FORM 1583M 2/04 INSTALLATION INSTRUCTIONS E-SPARK™ CONVERSION PART NO. 61003M 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 find 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 find 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 specified 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 INSTALLATION PROCEDURE 1 1 1 1 1 Step 1 Disconnect the point trigger wire from the coil (–) terminal. E-Spark™ Module Rotor/Shutter Wheel Distributor Wire Harness Female Connector Mounting Plate 1 1 2 1 Cable Tie Capsule, Silicone Grease Screws, 6-32 x 3/16 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. 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 and set aside the distributor cap to allow clear access to distributor. Do not remove plug wires from cap. If it is not necessary to remove distributor from engine to install E-Spark Kit, remember rotor location so distributor can be reinstalled in engine with the rotor pointing to the same location as when distributor was removed. NOTE: Review Figure 1 for the parts that will be reused during this conversion. 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. Step 5 Remove points, condenser, primary lead wire and rotor from distributor. Electric Welding: Unplug the distributor wire harness before welding on the vehicle. Step 7 With point plate assembly removed from distributor, disassemble upper point plate from lower stationary base plate by removing spring clip located beneath base plate. Use caution when gently removing the spring clip to avoid spring clip distortion. 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. Step 6 Remove point plate assembly from distributor housing. This can be done without removing vacuum diaphragm. Step 8 (See Figure 1) Reassemble plate assembly using new module adapter plate supplied. Step 9 Reinstall new plate assembly into distributor housing the same as original point plate. Be sure vacuum diaphragm arm is properly connected to removable plate. Step 10 Apply a thin coat of white silicone grease to the bottom of the new module. Install E-Spark module using the two 6-32 screws supplied. MALLORY IGNITION www.mrgasket.com 1 Step 11 Push supplied rubber grommet into hole inside distributor housing. Be sure flat on flange of rubber grommet is on the outside of the distributor housing facing upward. Push wires of module through rubber grommet. Step 12 Mount connector pins into plastic terminal pin housing supplied. Be sure wires are shoved in to pin housing as shown in Figure 2. Shove pins into pin housing until a definite click is heard. Install rotor-shutter onto cam sleeve. Make sure that you press on the top of the rotor and not the shutter assembly. Be sure it is seated all the way down onto cam sleeve. Step 13 If distributor was removed from engine, install back into engine with the rotor pointing to the same location from which it was originally removed. Step 14 Install new distributor cap onto distributor housing. Holding original distributor cap near new distributor cap, remove plug wires one at a time, installing them into new distributor cap in the same connector sockets as removed from original cap. Be sure to do this one at a time so as not to change the firing order. Remove coil wire from original cap and install into new cap. 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 find 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 DISTRIBUTOR CAP ROTOR E-SPARK™ MODULE DISTRIBUTOR WIRE HARNESS PART NO. 216 334 6100M 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. FIGURE 1 2 www.mrgasket.com MALLORY IGNITION FIGURE 2 3 2 1 RED BROWN GREEN FEMALE CONNECTOR DISTRIBUTOR WIRE HARNESS RED BROWN GREEN INDEX RIB FIGURE 3 MALLORY PROMASTER® COIL PART NO. 29450 E-SPARK™ WIRING DIAGRAM USING 12V IGNITION FEED AND A MALLORY 29219, 30450 OR A 29450 PERFORMANCE IGNITION COIL TO IGNITION SWITCH 12V MALLORY IGNITION www.mrgasket.com 3 FIGURE 4 E-SPARK™ WIRING DIAGRAM USING OEM PRIMARY RESISTANCE WIRE NOTE: WHEN USING THE UNILITE® DISTRIBUTOR WITH A HYFIRE® OR OTHER AFTERMARKET AMPLIFIER BOX, CONNECT DISTRIBUTOR ACCORDING TO THE AMPLIFIER BOX DIRECTIONS. MALLORY PROMASTER ® COIL PART NO. 29440 MUST USE SUPRESSOR COIL WIRE IGNITION COIL NOTE: A PROMASTER® COIL IS SHOWN FOR ILLUSTRATION PURPOSES. WHEN USING A STOCK COIL, CONNECT IT IN THE SAME MANNER SHOWN. + – GREEN OEM PRIMARY RESISTANCE WIRE RED BROWN TO IGNITION SWITCH DISTRIBUTOR WIRE HARNESS DISTRIBUTOR (TYPICAL) GROUND TO ENGINE BLOCK FIGURE 5 E-SPARK™ WIRING DIAGRAM USING BALLAST RESISTOR MUST USE SUPRESSOR COIL WIRE NOTE: WHEN USING THE UNILITE® DISTRIBUTOR WITH A HYFIRE® OR OTHER AFTERMARKET AMPLIFIER BOX, CONNECT DISTRIBUTOR ACCORDING TO THE AMPLIFIER BOX DIRECTIONS. MALLORY PROMASTER® COIL PART NO. 29440 IGNITION COIL NOTE: A PROMASTER® COIL IS SHOWN FOR ILLUSTRATION PURPOSES. WHEN USING A STOCK COIL, CONNECT IT IN THE SAME MANNER SHOWN. MALLORY BALLAST RESISTOR PART NO. 700 OR OEM BALLAST + – GREEN RED BROWN TO IGNITION SWITCH DISTRIBUTOR WIRE HARNESS DISTRIBUTOR (TYPICAL) GROUND TO ENGINE BLOCK 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 FORM 1583M 2/04 Made in U.S.A. Printed in U.S.A. www.mrgasket.com