MSD 6440 Installation

MSD 40th Anniversary

6AL Ignition Control

PN 6440

Congratulations on the purchase of your MSD 40th Anniversary 6AL Ignition Control! Not only is this limited
edition (one of 4,000) Ignition Control going to be a collector’s item, but its powerful CD sparks will fire up
the performance of your engine!

The 40th 6AL is supported with a Limited Lifetime Warranty for the original owner so be sure to register your
ignition with MSD at www.msdignition.com/40register. Also, see the last page of these instructions to get a
free t-shirt from MSD! Thanks for being a part of MSD’s 40 years of performance!

Par ts Inc lud ed:

1 - MSD 6 Series Ignition
1 - Harness, PN 8860
1 - Harness, PN 8861
1 - 18" Ground Wire
1 - White Jumpers
1 - Red Jumper
4 - 45° Faston Terminals
4 - #8 x 3/4" Screws
2 - 10-32 x 1/2" Screws

WARNING: During installation, disconnect the battery cables. When disconnecting the battery

always remove the Negative cable first and install it last.

4 - 10-32 Hex Nuts
6 - #10 Lock Washers
1 - 100V/1A Diode
4 - Wire Splicers
2 - Wire Ties
1 - Faston Receptacle
2 - Faston Straight Terminals
4 - Vibration Mounts and Hardware
4 - RPM Modules, 3,000, 6,000, 7,000, 8,000

Note: Solid Core spark plug wires cannot be used with an MSD Ignition.
Note: An MSD 6 Series cannot be used with distributorless ignition systems (DIS).

THEORY OF 6 SERIES IGNITION

CAPACITIVE DISCHARGE

The MSD 40th Anniversary Ignition features a capacitive discharge ignition design. The majority of
stock ignition systems are inductive ignitions. In an inductive ignition, the coil must store and step
up the voltage to maximum strength in between each firing. At higher rpm, since there is less time to
charge the coil to full capacity, the voltage falls short of reaching maximum energy which results in
a loss of power or top end miss.
The MSD Ignition features a capacitor which is quickly charged (within one millisecond) with 460 - 480
volts and stores it until the ignition is triggered. With the CD design, the voltage sent to the coil is always
at full power even at high rpm.

MULTIPLE SPARKS

The MSD 40th Anniversary Ignition produces full power multiple sparks for each firing of a plug. The
number of multiple sparks that occur decreases as rpm increases, however the spark series always
lasts for 20° of crankshaft rotation. Above 3,000 rpm there is simply not enough "time" to fire the spark
plug more than once, so there is only one powerful spark.

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REV LIMITER

The 40th Ignition is equipped with a built-in Adjustable Soft Touch Rev Control. MSD Rev Limiters are
adjustable with plug-in modules which are available in 100 rpm increments. The Soft Touch circuitry
provides a smooth and accurate rev limit by dropping the spark to individual cylinders. The Soft Touch
produces a load-free rev limit that is within 1% of the selected rpm.

GENERAL INFORMATION

BATTERY

An MSD 6 Series Ignition Control will operate on any negative ground, 12 volt electrical system with
a distributor. The MSD can be used with 16 volt batteries and can withstand a momentary 24 volts in
case of jump starts. The Ignitions will deliver full voltage with a supply of 9 - 18 volts and will operate
with a supply voltage as low as five volts.
If your application does not use an alternator, allow at least 15 amp/hour for every half hour of operation.
If the engine is cranked with the same battery or other accessories such as an electric fuel or water
pump are used, the amp/hour rating should be higher.

COILS

The MSD 6 Series Ignitions can be used with most stock coils and aftermarket coils designed to
replace the stock coils. There are some "race only" coils such as the MSD Pro Power Coil, PN 8201,
that cannot be used with a 6 Series MSD Ignition Control. For more information on recommended
coils, consult the supplied Coil Application Chart or check with the manufacturer of your coil. If you
have any questions concerning coils, contact our Customer Service Department at [phone].

TACHOMETERS

The MSD Ignition features a Tach Output Terminal on the side of the
unit. This terminal provides a trigger signal for tachometers, a shift
light or other add-on rpm activated devices. The Tach Output Terminal
produces a 12 volt square wave signal with a 20% duty cycle.
Some vehicles with factory tachometers may require a Tach Adapter
to operate with the MSD. For more information on Tachometers and
MSD Tach Adapters, see the Tachometer Section on page 7.

If your GM vehicle has an inline filter it may cause the tach to drop to
zero on acceleration. If this occurs, bypass the filter.

Figure 1 Tach Terminal

FOREIGN VEHICLES

Due to the fuel injection systems, some foreign vehicles may require a
special Tach/Fuel Injection Adapter to use an MSD Ignition. See pages 7 for wiring and Tach Adapter
information.
Note: Vehicles originally equipped with a CD ignition control cannot use an MSD.

SPARK PLUGS AND WIRES

Spark plug wires are very important to the operation of your ignition system. A good quality, helically
wound wire and proper routing are required to get the best performance from your ignition, such as
the MSD 8.5mm Super Conductor Wire.

Note: Solid Core spark plug wires cannot be used with an MSD Ignition.

A helically, or spiral wound wire must be used. This style wire provides a good path for the spark to
follow while keeping Electro Magnetic Interference (EMI) to a minimum. Excessive EMI, such as the
amount that solid core wires produce, will interfere with the operation of the MSD.

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Routing: Correct routing of the plug wires is also important to performance. Wires should be routed
away from sharp edges and engine heat sources. If there are two wires that are next to each other in
the engine's firing order, the wires should be routed away from each other to avoid inducing a spark
into the other wire. For example, in a Chevy V8, the firing order is 1-8-4-3-6-5-7-2. The #5 and #7
cylinders are next to each other in the engine and in the firing order. If the voltage from the #5 wire
is induced into #7 detonation could occur and cause engine damage.
To add more heat protection to your plug wires, MSD offers Pro-Heat Guard, PN 3411. This is a glass
woven and silicone coated protective sleeve that you slide over your plug wires. For extra protection
of the spark plug boots, MSD offers Pro-Heat Boot Guard, PN 3412.

Spark Plugs: Choosing the correct spark plug design and heat range is important when trying to get
the best performance possible. Since there are so many engine combinations and manufacturers,
MSD does not recommend which plug or gap is exactly right for your application.
It is recommended to follow the engine builder or manufacturer's specification for spark plugs. With
that, you can then experiment with the plug gap to obtain the best performance. The gap of the plugs
can be opened in 0.005" increments, then tested until the best performance is obtained. MSD judges
the plug gap by compression and components:

These examples are just starting
points to get you going in the right
direction. Every application is different
and should be tested and tuned.

Compression Spark Plug Gap

Up to 10.5:1: 0.050" - 0.060"

10.5:1 - 13.0:1: 0.040" - 0.050"
Above 13.0:1: 0.035" - 0.045"

MISCELLANEOUS INFORMATION

Sealing: Do not attempt to seal the MSD. All of the circuits of an MSD receive a thick conformal
coating of Humi-Seal. This sealant protects the electronics from moisture. If you were to seal the
unit, any moisture or water that may seep in through the wiring grommets will not be able to drain
and may result in corrosion.

Welding: If you are welding on your vehicle, to avoid the chance of damage, always disconnect both
Heavy Power cables of the MSD (You should also disconnect the tach ground wire too).

Distributor Cap and Rotor: It is recommended to install a new distributor cap and rotor when installing
the MSD Ignition Control. The cap should be clean inside and out especially the terminals and rotor tip.
On vehicles with smaller caps, it is possible for the air inside the cap to become electrically charged
causing crossfire which can result in misfire. This can be prevented by drilling a couple vent holes in
the cap. The holes should be placed between the terminals, at rotor height and face away from the
intake. If your environment demands it, place a small piece of screen over the hole to act as a filter.

Initial Spark: It is normal, yet not very common, for the MSD to produce a spark when the ignition
key is turned On. This is due to the capacitor being charged and if the pickup is in the right position,
it could trigger the ignition momentarily. This could also occur when installing the positive battery
cable.

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MOUNTING

The MSD can be mounted in most positions, except directly upside down (if upside down, moisture
or water cannot escape). It can be mounted in the engine compartment as long as it is away from
direct engine heat sources. It is not recommended to mount the unit in an enclosed area such as
the glovebox.
When you find a suitable location to mount the unit, make sure the wires of the ignition reach their
connections. Hold the Ignition in place and mark the location of the mounting holes, use a 3/16" drill
bit and drill the holes for the supplied vibration mounts. Install the vibration mounts, then mount the
Ignition.

CYLINDER SELECT

The Soft Touch Rev Limiter that is built into the Ignition is programmed for operation on a 8-cylinder
engine. If you are installing one of these units on a 4 or 6-cylinder even-fire engine, the ignition must
be modified. This is easily achieved through the cylinder select device on the side of the ignition. To
program the unit:

1. Locate and remove the round black cover with a single Phillips screw.

2. There are two wire loops, a Red and Blue loop. Refer to the chart in Figure 2 to determine which
loop to cut for your application.

3. After cutting the loop(s), turn the wire ends away from each other so they cannot come into contact.
Install the cover and screw.

Figure 2 Selecting the number of Cylinders.

WIRING

GENERAL WIRING INFORMATION

Wire Length: All of the wires of the MSD Ignition may be shortened as long as quality connectors
are used or soldered in place. To lengthen the wires, use one size bigger gauge wire (10 gauge for
the power leads and 16 gauge for the other wires) with the proper connections. All connections must
be soldered and sealed.

Grounds: A poor ground connection can cause many frustrating problems. When a wire is specified
to go to ground, it should be connected to the battery negative terminal, engine block or chassis.
There should always be a ground strap between the engine and the chassis. Always securely connect
the ground wire to a clean, paint free metal surface.

Ballast Resistor: If your vehicle has a ballast resistor in line with the coil wiring, it is recommended
to bypass it.

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ROUTING WIRES

The MSD wires should be routed away from direct heat sources such as exhaust manifolds and
headers and any sharp edges. The trigger wires should be routed separate from the other wires
and spark plug wires. It is best if they are routed along a ground plane such as the block or firewall
which creates an electrical shield. The magnetic pickup wires should always be routed separately
and should be twisted together to help reduce extraneous interference.

WIRE FUNCTIONS

POWER LEADS

HEAVY RED

HEAVY BLACK

RED

ORANGE

BLACK

TRIGGER
WIRES

These are the two heavy gauge wires (12 gauge) and are responsible for
getting direct battery voltage to the Ignition. The ignition has an internal fuse
so no fuse is necessary.

This wire connects directly to the battery positive (+) terminal or to a positive
battery junction or the positive side of the starter solenoid.
Note: Never connect the alternator.

This wire connects to a good ground, either at the battery negative (-) terminal
or to the engine.

Connects to a switched 12 volt source. Such as the ignition key or switch.

Connects to the positive (+) terminal of the coil.

This is the only wire that makes electrical contact with the coil positive
terminal.

Connects to the negative (-) terminal of the coil.

This is the only wire that makes electrical contact with the coil negative
terminal.

There are two circuits that can be used to trigger the MSD Ignition; a Points
circuit (White wire) and a Magnetic Pickup circuit (Violet and Green wires).
The two circuits will never be used together.

WHITE

VIOLET
AND GREEN
(MAGNETIC
PICKUP
CONNECTOR)

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This wire is used to connect to the points, electronic ignition amplifier output
or to the Yellow wire of an MSD Timing Accessory. When this wire is used,

the Magnetic Pickup connector is not used.

These wires are routed together in one harness to form the Magnetic Pickup
connector. The connector plugs directly into an MSD Distributor or Crank
Trigger. It will also connect to factory magnetic pickups or other aftermarket
pickups. The Violet wire is positive (+) and the Green is negative (-). When

these wires are used, the White wire is not.