MSD Mallory E-Spark Conversion 61001M Installation Instructions Manual

Mallory E-SparkTM Conversion

PN 61001M

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 nd 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 at idle at the coil (+) terminal. If
the measured voltage is within 1-volt of battery voltage, an ignition ballast resistor must be installed in the
wire from the ignition switch. In general, all vehicles equipped with the Delco point ignition were equipped
with an ignition ballast resistor. If you nd 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 specied 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.

Parts Included in this kit:

1 E-Spark™Module 1 Cable Tie
1 Shutter Wheel, 2-piece set 2 Bolts, 8-32 x

3/4 Hex

1 Distributor Wire Harness 2 Nuts, 8-32 Hex

1 Female Connector 2 Flathead Screws, 8-32 x

1/4
1 Mounting Plate 2 Screws, 6-32 x 3/16
1 Capsule, Heat Sink Compound
1 Grommet

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 specications. For racing applications, start with
your engine manufacturer’s specications, 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.

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2 INSTALLATION INSTRUCTIONS

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 the distributor cap from the distributor and lay it aside. Do not remove the spark plug

wires or coil wire. The rotor blade should point to the mark made on the distributor housing
(from Step 2). If it is not, turn the engine crankshaft one full turn (repeating Step 3) until the
timing mark lines up (again) with the TDC mark on the timing tab.

Note: Once you are nished with Step 4, DO NOT turn the crankshaft until the distributor is installed

– Step 12.

Step 5 - Note the direction the rotor is pointing. Note the direction the vacuum chamber is pointing.

Disconnect the vacuum chamber hose at the carburetor and temporarily plug this carburetor
tting. Remove the distributor hold down clamp and remove the distributor from the engine.

Step 6 - Remove the rotor. Disconnect the primary point wire. Remove the primary wire and grommet

from the distributor. Remove the points and the condenser from the breaker plate.

Step 7 - (See Figure 1) - Install the mounting plate at against the breaker plate where the points were.

Secure using two 8-32 x 1/4 athead screws.

Note: Occasionally, the breaker plate ground wire will interfere. Pry the breaker plate ground wire from

the breaker plate, and disconnect it from vacuum chamber mounting screw. The E-Spark™
Ignition System will operate without the breaker plate ground wire.

Step 8 - Apply a thin coat of heat sink compound to the bottom of the module. Install the module onto

the mounting plate with two 6-32 x 3/16 screws. See Figure 1. Secure the three module wire
to the breaker plate with a cable tie.

Step 9 - Install the grommet in the hole in the distributor hosing where the primary point wire had

previously fed through. Slide the three wires from the module, through the grommet, to outside
the distributor housing.

Step 10 - (See Figure 2) Put the three wires from the module in the female connector: green wire in hole

#1; brown wire in hole #2; red wire in hole #3. Plug the distributor wire harness into the female
connector. See Figure 2.

Step 11 - Install the two–piece shutter underneath the rotor drive plate and install two 8-32 bolts. The

hex heads of the 8-32 bolts ts into the matching holes on the underside of the shutter wheel.
Install the rotor on the rotor drive and install two 8-32 hex nuts. See Figure 1.

Note: Some distributors use a rotor made from a exible plastic. File or cut the rotor locator (on the

bottom of the rotor) so that it measures 1/8" in length. Install rotor and shutter as described in
Step 11.

Step 12 - Install the distributor with the rotor and vacuum chamber pointing in the direction as noted in

Step 5. The rotor must be pointing (approximately) at the mark on the distributor housing from
Step 2.

Note: The distributor must be fully seated into the engine. It may be necessary to turn the oil pump

drive, or turn the engine crankshaft two full turns until the timing mark lines up (again) with the
TDC mark on the timing tab, to allow the distributor to seat fully.

Step 13 - Turn the distributor housing until the nearest slot on the shutter wheel is approximately in

the center of the optics of the module. This will generally give timing close enough for starting
purposes. The rotor must be pointing (approximately) at the mark on the distributor housing
from Step 2. Put the distributor hold down clamp in place and tighten slightly, leaving it loose
enough to turn the distributor.

Step 14 - Install the distributor cap.

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INSTALLATION INSTRUCTIONS 3

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 nd 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. 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.

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.

DISTRIBUTOR TUNE–UP PARTS PART NO.

DISTRIBUTOR CAP 202
ROTOR 303
SHUTTER WHEEL (TWO PIECE) 338
E-Spark™ MODULE 6100M
DISTRIBUTOR WIRE HARNESS 29349

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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