Mallory E-SPARK - User Manual

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1MALLORY TECHNICAL SUPPORT (775) 882-6600 www.malloryracing.com

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.

INSTALLATION INSTRUCTIONS

FORM 1673 1/07

APPLICATIONS

Part No. 61010M For Left-Hand Rotation 27 Series

Mallory 8 cylinder point automotive

vacuum advance equipped

distributors which use a standard

stack cap (Part no. 209).

Part No. 61011M For Right-Hand Rotation 27

Series Mallory 8 cylinder point

automotive vacuum advance

equipped distributors which use a

standard stack cap (Part no. 209).

Refer to the Mallory Catalog’s distributor application section

if you need a to determine your distributor’s rotation.

PARTS INCLUDE IN THIS KIT:

1 E-Spark™ Plate Assembly

1 Wire Harness

1 Rotor/Shutter Wheel Assembly (PN 322)

1 Wire Connector

1 Grommet

1 Rubber Plug

1 Thrust Button

WARNING

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

Rotate the engine to the #1 cylinder firing position.

Remove the distributor cap and note the position of

the rotor. You will need to reference this when you

reinstall the distributor. Remove the distributor from

the engine.

Step 2

Remove the rotor, and then remove the condenser

and bracket. Remove the insulators (Figure 1).

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.

FIGURE 1

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Summary

E-Spark Breakerless Conversion Kit

Applications

Details specific kit applications for left and right-hand rotation Mallory distributors.

Installation Guide

Engine Preparation

Rotate engine to #1 firing position, note rotor position, remove distributor cap and unit.

Remove Existing Components

Remove the rotor, condenser, bracket, and insulators from the distributor housing.

Remove Vacuum Advance Chamber

Detach the vacuum advance chamber from the distributor housing after removing the e-clip.

Remove Point Plate Assembly

Loosen set screws to carefully lift the point plate assembly out of the distributor housing.

Remove Point Cam

Use a puller to remove the point cam from the rotor sleeve after placing the thrust button.

Drill Housing for Wiring Harness

Drill a 3/8" hole in the distributor housing to accommodate the new wiring harness.

Clean Distributor Housing

Remove all metal shavings from the housing to prevent damage to the advance assembly.

Install New Plate Assembly

Insert the new plate assembly, align, tighten screws, and reinstall vacuum advance chamber.

Install Grommet and Route Wiring

Install the supplied grommet into the drilled hole and route the wiring as indicated.

Install Rubber Plug

Insert the rubber plug into the existing grommet hole and trim any excess.

Install Wire Grommet and Lubricate Wires

Lubricate wires and run them through the grommet and out of the distributor housing.

Install Connector

Attach the connector to the wires, ensuring proper wire positioning.

Install Rotor Shutter Assembly

Mount the rotor shutter assembly, checking for clearance with modules and wires.

Reinstall Distributor and Cap

Reinstall the distributor using the rotor as a guide, then reattach the distributor cap.

Connect Wire Harness

Connect the wire harness to the distributor connector and route wires correctly.

Set Ignition Timing

Set the ignition timing, start the engine, and perform a final timing check.