FORM 1503 6/04 INSTALLATION INSTRUCTIONS E-SPARK™ BREAKERLESS CONVERSION KIT FOR MALLORY POINT DISTRIBUTORS NOTE: This product is legal in California only for racing vehicles which may never be operated upon a highway. IMPORTANT All kits listed below must be used with an ignition ballast resistor (or loom resistance wire) to prevent module failure. If your vehicle is not equipped with a ballast resistor or loom resistance wire, Mallory Ballast Resistor (Part No. 700) or Mallory Coils 29219, 29450 or 30450 (which are internally ballasted) may be used. These kits do not work with vacuum advance distributors. WARNING APPLICATIONS Part No. 61004M Part No. 61005M Part No. 61006M Part No. 61007M Part No. 61008M Part No. 61009M Mallory 8 cylinder point distributors (automotive and marine) which use a standard stack cap (Part No. 209 or 209D) Mallory 8 cylinder point distributors (automotive and marine) which use a flat cap (Part No. 221 or 221B) Mallory 6 cylinder point distributors (automotive and marine) which use a standard stack cap (Part No. 270 or 270B) Mallory 6 cylinder point distributors (automotive and marine) which use a mini bowl cap (Part No. 226 or 226B) Mallory 4 cylinder point distributors (automotive and marine) which use a standard stack cap (Part No. 271 or 271B) Mallory 4 cylinder point distributors (automotive and marine) which use a mini bowl cap (Part No. 225 or 225B) You must install the E-Spark™ Conversion Kit exactly as shown in these instructions. After the kit is installed—and before you start the engine— check all wiring again. Mis-wiring will cause the E-Spark™ Ignition to fail immediately. INSTALLATION Step 1 Remove the cap and rotor, then remove the condenser. Remove the plastic insulators (see Figure 1). Step 2 Loosen the 2 nuts that hold the cap clips/brackets in place (see Figure 1). NOTE: To loosen the nuts on a marine distributor, the aluminum pins in the brackets may need to be cut in two and removed. Replacement pins are provided. Step 3 Remove the point plate assembly by lifting it out of the housing (see Figure 1). Point Plate FIGURE 1 Insulators PARTS INCLUDE IN THIS KIT: 1 E-Spark™ Plate Assembly 1 Wire Harness 1 Rotor/Shutter Wheel Assembly (PN 559 contains 2 rotor/shutter wheel assemblies) 1 Wire Connector 1 Grommet, 3-Hole (Marine Approved) 2 Pins, Aluminum 1 Thrust Button MALLORY IGNITION Cap Clip Nuts Condenser www.mrgasket.com 1 Step 4 Use a 2-arm or 3-arm puller and the thrust button (provided) to remove the cam from the rotor sleeve (see Figure 2). FIGURE 2 Puller WARNING: Do not try to remove the cam by prying on it with a screwdriver(s). This will damage the advance assembly. Step 5 Install the E-Spark™ plate assembly into the housing. Make sure that the cut-out in the plate is directly below the hole in the housing where the wires will exit (see Figure 3). Thrust Button Remove button after cam has been removed Step 6 Tighten the two nuts that hold the cap clips/brackets in place. This also secures the E-Spark™ plate. Step 7 Marine Distributors Only Replace the cap clips using the new aluminum pins provided. Cam Step 8 Install the wire grommet. Lubricate the wires with light oil. Run the wires through the grommet and out of the distributor housing (see Figure 3). Step 9 Install the connector onto the wires. Be sure the wires are in the correct positions (see Figure 4). Step 10 Install the rotor/shutter wheel assembly. Make sure that the rotor is fully seated and that it does not rub the module wires. Replace the cap. FIGURE 3 E-SPARK Plate Assembly Grommet Step 11 If you removed the distributor to install the E-Spark™ Conversion Kit, reinstall the distributor in the engine. Step 12 Connect the wire harness to the connector. Connect the 3 wires to the correct locations, as shown in Figures 5 and 6. Connector Step 13 Set the ignition timing. Start the engine and recheck timing. FIGURE 4 Distributor Wire Harness Female Connector ▼ Red Brown Green Red Brown Green Index Rib 2 MALLORY TECHNICAL SUPPORT (216)688-8300 www.mrgasket.com FIGURE 5 EQUIPPED WITH EXTERNAL BALLAST RESISTOR All other wires originally connected to the coil (+) terminal 12V/Ignition Switch Ignition Ballast Resistor Distributor Wire Harness Part No. 29349 Red Ignition Module Female Connector Green NOTE: The purpose of an ignition ballast resistor between the ignition switch (12V) and the ignition coil positive terminal is to restrict current flow through the ignition coil. Failure to use an ignition ballast resistor will eventually destroy the Ignition Module. EXCEPTION: If your vehicle is equipped with a HYFIRE® Electronic Ignition Control or similar aftermarket ignition control, use the wiring procedures stated in the instructions included with the ignition control. FIGURE 6 Brown + – Engine Ground To prevent false triggering and possible premature ignition failure, you must use suppression type (carbon core, spiral core, or radio suppression core) spark plug wire. DO NOT USE SOLID CORE (COPPER CORE OR STAINLESS STEEL CORE) SPARK PLUG WIRE WITH ANY ELECTRONIC IGNITION SYSTEM. COIL EQUIPPED WITH LOOM RESISTANCE WIRE All other wires originally connected to the coil (+) terminal 12V/Ignition Switch Loom Resistance Wire Distributor Wire Harness Part No. 29349 Red Ignition Module Female Connector Green Brown NOTE: The purpose of loom resistance wire between the ignition switch (12V) and the ignition coil positive terminal is to restrict current flow through the ignition coil. Failure to use an ignition ballast resistor will eventually destroy the Ignition Module. EXCEPTION: If your vehicle is equipped with a HYFIRE® Electronic Ignition Control or similar aftermarket ignition control, use the wiring procedures stated in the instructions included with the ignition control. MALLORY TECHNICAL SUPPORT + – Engine Ground To prevent false triggering and possible premature ignition failure, you must use suppression type (carbon core, spiral core, or radio suppression core) spark plug wire. DO NOT USE SOLID CORE (COPPER CORE OR STAINLESS STEEL CORE) SPARK PLUG WIRE WITH ANY ELECTRONIC IGNITION SYSTEM. (216)688-8300 www.mrgasket.com COIL 3 FIGURE 7 EQUIPPED WITH 29219, 29450, OR 30450 COILS ONLY All other wires originally connected to the coil (+) terminal 12V/Ignition Switch Distributor Wire Harness Part No. 29349 Red Ignition Module Female Connector Green + – Brown Engine Ground To prevent false triggering and possible premature ignition failure, you must use suppression type (carbon core, spiral core, or radio suppression core) spark plug wire. DO NOT USE SOLID CORE (COPPER CORE OR STAINLESS STEEL CORE) SPARK PLUG WIRE WITH ANY ELECTRONIC IGNITION SYSTEM FIGURE 8 COIL FOR MARINE USE ONLY After installing your Mallory Electronic Distributor, the Electronic Shift Assist (ESA) circuit in your boat must be function tested.Shifting into or out of gear can be difficult or impossible if the ESA circuit is malfunctioning or missing. If you encounter shifter related problems with your boat after installing any Mallory distributor, contact the Mallory Technical Service Department at 216.688.8300. All Mallory Marine Electronic Ignition Systems in Outboard Marine Corp (OMC) applications with a shift box require the gray wire from the coil to the shift box be modified as follows: The gray wire from the coil (–) terminal triggers the shift box. The gray wire should be cut or disconnected at the coil terminal so that the components shown here can be inserted. Solder all connections and confirm correct operation, then insulate well, especially if the boat is being used in salt water. FROM COIL (–) TERMINAL TO SHIFT BOX GRAY WIRE SOLDER AND INSULATE 2 EA. 400V 3A DIODES IN SERIES (RADIO SHACK PART NO. 276-1144) NOTE POSITION OF BANDS ON DIODES SOLDER AND INSULATE 2 EA. 4.7K, 1/2W RESISTORS IN PARALLEL (RADIO SHACK PART NO. 271-1124 MALLORY IS A DIVISION OF THE MR. GASKET PERFORMANCE GROUP 10601 MEMPHIS AVE. #12, CLEVELAND, OH 44144 216.688.8300 FAX 216.688.8306 4 TO ENGINE GROUND FORM 1503 Made in U.S.A. Printed in U.S.A. www.mrgasket.com