61002M Datasheet, PDF (1/4 Pages) Mallory performance club – E-SPARK CONVERSION

INSTALLATION INSTRUCTIONS
FORM 1580 12/03
E-SPARK™ CONVERSION PART NO. 61002M
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 Ford 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
1 E-Spark™ Module
1 Cable Tie
1 Rotor/Shutter
2 Screws, 6-32 x .18
1 Distributor Wire Harness
2 Screws, 8-32 x .25
1 Female Connector
1 Screw, 8-32 x .375
2 Mounting Plates
1 Grommet
1 Capsule, Silicone Grease
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 specifications. For
racing applications, start with your engine manufacturer’s specifications,
then experiment with and closely monitor various gaps to achieve maxi-
mum 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.
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 finished 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 carbure-
tor and temporarily plug this carburetor fitting. 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)
Position the lower mounting plate (with one countersunk hole) against
the breaker plate. Align the countersunk hole over one existing breaker
plate threaded hole. Align one non-threaded hole with the other breaker
plate threaded hole. Install one 8-32 x 3/8" flathead screw through the
non-threaded hole (temporarily, do not tighten) to help in the alignment of
the lower mounting plate onto the breaker plate. Install one 8-32 x 1/4"
flathead screw through the countersunk hole and tighten firmly into the
breaker plate. Remove the 8-32 x 3/8" flathead screw.
Step 8
Position the upper mounting plate with its countersunk holes aligned
with the holes in the lower mounting plate. Install one 8-32 x 3/8" flat-
head screw through the non-threaded hole in the lower mounting plate
into the breaker plate. Install one 8-32 x 1/4" flathead screw into the
threaded hole in the lower mounting plate. Make sure to tighten these
screws firmly.
Step 9
Apply a thin coat of white silicone grease to the bottom of the
E-Spark^TM Module. Install the E-Spark^TM Module onto the upper mounting
plate with two 6-32 screws. Make sure to tighten these screws firmly.
MALLORY IGNITION
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