Mallory Ignition 692, 697 User Manual
FORM 1351 (REV. E) 10/99
INSTALLATION INSTRUCTIONS
®
HYFIRE® IV SERIES OF ELECTRONIC
IGNITION CONTROLS
HYFIRE® IVC Ignition System Part No. 692, Universal
HYFIRE® IVA Ignition System Part No. 697, Universal
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).
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® IV Electronic Ignition Controls are not compatible with distributorless systems or positive
ground applications. The RPM Limiter in the HYFIRE® IVC (Part No. 692) will not work properly with odd-fire or semieven fire V6 applications.
Parts included in this kit:
1 HYFIRE® IV Electronic Ignition Control - Part No. 692 or 697
1 Ignition Control Harness - Part No. 29348
2 Terminal Connectors - Part No. 450
1 Bypass Connector
4 Cable Ties
2 Spade Terminals
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
HYFIRE® IVC Ignition System 4 and 6 Cylinder Operation ...............2
Mounting Procedure .............................................................................2
Mounting to a Flat Surface Without Mounting Brackets ............... 2
Mounting to a Flat or Uneven Surface
Using Mounting 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 ........................................................................4, 6
8 Ring Terminals, 1/4"
1 Ring Terminal, 3/8"
5 Spade Receptacle Terminals
4 Mounting Brackets
4 #10 Sheet Metal Screws
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/amplifiers
(Chrysler, Ford, and import) ...............................................7, 10
Magnetic Pickup Trigger Pulses (magnetic
pickup distributors or crank trigger ignition) ..........................7, 10
RPM Limiter Operation HYFIRE® IVC Ignition System
(PN 692 only) .................................................................................11
Optional Ignition Accessories ............................................................11
Bypass Connector..............................................................................12
Mounting Template ............................................................................12
1
GENERAL INFORMATION
The HYFIRE® IV Ignition System Part Nos. 692 and 697 are not for marine use.
The RPM limiter in the HYFIRE® IVC 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® IV 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 vehicles 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® IV 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 it will
operate properly. This signal changes once HYFIRE® IV 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 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® IV 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® IV Electronic Ignition Controls.
Mallory PRO TACH® I, IV and VI
The RPM needle and shift light will work with the HYFIRE® IV. However, the tach's proportional
controller that limits RPM WILL NOT function with the HYFIRE® IV. Turn the LIMIT RPM knob
slightly past 11,000 to prevent the limiter from interfering with the tachs other functions. See
Optional Ignition Accessories for more information.
FIGURE 1
4 CYL
2
6 CYL
4 - 6 CYL
SWITCH
1
OF
BOTTOM
HYFIRE® IVC IGNITION SYSTEM
4 AND 6 CYLINDER OPERATION
The HYFIRE® IVC Ignition System comes from the factory set for 8 cylinder engines. 4 or 6
cylinder operations require you to set a switch inside the housing. DO THIS BEFORE
MOUNTING THE IGNITION BOX!
Use a T-15 Torx® tool to remove the four screws that holds the blank end panel to the
housing. Remove the blank end panel (see Figure 1).
With the ignition upside-down, look inside and on the left side of the PC board you will
see a small two position switch. The switch (#1) nearest the end of the PC board is the 6
cylinder switch. The other switch (#2) is the 4 cylinder switch. These switches are OFF
for 8 cylinder engines. Turn the appropriate switch ON for 4 or 6 cylinder operations.
Attach the blank end panel to the housing.
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® IV 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® IV Electronic Ignition
Control (3a, 3b, or 3c).
(3a) Mounting to a flat surface without brackets
Center punch the mounting pattern on the mounting surface using the mounting
template to mark locations for drilling mounting holes. Drill holes using a 7/32" drill bit.
Hold the HYFIRE® IV 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 into the tapped holes in the bottom plate of HYFIRE® IV
Electronic Ignition Control. Tighten each screw until snug.
(3b) Mounting to a flat or uneven surface using brackets
Refer to Figure 2 while performing the following steps.
Position one hole of each bracket over each tapped hole in the bottom plate of the
HYFIRE® IV. Insert 10-32 screws with lock washers through these holes and into the
tapped hole in the bottom plate of the HYFIRE® IV. Tighten each screw until snug.
Hold the HYFIRE® IV in position where it will be mounted. Bend the brackets slightly to
meet uneven surfaces. Center punch the mounting pattern on the mounting surface to
mark locations for drilling mounting holes. Drill holes using a 9/64" drill bit.
Insert the #10 sheet metal screws through the remaining holes in the mounting brackets
and into the holes in the mounting surface. Tighten each screw until snug.
(3c) Mounting to a flat surface with shock mounts (available separately)
Center punch the mounting pattern on the mounting surface using the mounting
template to mark locations for drilling mounting holes. Drill holes using a 7/32" drill bit.
Install the shock mounts into the bottom plate of the HYFIRE® IV. 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 2
2
WIRING PROCEDURE
Step 1
Refer to Figure 3
Ensure that your vehicle is equipped with a ground cable between the engine block and firewall
(10 gauge or larger is required). Locate one LONG RED WIRE and one LONG BLACK WIRE
at the end plate of the HYFIRE® IV 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.
Connect the Ignition Control Harness to the Ignition Control Plug at the end plate of the
HYFIRE® IV Electronic Ignition Control.
Step 2
Choose one method listed below for wiring the HYFIRE® IV 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® IV Electronic
Ignition Control into newer vehicles. These adapters and harnesses allow you to connect the
HYFIRE® IV 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 4, 5, and 8 when connecting to GM HEI Systems; Figure 6 when connecting
to Late Model GM HEI/EST Systems; Figure 7 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 3
ENGINE OR CHASSIS
GROUND
TO THE STARTER
IGNITION CONTROL
DISCONNECT UNTIL INSTALLATION IS COMPLETE
(–) 12V/BATTERY (+)
PLUG
STARTER
SOLENOID
(TYPICAL)
LONG RED WIRE
LONG BLACK WIRE
®
HYFIRE® IGNITION
SYSTEM
CONNECT RED WIRE
AT EITHER LOCATION
ENGINE OR
CHASSIS
GROUND
MALLORY 8MM SUPPRE
GM/DELCO HEI DISTRIBUTOR
WITH COIL MOUNTED INSIDE
DISTRIBUTOR CAP
PINK OR RED
BLACK
BROWN
TO VEHICLE HARNESS
(12 VOLT/IGNITION SWITCH)
FIGURE 4
(DISCONNECT)
DISTRIBUTOR
PLUG
BAT
PLUG
PINK OR RED
SMALL GREEN AND BLACK
WIRES – NOT USED
RED
GREEN
BLACK
YELLOW
IGNITION CONTROL HARNESS
3
MALLORY 8MM SUPPRE
GM/DELCO HEI DISTRIBUTOR
WITH COIL MOUNTED INSIDE
TO VEHICLE HARNESS
DISTRIBUTOR CAP
PINK OR RED
DISTRIBUTOR
PLUG
NOTE: LEAVE TACH PLUG, IF THERE IS ONE,
PLUGGED INTO THE DISTRIBUTOR CAP
ADAPTER / HARNESS
PART NO. 29042
BROWN
YELLOW
TO ENGINE
GROUND
BLACK
BAT
PLUG
RED
GM/DELCO HEI DISTRIBUTOR
(WITH COIL MOUNTED INSIDE DISTRIBUTOR CAP)
ADAPTER / HARNESS
PART NO. 29042
IGNITION
IGNITION CONTROL
HARNESS
ABCD
SMALL GREEN AND BLACK
WIRES – NOT USED
CONTROL
PLUG
LONG RED
(–) BATTERY (+)
HYFIRE® IGNITION
SYSTEM
LONG BLACK
CHASSIS/FRAME GROUND
(DO NOT CONNECT TO
ENGINE BLOCK)
FIGURE 5
®
TO THE
IGNITION
COIL
BOTH OF THE
FACTORY
HARNESS
PLUGS
(ORIGINALLY
CONNECTED
TO THE COIL)
NOTE:
YELLOW/COIL (+)
BLACK/COIL (–)
YELLOW AND BLACK
ADAPTER /HARNESS
PART NO. 29068
YELLOW
BLACK
GREEN
RED
RED AND GREEN
GREEN
NOTE: MOST AFTERMARKET REPLACEMENT IGNITION MODULES WILL NOT
TRIGGER THE HYFIRE
ORIGINAL GM/DELCO IGNITION MODULE.
®
IGNITION SYSTEM. THE BEST TYPE TO USE IS AN
GM HEI/EST DISTRIBUTOR - EXTERNAL
IGNITION COIL
AND ADAPTER / HARNESS PART NO. 29068
IGNITION
CONTROL
IGNITION CONTROL HARNESS
YELLOW
BLACK
GREEN
RED
ABCD
SMALL GREEN AND BLACK
WIRES – NOT USED
PLUG
LONG RED
(–) BATTERY (+)
LONG BLACK
FIGURE 6
HYFIRE® IGNITION
CHASSIS/FRAME GROUND
(DO NOT CONNECT TO
ENGINE BLOCK)
®
SYSTEM
4
TO THE
IGNITION
BLACK
FA CTORY
HARNESS
PLUG
(ORIGINALL Y
CONNECTED
TO THE COIL)
COIL
ADAPTER /HARNESS
NOTE:
YELLOW/COIL (+)
BLACK/COIL (–)
YELLOW
RED
PART NO. 29062
YELLOW
BLACK
GREEN
RED
GREEN
FORD TFI SYSTEMS
ADAPTER / HARNESS
PART NO. 29062
IGNITION CONTROL HARNESS
YELLOW
BLACK
GREEN
RED
ABCD
SMALL GREEN AND BLACK
WIRES – NOT USED
IGNITION
CONTROL
PLUG
LONG RED
(–) BATTERY (+)
HYFIRE® IGNITION
SYSTEM
LONG BLACK
CHASSIS/FRAME GROUND
(DO NOT CONNECT TO
ENGINE BLOCK)
FIGURE 7
®
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