Mallory Ignition 686m User Manual

HYFIRE®6.6 SERIES OF

ELECTRONIC IGNITION CONTROL

HYFIRE®6.6 IGNITION SYSTEM PART NO. 686M

FOR APPLICATIONS TRIGGERED BY POINTS, MALLORY ELECTRONIC IGNITION DISTRIBUTOR
(ALL MODELS), ORIGINAL EQUIPMENT ELECTRONIC IGNITION AMPLIFIERS 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).

NOTE: MALLORY HYFIRE® 6.6 ELECTRONIC IGNITION CONTROLS ARE NOT COMPATIBLE WITH
DISTRIBUTORLESS SYSTEMS OR POSITIVE GROUND APPLICATIONS. THE RPM LIMITERS IN THE
HYFIRE® 6.6 (PART NO. 686M) WILL NOT WORK PROPERLY WITH ODD-FIRE OR SEMI-EVEN FIRE V6
APPLICATIONS.

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
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) 4
Late Model GM HEI/EST Systems (external coil) 4
Ford TFI Systems 4

Ford DuraSpark Systems (non-computer type,
without module) 5

Early Model GM HEI Systems (non-computer type,
without module) 5

FORM 1486M 03/05

Mopar/Chrysler Corp. Electronic Systems
(non-computer type, without module) 7

Wiring Method Without Adapters 7

Mallory Electronic Ignition, UNILITE® Distributors,
Magnetic Breakerless Distributors or Electronic
Advance Distributors (3-wire/red, brown, green) 7

For OEM Electronic Systems with modules/amplifiers
(Chrysler, Ford, and import) 7

Magnetic Pickup Trigger Pulses (magnetic
pickup distributors or crank trigger ignition) 8

HYFIRE® 6.6 Ignition System Features 11

Bypass Connector 11

INSTALLATION INSTRUCTIONS

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1 HYFIRE® 6.6 Electronic Ignition Control - Part No. 686M
1 Ignition Control Harness
1 Universal Installation Hardware Kit
1 Hand Held Controller

PARTS INCLUDED IN THIS KIT:

WARNING: USE ONLY SUPPRESSION CORE STYLE SPARK PLUG WIRES WITH THE

HYFIRE® 6.6 IGNITION CONTROL.

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

GENERAL INFORMATION

The HYFIRE®6.6 Ignition System Part Nos. 686M are
not for marine use.

The RPM limiters in the HYFIRE® 6.6 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-fire V6 applications.

Ignition Ballast Resistor / Loom Resistance Wire

The performance of the HYFIRE® 6.6 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) fits into the Ignition
Control Harness to convert back to standard 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® 6.6 Electronic Ignition Controls are designed
to work with most original equipment ignition coils. For
optimum performance use the Mallory PROMASTER E Coil
Part Number 30440 (Up to 7,500 RPM), Part No. 30625 (Up
to 10,000 RPM), 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® 6.6 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

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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 Ignition Control Harness from the HYFIRE® 6.6
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® 6.6 Electronic Ignition Controls.

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® 6.6
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. Excessive moisture will damage components
inside the unit. Chose a location that will allow easy
access to the control port for adjusting the various
functions of the ignition.

Step 3

Choose one mounting method listed below for mounting
the HYFIRE® 6.6 Electronic Ignition Control (3a, 3b, or 3c).

(3a) Mounting to a flat 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® 6.6 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 flat 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 flanges of the
HYFIRE® 6.6 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. When running shock
mounts, it is necessary to run a ground wire (10-14 gauge)
from the ignition housing to a chassis ground.

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FIGURE 1

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FIGURE 3

BASIC WIRING PROCEDURE

Step 1

Refer to Figure 2

Ensure that your vehicle is equipped with a ground cable
between the engine block and firewall (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® 6.6 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® 6.6.

• Connect the Ignition Control Harness to the Ignition
Control Plug at the end plate of the HYFIRE® 6.6
Electronic Ignition Control.

Step 2

Choose one method listed below for wiring the HYFIRE®

6.6 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® 6.6 Electronic Ignition Control
into newer vehicles. These adapters and harnesses allow
you to connect the HYFIRE® 6.6 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)

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.

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FIGURE 2

BLA

BRO

FIGURE 6

FORD TFI SYSTEMS

FIGURE 4

GM/DELCO HEI DISTRIBUTOR (WITH COIL MOUNTED IINSIDE DISTRIBUTOR CAP)

FIGURE 5

GM HEI/EST DISTRIIBUTOR - EXTERNAL COIL

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