RED WIRE to the battery (+) post or battery (+) terminal on the starter solenoid.

• Connect the LONG BLACK WIRE to engine ground or chassis ground.

• Plug into 2-pin connector with red and black wires coming from the end plate on the HYFIRE

• Connect the Ignition Control Harness to the Ignition Control Plug at the end plate of the HYFIRE

Step 2

Choose one method listed below for wiring the HYFIRE® VI Electronic Ignition Control (2a, 2b, or 2c)

(2a) Wiring method using Adapters and Harnesses (sold separately)

Special wiring Adapters and Harnesses simplify the installation of the HYFIRE® VI Electronic Ignition Control into newer vehicles. These adapters and harnesses allow you to connect the HYFIRE® VI Electronic Ignition Control between the ignition coil and the factory coil connector. They reduce installation time and wiring errors. Also, converting back to the factory ignition is easy because there is no need to cut the original wiring. These instructions cover:

PART NO. 29042 – Connecting to GM HEI Systems (coil-in-cap, with OEM

ignition module)

PART NO. 29068 – Connecting to Late Model GM HEI/EST Systems (external coil)

VI.

VI Electronic Ignition Control.

PART NO. 29062 – Connecting to Ford TFI Systems. PART NOS. 29039 and 29040 – Connecting to Ford DuraSpark Systems

(non-computer type, without ignition module).

PART NOS. 29040 and 29043 – Connecting to Early Model GM HEI Systems

(non-computer type, without ignition module)

PART NO. 29040 – Connecting to Mopar/Chrysler Electronic Systems (non-computer

type, without ignition module).

Connecting to: GM HEI Systems (coil-in-cap, with OEM ignition module), use Adapter PART NO. 29042; Late Model GM HEI/EST Systems, use Adapter PART NO. 29068; Ford TFI Systems, use Adapter PART NO. 29062.

Connecting Adapter PART NO. 29042, 29062 or 29068

Refer to Figures 3, 4, and 7 when connecting to GM HEI Systems; Figure 5 when connecting to Late Model GM HEI/EST Systems; Figure 6 when connecting to Ford TFI Systems.

• Match wires by color from the Adapter to the Ignition Control Harness. Crimp all wires together.

• Disconnect the factory harness(es) at the ignition coil. Connect them to the Adapter that has the RED and GREEN WIRES.

• Connect the Adapter that has the YELLOW and BLACK WIRES to the ignition coil. NOTE: When using an aftermarket ignition coil with post type terminals, discard the Adapter that has the YELLOW and BLACK WIRES. Install ring terminals on the Ignition Control Harness YELLOW and BLACK WIRES. Connect the YELLOW WIRE to the ignition coil (+) terminal. DO NOT allow any wire except the YELLOW WIRE to make contact with the ignition coil (+) terminal. Connect the BLACK WIRE to the ignition coil (–) terminal.

• Go to Step 3, page 9.

FIGURE 2

FIGURE 3

ABCD

MALLORY 8MM SUPPRE

FIGURE 4

ABCD

FIGURE 5

FIGURE 6

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