FORM 1478 (REV. D) 09/2008
INSTALLATION INSTRUCTIONS
HYFIRE
®
VI SERIES OF ELECTRONIC
IGNITION CONTROLS
HYFIRE
®
VI Ignition System Part No. 685, Advanced
HYFIRE
®
VI Ignition System Part No. 6851, Basic
For applications triggered by points, Mallory Electronic Ignition Distributor (all models), original equipment electronic
ignition amplifiers and magnetic trigger pulses (magnetic pickup distributor or crank trigger ignition). Optional adapters are
available for easy connection to early model Delco/GM HEI Systems, late model GM HEI/EST Systems, Ford TFI Systems,
and OEM magnetic pickup (non-computer; Ford DuraSpark, GM HEI and Mopar/Chrysler Electronic Systems).
This product is legal to sell, distribute or install on vehicles in California. C.A.R.B. Executive Order D-70-26.
NOTE: Mallory HYFIRE
®
VI Electronic Ignition Controls are not compatible with distributorless systems or positive
ground applications. The RPM Limiter in the HYFIRE
®
VI (Part No. 685) will not work properly with odd-fire or
semi-even fire V6 applications.
Parts included in this kit:
1 HYFIRE
®
VI Electronic Ignition Control - Part No. 685 or 6851
1 Ignition Control Harness - Part No. 29348
2 Terminal Connectors - Part No. 450
1 Bypass Connector
4 Cable Ties
2 Spade Terminals
8
1
5
4
4
Ring Terminals, 1/4”
Ring Terminal, 3/8”
Spade Receptacle Terminals
10-32 Screws
10-32 Nuts with Lockwashers
WARNING: DO NOT USE NON-SUPPRESSOR SPARK PLUG
WIRES WITH THE HYFIRE
®
VI IGNITION CONTROL.
KEEP ALL IGNITION SYSTEM WIRES AS FAR FROM SPARK PLUG WIRES AS POSSIBLE.
CONTENTS
Early Model GM HEI Systems (non-computer type,
General Information ............................................................................... 2
Ignition Ballast Resistor/Loom Resistance Wire ............................ 2
without module) ..................................................................... 6, 8
Mopar/Chrysler Corp. Electronic Systems
Standard Ignition Bypass (Bypass Connector) .............................. 2
(non-computer type, without module) ................................. 6, 9
Ignition Coils .................................................................................... 2
Fuel Injection .................................................................................... 2
Spark Plug Wires .............................................................................. 2 Wiring Method Without Adapters .......................................................... 7
Breaker Point Systems ................................................................ 7, 9
Spark Plug Gaps .............................................................................. 2
Mallory Electronic Ignition, UNILITE
®
Distributors,
Electric Welding ............................................................................... 2
Magnetic Breakerless Distributors or Electronic
External RPM Limiters
Advance Distributors (3-wire/red, brown, green) ............. 7, 10
Mallory PRO TACH
®
I, IV and VI ...................................................... 2
For OEM Electronic Systems with modules/amplifiers
Mounting Procedure .............................................................................. 2
(Chrysler, Ford, and import) ............................................... 7, 10
Mounting to a Flat Surface Without Brackets ................................ 2
Magnetic Pickup Trigger Pulses (magnetic
Mounting to a Flat or Uneven Surface Using Brackets ................ 2
pickup distributors or crank trigger ignition) ......................... 7, 10
Mounting to a Flat Surface with Shock Mounts ............................ 2
Top Panel Operation and Features .................................................... 11
Wiring Procedure ................................................................................... 3 RPM Limiter Operation – HYFIRE
®
VI Ignition System
Wiring Method using Adapters and Harnesses .............................. 3
(PN 685 only) .................................................................................. 11
GM HEI Systems/coil-in-cap with OEM module) ..................3-4
Late Model GM HEI/EST Systems (external coil) .................3-5 Optional Ignition Accessories ............................................................. 11
Ford TFI Systems .........................................................................3-4 Bypass Connector ............................................................................... 12
Mounting Template .............................................................................. 12
Ford DuraSpark Systems (non-computer type,
without module) ......................................................................5-6
1
GENERAL INFORMATION
The HYFIRE
®
VI Ignition System Part Nos. 685 and 6851 are not for marine use.
The RPM limiter in the HYFIRE
®
VI is not recommended as an engine speed governor. The use
of the RPM limiters is not recommended for applications equipped with a catalytic converter.
Similarly, forcing engine RPM past the RPM limiter continuously for long sustained intervals
can cause fuel build up in the exhaust system that may adversely affect your application. The
RPM limiting systems will not work properly with odd-fire V6 applications.
MOUNTING PROCEDURE
Step 1
Disconnect the battery (–) cable to cut power to the system. Computerized vehicles: Discon-
nect the battery (–) cable and let the vehicle sit overnight before proceeding. This allows the
computer to calibrate for the new ignition.
Step 2
Select a convenient location to mount the HYFIRE
®
VI Electronic Ignition Control. Keep the unit
away from hot engine components or extreme heat such as the exhaust system and manifolds.
Also, keep it away from moving devices, such as fans, belts and linkages. The location must
be dry. Moisture will damage components inside the unit.
Ignition Ballast Resistor / Loom Resistance Wire
The performance of the HYFIRE
®
VI is not affected by the presence of the factory ignition
resistors or ignition ballast resistors in the wire from the ignition switch.
Standard Ignition Bypass (Bypass Connector)
The Bypass Connector (supplied) fits into the Ignition Control Harness to convert back to stan-
dard ignition. If you use the Bypass Connector, use ignition ballast resistors designed for your
vehicle’s distributor and coil (see diagrams for more information). This bypass method does
not work with magnetic pickup distributor or crank trigger ignition. Racing Applications: It is not
necessary to install ignition ballast resistors. However, do not use the Bypass Connector until
the ignition ballast resistors are installed in the wire from the ignition switch.
Step 3
Choose one mounting method listed below for mounting the HYFIRE
®
VI Electronic Ignition
Control (3a, 3b, or 3c).
(3a) Mounting to a flat surface
• Center punch the mounting pattern on the mounting surface using the housing holes to
mark locations for drilling mounting holes. Drill holes using a 7/32” drill bit.
• Hold the HYFIRE
®
VI Electronic Ignition Control in position over the mounting holes.
• From the backside of the mounting surface, insert the 10-32 screws with lock washers
through the mounting holes and attach with the 10-32 nuts supplied.
Ignition Coils
The HYFIRE
®
VI Electronic Ignition Controls are designed to work with most original equipment
ignition coils. For optimum performance use the Mallory PROMASTER
®
Coil Part No. 29440
(up to 7,500 RPM) or Part No. 29625 (up to 10,000 RPM).
Fuel Injection
Some fuel injection systems need a voltage spike signal from the ignition coil before they
will operate properly. This signal changes once HYFIRE
®
VI Electronic Ignition Controls are
installed. The Mallory Fuel Injection and Tachometer Adapters Part Nos. 29074 and 29078
supply the proper signal to the vehicle computer to operate the fuel injection system. Installation
procedure and diagrams are supplied with these adapters.
(3c) Mounting to a flat surface with shock mounts (available separately, PN
29069)
• Center punch the mounting pattern on the mounting surface using the housing holes to
mark locations for drilling mounting holes. Drill holes using a 7/32” drill bit.
• Install the shock mounts into the side flanges of the HYFIRE
®
VI and tighten nuts. Hold
the unit in position where it will be mounted.
• From the backside of the mounting surface, insert the 10-32 nuts with lock washers onto
the shock mount studs. Tighten each nut until snug.
Spark Plug Wires
YOU MUST USE suppression type (carbon core, spiral core, suppression core) spark plug
wire. We recommend spiral core ignition wire, such as Mallory PRO SIDEWINDER
®
Ignition
Wire. Suppression type spark plug wires prevent false triggering and possible premature
ignition or accessory failures.
DO NOT USE solid core (copper core; stainless steel core)
spark plug wire with any electronic ignition system or accessory.
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.
Electric Welding
Unplug the Ignition Control Harness from the HYFIRE
®
VI Electronic Ignition Control and un-
plug any distributor harnesses (if possible) before any welding is done on the vehicle.
External RPM Limiters
Mallory Proportional RPM Limiter Part Nos. 641-4, 641-6, 641-8, 642, 643 and 644 WILL NOT
function with the HYFIRE
®
VI Electronic Ignition Controls.
Mallory PRO TACH
®
I, IV and VI
The RPM needle and shift light will work with the HYFIRE
®
VI. However, the tach’s proportional
controller that limits RPM WILL NOT function with the HYFIRE
®
VI. Turn the LIMIT RPM knob
slightly past 11,000 to prevent the limiter from interfering with the tach’s other functions. See
Optional Ignition Accessories for more information.
®
FIGURE 1
2
BASIC WIRING PROCEDURE
Step 1
Refer to Figure 2
Ensure that your vehicle is equipped with a ground cable between the engine block and firewall
(10 gauge or larger is required). Locate the harness with the LONG RED WIRE and one LONG
BLACK WIRE at the end plate of the HYFIRE
®
VI Electronic Ignition Control.
• Connect the LONG RED WIRE to the battery (+) post or battery (+) terminal on the
starter solenoid.
• Connect the LONG BLACK WIRE to engine ground or chassis ground.
• Plug into 2-pin connector with red and black wires coming from the end plate on
the HYFIRE
®
VI.
• Connect the Ignition Control Harness to the Ignition Control Plug at the end plate of
the HYFIRE
®
VI Electronic Ignition Control.
PART NO. 29062
– Connecting to Ford TFI Systems.
PART NOS. 29039 and 29040
– Connecting to Ford DuraSpark Systems
(non-computer type, without ignition module).
PART NOS. 29040 and 29043
– Connecting to Early Model GM HEI Systems
(non-computer type, without ignition module)
PART NO. 29040
– Connecting to Mopar/Chrysler Electronic Systems (non-computer
type, without ignition module).
Connecting to: GM HEI Systems (coil-in-cap, with OEM ignition module), use Adapter
PART NO. 29042; Late Model GM HEI/EST Systems, use Adapter PART NO. 29068; Ford
TFI Systems, use Adapter PART NO. 29062.
Step 2
Choose one method listed below for wiring the HYFIRE
®
VI Electronic Ignition Control
(2a, 2b, or 2c)
Connecting Adapter PART NO. 29042, 29062 or 29068
Refer to Figures 3, 4, and 7 when connecting to GM HEI Systems; Figure 5 when connecting to
Late Model GM HEI/EST Systems; Figure 6 when connecting to Ford TFI Systems.
• Match wires by color from the Adapter to the Ignition Control Harness. Crimp all wires together.
• Disconnect the factory harness(es) at the ignition coil. Connect them to the Adapter that has
the RED and GREEN WIRES.
• Connect the Adapter that has the YELLOW and BLACK WIRES to the ignition coil. NOTE:
When using an aftermarket ignition coil with post type terminals, discard the Adapter that
has the YELLOW and BLACK WIRES. Install ring terminals on the Ignition Control
Harness YELLOW and BLACK WIRES. Connect the YELLOW WIRE to the ignition coil
(+) terminal. DO NOT allow any wire except the YELLOW WIRE to make contact with the
ignition coil (+) terminal. Connect the BLACK WIRE to the ignition coil (–) terminal.
• Go to Step 3, page 9.
(2a) Wiring method using Adapters and Harnesses (sold separately)
Special wiring Adapters and Harnesses simplify the installation of the HYFIRE VI Electronic
Ignition Control into newer vehicles. These adapters and harnesses allow you to connect the
HYFIRE
®
VI Electronic Ignition Control between the ignition coil and the factory coil connector.
They reduce installation time and wiring errors. Also, converting back to the factory ignition is
easy because there is no need to cut the original wiring. These instructions cover:
®
PART NO. 29042
– Connecting to GM HEI Systems (coil-in-cap, with OEM
ignition module)
PART NO. 29068
– Connecting to Late Model GM HEI/EST Systems (external coil)
FIGURE 2
FIGURE 3
BLA
BRO
®
3
MALLORY 8MM SUPPRE
FIGURE 4
®
D C BA
FIGURE 5
®
D CB A
FIGURE 6
®
D CB A
4
京公网安备 11010802033920号
Copyright © 2005-2026 EEWORLD.com.cn, Inc. All rights reserved
电子工程世界
