Mallory HYFIRE IV SERIES User manual

1
®
HYFIRE®IV SERIES OF ELECTRONIC
IGNITION CONTROLS
HYFIRE®IVCIgnition System Part No. 692, Universal
HYFIRE®IVAIgnition System Part No. 697, Universal
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®IV Electronic Ignition Controls are not compatible with distributorless systems or positive
ground applications. The RPM Limiter in the HYFIRE®IVC (Part No. 692) will not work properly with odd-fire or semi-
even fire V6 applications.
General Information ..............................................................................2
Ignition Ballast Resistor/Loom Resistance Wire ...........................2
Standard Ignition Bypass (Bypass Connector) .............................2
Ignition Coils ...................................................................................2
Fuel Injection ...................................................................................2
Spark Plug Wires.............................................................................2
Spark Plug Gaps .............................................................................2
Electric Welding ..............................................................................2
External RPM Limiters
Mallory PRO TACH®I, IV and VI ......................................................2
HYFIRE®IVC Ignition System  4 and 6 Cylinder Operation ...............2
Mounting Procedure .............................................................................2
Mounting to a Flat Surface Without Mounting Brackets ...............2
Mounting to a Flat or Uneven Surface
Using Mounting Brackets .........................................................2
Mounting to a Flat Surface with Shock Mounts .............................2
Wiring Procedure ..................................................................................3
Wiring Method using Adapters and Harnesses .............................3
GM HEI Systems/coil-in-cap with OEM module) .................. 3-4
Late Model GM HEI/EST Systems (external coil) ................. 3-5
Ford TFI Systems ........................................................................4, 6
Ford DuraSpark Systems (non-computer type,
without module) .................................................................... 5-6
Early Model GM HEI Systems (non-computer type,
without module) ....................................................................6, 8
Mopar/Chrysler Corp. Electronic Systems
(non-computer type, without module)..................................6, 9
Wiring Method Without Adapters .........................................................7
Breaker Point Systems ...............................................................7, 9
Mallory Electronic Ignition, UNILITE®Distributors,
Magnetic Breakerless Distributors or Electronic
Advance Distributors (3-wire/red, brown, green)...............7, 10
For OEM Electronic Systems with modules/amplifiers
(Chrysler, Ford, and import) ...............................................7, 10
Magnetic Pickup Trigger Pulses (magnetic
pickup distributors or crank trigger ignition) ..........................7, 10
RPM Limiter Operation  HYFIRE®IVC Ignition System
(PN 692 only) .................................................................................11
Optional Ignition Accessories ............................................................11
Bypass Connector..............................................................................12
Mounting Template ............................................................................12
CONTENTS
Parts included in this kit:
1 HYFIRE®IV Electronic Ignition Control - Part No. 692 or 697
1 Ignition Control Harness - Part No. 29348
2 Terminal Connectors - Part No. 450
1 Bypass Connector
4 Cable Ties
2 Spade Terminals
8 Ring Terminals, 1/4"
1 Ring Terminal, 3/8"
5 Spade Receptacle Terminals
4 Mounting Brackets
4 #10 Sheet Metal Screws
INSTALLATION INSTRUCTIONS
FORM 1351 (REV. E) 10/99

2
GENERAL INFORMATION
The HYFIRE®IV Ignition System Part Nos. 692 and 697 are not for marine use.
The RPM limiter in the HYFIRE®IVC 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.
Ignition Ballast Resistor / Loom Resistance Wire
The performance of the HYFIRE®IV 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
standard 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.
Ignition Coils
The HYFIRE®IV 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 it will
operate properly. This signal changes once HYFIRE®IV 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.
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®IV Electronic Ignition Control and
unplug 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®IV Electronic Ignition Controls.
Mallory PRO TACH®I, IV and VI
The RPM needle and shift light will work with the HYFIRE®IV. However, the tach's proportional
controller that limits RPM WILL NOT function with the HYFIRE®IV. 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.
HYFIRE®IVC IGNITION SYSTEM
4 AND 6 CYLINDER OPERATION
The HYFIRE®IVC Ignition System comes from the factory set for 8 cylinder engines. 4 or 6
cylinder operations require you to set a switch inside the housing. DO THIS BEFORE
MOUNTING THE IGNITION BOX!
 Use a T-15 Torx®tool to remove the four screws that holds the blank end panel to the
housing. Remove the blank end panel (see Figure 1).
 With the ignition upside-down, look inside and on the left side of the PC board you will
see a small two position switch. The switch (#1) nearest the end of the PC board is the 6
cylinder switch. The other switch (#2) is the 4 cylinder switch. These switches are OFF
for 8 cylinder engines. Turn the appropriate switch ON for 4 or 6 cylinder operations.
 Attach the blank end panel to the housing.
MOUNTING PROCEDURE
Step 1
Disconnect the battery () cable to cut power to the system. Computerized vehicles:
Disconnect 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®IV 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.
Step 3
Choose one mounting method listed below for mounting the HYFIRE®IV Electronic Ignition
Control (3a, 3b, or 3c).
(3a) Mounting to a flat surface without brackets
 Center punch the mounting pattern on the mounting surface using the mounting
template to mark locations for drilling mounting holes. Drill holes using a 7/32" drill bit.
 Hold the HYFIRE®IV 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 into the tapped holes in the bottom plate of HYFIRE®IV
Electronic Ignition Control. Tighten each screw until snug.
(3b) Mounting to a flat or uneven surface using brackets
Refer to Figure 2 while performing the following steps.
 Position one hole of each bracket over each tapped hole in the bottom plate of the
HYFIRE®IV. Insert 10-32 screws with lock washers through these holes and into the
tapped hole in the bottom plate of the HYFIRE®IV. Tighten each screw until snug.
 Hold the HYFIRE®IV in position where it will be mounted. Bend the brackets slightly to
meet uneven surfaces. Center punch the mounting pattern on the mounting surface to
mark locations for drilling mounting holes. Drill holes using a 9/64" drill bit.
 Insert the #10 sheet metal screws through the remaining holes in the mounting brackets
and into the holes in the mounting surface. Tighten each screw until snug.
(3c) Mounting to a flat surface with shock mounts (available separately)
 Center punch the mounting pattern on the mounting surface using the mounting
template to mark locations for drilling mounting holes. Drill holes using a 7/32" drill bit.
 Install the shock mounts into the bottom plate of the HYFIRE®IV. 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.
FIGURE 2
4 CYL
4 - 6 CYL
SWITCH
6 CYL
BOTTOM
OF
12
FIGURE 1

3
WIRING PROCEDURE
Step 1
Refer to Figure 3
Ensure that your vehicle is equipped with a ground cable between the engine block and firewall
(10 gauge or larger is required). Locate one LONG RED WIRE and one LONG BLACK WIRE
at the end plate of the HYFIRE®IV 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.
 Connect the Ignition Control Harness to the Ignition Control Plug at the end plate of the
HYFIRE®IV Electronic Ignition Control.
Step 2
Choose one method listed below for wiring the HYFIRE®IV Electronic Ignition Control (2a, 2b,
or 2c)
(2a) Wiring method using Adapters and Harnesses (sold separately)
Special wiring Adapters and Harnesses simplify the installation of the HYFIRE®IV Electronic
Ignition Control into newer vehicles. These adapters and harnesses allow you to connect the
HYFIRE®IV 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)
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.
Connecting Adapter PART NO. 29042, 29062 or 29068
Refer to Figures 4, 5, and 8 when connecting to GM HEI Systems; Figure 6 when connecting
to Late Model GM HEI/EST Systems; Figure 7 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.
(DISCONNECT)
GM/DELCO HEI DISTRIBUTOR
WITH COIL MOUNTED INSIDE
DISTRIBUTOR CAP
MALLORY 8MM SUPPRE
BAT
PLUG
DISTRIBUTOR
PLUG
PINK OR RED
BLACK
BROWN
PINK OR RED
TOVEHICLE HARNESS
(12VOLT/IGNITION SWITCH)
FIGURE 4
IGNITION CONTROL HARNESS
DISCONNECT UNTIL INSTALLATION IS COMPLETE
ENGINE OR CHASSIS
GROUND
TOTHE STARTER
RED
GREEN
BLACK
YELLOW
(–) 12V/BATTERY (+)
ENGINE OR
CHASSIS
GROUND
CONNECT REDWIRE
AT EITHER LOCATION
IGNITION CONTROL
PLUG
LONG REDWIRE
LONG BLACKWIRE
SMALL GREEN AND BLACK
WIRES – NOT USED
HYFIRE
®
IGNITION
SYSTEM
®
STARTER
SOLENOID
(TYPICAL)
FIGURE 3

4
GM HEI/EST DISTRIBUTOR - EXTERNAL
IGNITION COIL
AND ADAPTER / HARNESS PART NO. 29068
ABCD
IGNITION CONTROL HARNESS
ADAPTER /HARNESS
PART NO. 29068
TOTHE
IGNITION
COIL
BOTH OFTHE
FACTORY
HARNESS
PLUGS
(ORIGINALLY
CONNECTED
TOTHE COIL)
IGNITION
CONTROL
PLUG
LONG BLACK
(–) BATTERY (+)
LONG RED
CHASSIS/FRAME GROUND
(DO NOT CONNECTTO
ENGINE BLOCK)
HYFIRE
®
IGNITION
SYSTEM
®
YELLOW
BLACK
GREEN
RED
YELLOW
BLACK
GREEN
RED
RED AND GREEN
YELLOW AND BLACK
NOTE:
YELLOW/COIL (+)
BLACK/COIL (–)
SMALL GREEN AND BLACK
WIRES – NOT USED
FIGURE 6
GM/DELCO HEI DISTRIBUTOR
(WITH COIL MOUNTED INSIDE DISTRIBUTOR CAP)
ADAPTER / HARNESS
PART NO. 29042
ABCD
PINK OR RED
GM/DELCO HEI DISTRIBUTOR
WITH COIL MOUNTED INSIDE
DISTRIBUTOR CAP
MALLORY 8MM SUPPRE
DISTRIBUTOR
PLUG
NOTE:LEAVETACH PLUG, IFTHERE IS ONE,
PLUGGED INTOTHE DISTRIBUTOR CAP
ADAPTER / HARNESS
PART NO. 29042
GREEN
RED
BAT
PLUG
BLACK
TO ENGINE
GROUND
BROWN
YELLOW IGNITION CONTROL
HARNESS
NOTE:MOST AFTERMARKET REPLACEMENT IGNITION MODULESWILL NOT
TRIGGERTHE HYFIRE
®
IGNITION SYSTEM.THE BEST TYPE TO USE IS AN
ORIGINAL GM/DELCO IGNITION MODULE.
TOVEHICLE HARNESS
IGNITION
CONTROL
PLUG
LONG BLACK
(–) BATTERY (+)
LONG RED
CHASSIS/FRAME GROUND
(DO NOT CONNECTTO
ENGINE BLOCK)
SMALL GREEN AND BLACK
WIRES – NOT USED
HYFIRE®IGNITION
SYSTEM
®
FIGURE 5
FORDTFI SYSTEMS
ADAPTER / HARNESS
PART NO. 29062
ABCD
IGNITION
CONTROL
PLUG
LONG BLACK
(–) BATTERY (+)
LONG RED
CHASSIS/FRAME GROUND
(DO NOT CONNECTTO
ENGINE BLOCK)
HYFIRE
®
IGNITION
SYSTEM
®
YELLOW
BLACK
GREEN
RED
YELLOW
BLACK
GREEN
RED
NOTE:
YELLOW/COIL (+)
BLACK/COIL (–)
ADAPTER /HARNESS
PART NO. 29062
TOTHE
IGNITION
COIL
YELLOW
GREEN
RED
BLACK
FACTORY
HARNESS
PLUG
(ORIGINALLY
CONNECTED
TOTHE COIL)
SMALL GREEN AND BLACK
WIRES – NOT USED
IGNITION CONTROL HARNESS
FIGURE 7

5
SMALL RED / MAG + SMALL GREEN
SPADE TERMINAL CONNECTORS
SMALL BLACK
SMALL BLACK / MAG –
ADAPTER PART NO. 29040
NOT USED
YELLOW
ORANGE
ADAPTER PART NO.
29039; 2 OF 2
DISTRIBUTOR PLUG
PUSH CONNECTORS ONTO
PINS AS FAR AS POSSIBLE
IGNITION
CONTROL
HARNESS
RED
IGNITION
CONTROL
PLUG
LONG BLACK
(–) BATTERY (+)
LONG RED
CHASSIS/FRAME GROUND
(DO NOT CONNECTTO
ENGINE BLOCK)
®
HYFIRE
®
IGNITION
SYSTEM
®
ADAPTER PART NO. 29039;1 OF 2
FEMALE SOCKET
IGNITION COIL
TO MATCHING
MALE SOCKET ON
THEVEHICLE
SPADE
RECEPTACLE
TERMINALS
BLACK
YELLOW
GREEN
(NOT USED)
FORD AND AMERICAN MOTORS
MOTORCRAFT DURASPARK (SSI, I AND II),
MALLORY 85 SERIES DISTRIBUTOR ADAPTER
PART NOS. 29039 AND 29040
+–
FIGURE 9
+
-
MALLORY
PROMASTER®
COIL
Part No. XXXXX
MALLORY 8MM SUPPRE
GM/DELCO HEI DISTRIBUTOR
(WITH REMOTE COIL ADAPTER)
ADAPTER / HARNESS
PART NO. 29042
.
IGNITION
CONTROL
PLUG
LONG BLACK
(–) BATTERY (+)
LONG RED
CHASSIS/FRAME GROUND
(DO NOT CONNECTTO
ENGINE BLOCK)
HYFIRE
®
IGNITION
SYSTEM
®
SMALL GREEN AND BLACK
WIRES – NOT USED
NOTE:DO NOT USE IGNITION
BALLAST RESISTORS SUPPLIED
WITH PROMASTER® COILS OR
OTHER AFTERMARKET COILS.
TACHOMETER / RPM SENSING LEAD:
CONNECTTHE TACH LEAD TOTHE
COIL (–)TERMINAL.
IGNITION CONTROL HARNESS
YELLOW
BLACK
GREEN RED
GREEN
RED
DISTRIBUTOR
PLUG
BAT
PLUG
PINK
OR
RED
ADAPTER / HARNESS PART NO. 29042
WITH GREEN AND REDWIRES
NOTE:DISCARD ADAPTER / HARNESS PART NO. 29042
WITHYELLOW, BROWN AND BLACK WIRES. MOST
AFTERMARKET REPLACEMENT IGNITION MODULES
WILL NOTTRIGGERTHE HYFIRE® IGNITION SYSTEM.
THE BESTTYPE TO USE IS AN ORIGINAL GM/DELCO
IGNITION MODULE.
GM/DELCO HEI DISTRIBUTOR
WITH MALLORY HEI REMOTE COIL
ADAPTER INSTALLED
TOVEHICLE
HARNESS
FIGURE 8

6
Connecting to Ford DuraSpark Systems (non-computer type) using Adapter PART
NO. 29039 and Harness PART NO. 29040 for OEM magnetic pickup
Refer to Figure 9 while performing the following steps.
Connecting Adapter PART NO. 29039:
 Disconnect all connectors at the ignition module, ignition coil and distributor. Remove the
ignition module. Remove the distributor and coil harnesses.
 Connect the Adapter ORANGE WIRE to the distributor plugs ORANGE WIRE.
 Connect the Adapter YELLOW WIRE to the distributor plugs PURPLE WIRE.
 Connect the other Adapter female socket to the vehicles matching male socket. (The
matching male socket was originally connected the ignition module.)
Connecting the Harness PART NO. 29040:
 Connect the HYFIRE®IV Electronic Ignition Controls SMALL GREEN WIRE to the
Harness RED WIRE.
 Connect the HYFIRE®IV Electronic Ignition Controls SMALL BLACK WIRE to the
Harness BLACK WIRE.
 Connect the mating plug of the Harness to the mating plug of the Adapter Part No. 29039
from the distributor.
Connecting the Ignition Control Harness:
 Route the Ignition Control Harness to the coil so that its wires do not make contact with
extreme heat, sharp objects or moving devises such as fans, belts and linkages.
 Crimp the Ignition Control Harness RED WIRE to the slice connector on the Adapter Part
No. 29039 female socket.
 Crimp a spade receptacle terminal on the Ignition Control Harness YELLOW WIRE.
Connect the YELLOW WIRE to the ignition coil (+) terminal. DO NOT allow any wire
except the YELLOW WIRE to make contact with the coil (+) terminal.
 Crimp a spade receptacle terminal on the Ignition Control Harness BLACK WIRE.
Connect the BLACK WIRE to the ignition coil () terminal.
 NOTE: Do not connect the GREEN WIRE of the Ignition Control Harness to anything.
Tape the end of the wire to insulate it.
 Go to Step 3, page 9.
Connecting to Early Model GM HEI Systems (non-computer type) using Adapter
PART NO. 29043 and Harness PART NO. 29040 for OEM magnetic pick-up. Refer to
Figures 11 and 12 while performing the following steps.
Connecting Adapter PART NO. 29043:
For coil-in-cap distributors only
 Disconnect the (RED or PINK) BAT PLUG/wire from the distributor cap.
 Disconnect the tachometer wire from the TACH terminal on the distributor cap.
 Disconnect the distributor plug from the distributor cap. For coil-in-cap distributors and
external coil
 Remove the distributor cap.
 Disconnect the pickup plug from the ignition module.
 Remove the ignition module, radio noise filter/capacitor and distributor plug harness.
 Slide the Adapter ORANGE and YELLOW WIRES through the grommet (supplied).
 Connect the Adapter ORANGE WIRE to the pickup plugs WHITE WIRE.
 Connect the Adapter YELLOW WIRE to the pickup plugs GREEN WIRE.
 Position the grommet into the slot on the edge of the distributor housing. Use cable ties
and 8-32 screws to hold wires in place.
 Install the distributor cap.
Connecting the Harness PART NO. 29040:
 Connect the HYFIRE®IV Electronic Ignition Controls SMALL GREEN WIRE to the
Harness RED WIRE.
 Connect the HYFIRE®IV Electronic Ignition Controls SMALL BLACK WIRE to the
Harness BLACK WIRE.
 Connect the mating plug of the Harness to the mating plug of the Adapter Part No. 29043
from the distributor.
Connecting the Ignition Control Harness:
 Route the Ignition Control Harness to the coil so that its wires do not make contact with
extreme heat, sharp objects or moving devises such as fans, belts and linkages.
 Crimp a spade terminal on the Ignition Control Harness RED WIRE.
For coil-in-cap distributors only
Refer to Figure 11 while performing the following steps.
 Connect the BAT PLUG/wire to the RED WIRE.
 Crimp the YELLOW WIRE to the YELLOW WIRE of the Adapter Part No. 29043 3-pin
connector.
 Crimp the BLACK WIRE to the BROWN WIRE of the Adapter Part No. 29043 3-pin
connector.
 Plug the Adapter Part No. 29043 3-pin connector into the distributor cap.
 Note: DO NOT connect the GREEN WIRE of the Ignition Control Harness to anything.
Tape the end of it to insulate it.
 Go to Step 3, page 9.
For external coil only
Refer to Figure 12 while performing the following steps.
(Replace the words spade receptacle terminal with ring terminal when after-
market coils with post type terminals are used.)
 Disconnect the BAT wire from the ignition coil BAT/(+) terminal. Connect the BAT wire to
the RED WIRE.
 Disconnect the tachometer wire from the ignition coil TACH/() terminal.
 Crimp a spade receptacle terminal on the Ignition Control Harness YELLOW WIRE.
Connect the YELLOW WIRE to the ignition coil BAT/(+) terminal. DO NOT allow any wire
except the YELLOW WIRE to make contact with the ignition coil BAT/(+) terminal.
 Crimp a spade receptacle terminal on the Ignition Control Harness BLACK WIRE.
Connect the BLACK WIRE to the ignition coil BAT/() terminal.
 Discard the adapter plug with the yellow and brown wires from the Adapter PART NO.
29043. It is not used on external ignition coil HEI systems.
Note: DO NOT connect the GREEN WIRE of the Ignition Control Harness to
anything. Tape the end of it to insulate it.
 Go to Step 3, page 9.
Connecting to Mopar/Chrysler Electronic Systems (non-computer type) using
Harness PART NO. 29040 for OEM magnetic pickup
Refer to Figure 13 while performing the following steps.
 Disconnect all connectors at the ignition module, ignition coil and distributor. Remove the
ignition module. Take notice of a DARK GREEN/RED WIRE connected to the ignition
ballast resistor. Remove the distributor and coil harnesses.
Connecting the Harness PART NO. 29040:
 Connect the HYFIRE®IV Electronic Ignition Controls SMALL GREEN WIRE to the
Harness RED WIRE.
 Connect the HYFIRE®IV Electronic Ignition Controls SMALL BLACK WIRE to the
Harness BLACK WIRE.
 Connect the mating plug of the Harness to the distributor plug.
Connecting the Ignition Control Harness:
 Route the Ignition Control Harness to the ignition coil so that its wires do not make
contact with extreme heat, sharp objects or moving devices such as fans, belts and
linkages.
 Connect the RED WIRE to the terminal on the ignition ballast resistor that previously had
the DARK GREEN/RED WIRE connected to it (or to a 12-volt wire from the ignition
switch). NOTE: The RED WIRE must get voltage when the ignition switch is in the
START and RUN positions.
 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.
 DO NOT connect the GREEN WIRE of the Ignition Control Harness to anything. Tape
the end of it to insulate it.
 Go to Step 3, page 9.

7
MAGNETIC PICKUP/CRANK TRIGGER COLOR CODES
BRAND/TYPE MAG+ MAG
MALLORY CRANK TRIGGER PURPLE GREEN
MALLORY BILLET COMPETITION DISTRIBUTOR,
SERIES NOS. 81 AND 84 ORANGE PURPLE
MALLORY COMP 9000®SERIES NOS 96-99 ORANGE PURPLE
MALLORY HARNESS PART NO. 29040 RED BLACK
MSD CRANK TRIGGER PURPLE GREEN
MSD CRANK TRIGGER (OLD STYLE) ORANGE BLACK
MSD DISTRIBUTOR ORANGE PURPLE
MOROSO CRANK TRIGGER BLACK WHITE
ACCEL®CRANK TRIGGER BLACK WHITE
CHRYSLER ELECTRONIC DISTRIBUTOR ORANGE BLACK
FORD DURASPARK DISTRIBUTOR ORANGE PURPLE
DELCO/GM HEI DISTRIBUTOR WHITE GREEN
2BWiring method without adapters; all breaker point distributors;
Mallory Electronic Ignitions (three wire/red, brown, green); OEM
electronic ignition amplifiers.
Refer to: Figure 14 for breaker point distributors; Figure 16 for Mallory UNILITE®
Distributors, Magnetic Breakerless Distributors or Electronic Advance Distributors
(three wire/red, brown, green); Figure 17 for OEM electronic ignition amplifiers
Connecting the Ignition Control Harness
 Route the Ignition Control Harness to the ignition coil so that its wires do not make contact with
extreme heat, sharp objects or moving devises such as fans, belts and linkages.
 Disconnect ALL wires located on the ignition coil (+) terminal. These include the wires from the
ignition switch/ignition ballast resistor, start/ignition bypass and any other wires normally
connected to the ignition coil (+) terminal. Connect these wires to the RED WIRE. NOTE: The
RED WIRE must get voltage when the ignition switch is in the START and RUN positions. If
you are using a Mallory Electronic Ignition, connect its BROWN WIRE to engine ground and
add its RED WIRE to the Ignition Control Harness RED WIRE. Use Ring Terminal Connectors
to join wires together (See page 2 - Ignition Ballast Resistor / Loom Resistance Wire and
Standard Ignition Bypass).
 Similarly, disconnect ALL wires located on the ignition coil () terminal. Connect these wires to
the GREEN WIRE. If you are using a Mallory Electronic Ignition, add its GREEN WIRE to the
Ignition Control Harness GREEN WIRE. Use Ring Terminal Connectors to join wires together.
 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.
RING TERMINAL CONNECTORS:
Furnished with the HYFIRE®IV Electronic Ignition Controls are two Ring Terminal Connectors
for the convenience of getting a neat installation when the HYFIRE®IV Electronic Ignition
Control is added to an existing ignition system. These Ring Terminal Connectors allow the
existing ignition system wiring to remain in the area of the ignition coil.
 Move wires onto the stud that is inside the Ring Terminal Connector body.
 Secure these wires to the stud with the nut and washer.
 Install the Ring Terminal Connector cap.
2CWiring Method without adapters for Magnetic Pickup Trigger
Pulses (Non-Computer Type); Magnetic Pickup Distributors or
Crank Trigger Ignition
Connecting to Magnetic Pickup Distributors and Crank Trigger Ignition  Refer to
Figure 18.
 Connect the magnetic pickup (+) wire to the SMALL GREEN WIRE from the HYFIRE®IV
Electronic Ignition Control.
 Connect the magnetic pickup () wire to the SMALL BLACK WIRE from the HYFIRE®IV
Electronic Ignition Control.
Connecting the Ignition Control Harness:
 Route the Ignition Control Harness to the ignition coil so that its wires do not make
contact with extreme heat, sharp objects or moving devises such as fans, belts and
linkages.
 Connect the RED WIRE to the 12-volt wire from the ignition switch. NOTE: The RED
WIRE must get voltage when the ignition switch is in the START and RUN positions. Use
a Ring Terminal Connector to join wires together.
 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.
 DO NOT connect the GREEN WIRE of the Ignition Control Harness to anything. Tape
the end of it to insulate it.
 Go to Step 3, Page 9.
FIGURE 10

8
MALLORY 8MM SUPPRE
GM/DELCO HEI DISTRIBUTOR
(WITH COIL MOUNTED INSIDE DISTRIBUTOR CAP)
ADAPTER / HARNESS
PART NOS. 29040 AND 29043
GM/DELCO HEI DISTRIBUTOR
(WITH REMOTE COIL ADAPTER)
ADAPTER / HARNESS
PART NOS. 29040 AND 29043
+
-
MALLORY
PROMASTER®
COIL
Part No. XXXXX
MALLORY 8MM SUPPRE
ABCD
ORANGE
GREEN
WHITE
PICKUP PLUG
CABLETIE
YELLOW
CABLETIE
IGNITION
CONTROL
PLUG
IGNITION
CONTROL
HARNESS
LONG BLACK
(–) BATTERY (+)
LONG RED
SMALL RED / MAG +
PINK OR RED
NOTE: LEAVETACH PLUG, IFTHERE IS ONE,
PLUGGED INTOTHE DISTRIBUTOR CAP
YELLOW
BLACKBROWN
TOVEHICLE
HARNESS
SMALL
GREEN
SMALL
BLACK
SMALL BLACK / MAG –
SMALL RED / MAG +
ADAPTER / HARNESS
PART NO. 29040
SMALL
GREEN
SMALL
BLACK
YELLOW
GREEN NOT USED
BLACK
SMALL BLACK / MAG –
RED
BAT
PLUG
GREEN
NOT USED
CHASSIS/FRAME GROUND
(DO NOT CONNECTTO
ENGINE BLOCK)
HYFIRE
®
IGNITION
SYSTEM
®
IGNITION
CONTROL
PLUG
IGNITION
CONTROL
HARNESS
LONG BLACK
(–) BATTERY (+)
LONG RED
TOVEHICLE
HARNESS
GM/DELCO HEI DISTRIBUTOR
WITH MALLORY HEI REMOTE
COIL ADAPTER INSTALLED BAT
PLUG
CHASSIS/FRAME GROUND
(DO NOT CONNECTTO
ENGINE BLOCK)
NOTE:DO NOT USE IGNITION BALLAST
RESISTORS SUPPLIEDWITH
PROMASTER® COILS OR OTHER
AFTERMARKET COILS.
TACHOMETER / RPM SENSING LEAD:
CONNECTTHE TACH LEADTOTHE
COIL (–)TERMINAL.
HYFIRE
®
IGNITION
SYSTEM
®
ADAPTER / HARNESS
PART NO. 29040
ADAPTER / HARNESS
PART NO.29043; 2 OF 2
ADAPTER / HARNESS
PART NO.29043; 1 OF 2
GM/DELCO HEI DISTRIBUTOR
WITH COIL MOUNTED INSIDE
DISTRIBUTOR CAP
MAGNETIC
PICK-UPWIRES
NOTE:DISCARD ADAPTER / HARNESS PART
NO.29043 WITHYELLOW AND BROWN WIRES.
SPADE RECEPTACLE TERMINALS
SPADE RECEPTACLE TERMINALS
FIGURE 11
FIGURE 12

9
IGNITION
CONTROL
PLUG
IGNITION
CONTROL
HARNESS
LONG BLACK
(–) BATTERY (+)
LONG RED
SMALL
BLACK
SPADETERMINAL
CONNECTORS
SMALL
GREEN
GREEN (NOT USED) RED
BLACK
YELLOW
IGNITION COIL
SMALL BLACK / MAG –
SMALL RED / MAG +
ALLWIRES NORMALLY CONNECTED
TOTHE COIL (+)TERMINAL
CHASSIS/FRAME GROUND
(DO NOT CONNECTTO
ENGINE BLOCK)
HYFIRE
®
IGNITION
SYSTEM
®
MOPAR / CHRYSLER
ADAPTER PART NO. 29040
ADAPTER PART NO. 29040
+
–
FIGURE 13
IGNITION COIL
GREEN
BLACK YELLOW
IGNITION CONTROL
HARNESS
OEM BALLAST OR
MALLORY BALLAST
RESISTOR (PN. 700)
NOTE:DO NOT DISCONNECT CONDENSOR
+12VOLTS FROM IGNITION SWITCH
ALL OTHERWIRES ORIGINALLY
CONNECTEDTOTHE COIL (+)TERMINAL
RINGTERMINAL
CONNECTOR
RINGTERMINAL
CONNECTOR
BREAKER POINT DISTRIBUTOR
RED
+–
IGNITION
CONTROL
PLUG
LONG BLACK
(–) BATTERY (+)
LONG RED
CHASSIS/FRAME GROUND
(DO NOT CONNECTTO
ENGINE BLOCK)
HYFIRE
®
IGNITION
SYSTEM
®
SMALL GREEN AND BLACK
WIRES – NOT USED
FIGURE 14
Step 3
Tachometer Operation:
If a tachometer is used, connect tachometer ignition sensing lead to the TACH terminal on the
HYFIRE®IV Electronic Ignition Control.
If the tachometer does not work after being connected to the TACH terminal, connect the
tachometer ignition sensing lead to the GREEN WIRE from the Ignition Control Harness.
Install the Mallory Fuel Injection and Tachometer Adapter Part No. 29074 to supply the
proper signal for the tachometer to operate.
Step 4
Secure all wires with cable ties to prevent contact extreme heat, sharp objects or moving
devices such as fans, belts and linkages.
Step 5
Recheck all wire and connections to ensure they are correct before applying power.
Step 6
Connect the battery () terminal cable. Start engine and check operation of the ignition system.
TACH/RPM OUTPUT
MAGNETIC
PICKUP
IGNITION CONTROL
FIGURE 15

10
OEM IGNITION AMPLIFIER
IGNITION COIL
GREEN
BLACK YELLOW
IGNITION CONTROL
HARNESS
OEM BALLAST OR
MALLORY BALLAST
RESISTOR (PN. 700)
+12VOLTS FROM IGNITION SWITCH
ALL OTHERWIRES ORIGINALLY
CONNECTEDTOTHE COIL (+)TERMINAL
IGNITION CONTROL
PLUG
RINGTERMINAL CONNECTOR
RINGTERMINAL
CONNECTOR
LONG BLACK
LONG RED
CHASSIS/FRAME GROUND
(DO NOT CONNECTTO
ENGINE BLOCK)
SMALL GREEN AND BLACK
WIRES – NOT USED
RED
+–
ALL OTHERWIRES
ORIGINALLY
CONNECTEDTOTHE
COIL (–)TERMINAL
(–) BATTERY (+)
HYFIRE
®
IGNITION
SYSTEM
®
FIGURE 17
GREEN
(NOT USED –TAPE LEAD)
BLACK
YELLOW
IGNITION CONTROL HARNESS
ALL OTHERWIRES ORIGINALLY CONNECTEDTOTHE COIL (+)TERMINAL
IGNITION CONTROL PLUG
RINGTERMINAL
CONNECTOR
LONG BLACK
(–) BATTERY (+)
LONG RED
SMALL RED
SMALL BLACK SMALL BLACK
SMALL GREEN
MAGNETIC PICK-UP DISTRIBUTOR
OR CRANKTRIGGER IGNITION
CHASSIS/FRAME GROUND
(DO NOT CONNECTTO
ENGINE BLOCK)
RED
IGNITION COIL
+
–
+12VOLTS FROM IGNITION SWITCH
HYFIRE
®
IGNITION
SYSTEM
®
SPADETERMINAL
CONNECTORS
FIGURE 18
IGNITION COIL
GREEN
GREEN
BROWN
BLACK YELLOW
IGNITION CONTROL HARNESS
OEM BALLAST OR
MALLORY BALLAST
RESISTOR (PN. 700)
NOTE:DO NOT
DISCONNECT
CONDENSOR
+12VOLTS FROM IGNITION SWITCH
ALL OTHERWIRES ORIGINALLY
CONNECTEDTOTHE COIL (+)TERMINAL
IGNITION CONTROL PLUG
RINGTERMINAL
CONNECTOR
GROUNDTO
ENGINE BLOCK
OR FRAME
RINGTERMINAL
CONNECTOR
LONG BLACK
LONG RED
MALLORY UNILITE DISTRIBUTORS,
MAGNETIC BREAKERLESS
DISTRIBUTORS, OR ELECTRONIC
ADVANCE DISTRIBUTORS (3-WIRE:
RED, BROWN, GREEN)
CHASSIS/FRAME GROUND
(DO NOT CONNECTTO
ENGINE BLOCK)
SMALL GREEN AND BLACK
WIRES – NOT USED
RED
RED
+–
(–) BATTERY (+)
HYFIRE
®
IGNITION
SYSTEM
®
FIGURE 16

11
RPM LIMITER OPERATION
HYFIRE®IVC Ignition System Part No. 692 only
The HYFIRE
®
IVC Ignition System has a microcomputer controlled RPM limiting system. The RPM
limiting system has an engine protection RPM limiter and a staging control RPM limiter. The staging
control RPM limiter is triggered by applying 12 volts to the ORANGE WIRE. Connect the ORANGE
WIRE to 12-volt/line-lock, trans-brake or manual/toggle switches.
The RPM limiters are adjustable from 1,000 to 12,000 RPM in increments of 100 RPM. The
engine protection RPM limiter is factory set at 4,000 RPM.
NOTE:The engine protection RPM limiter must be set between 1,000 and 12,000 RPM. Any
other RPM setting outside the adjustment range stops the ignition system from operating.
The ignition system will resume operation once the engine protection RPM limiter is set
properly between 1,000 and 12,000 RPM.
If you are not going to use the engine protection RPM limiter, set the RPM value higher than
your engine will normally run (up to 12,000 RPM). Similarly, if you are not going to use the
staging control RPM limiter, avoid applying 12 volts to the ORANGE WIRE.
The RPM limiter switches for setting the RPM limiters are under the slide-back cover on top
of the housing. Loosen the four screws and slide the cover to see the RPM limiter switches.
You will see two sets of RPM limiter switches. One set of switches is marked HIGH SIDE.
These are the engine protection RPM limiter switches. One set of switches is marked
STAGE. These are the staging control set of RPM limiter switches. Between the two
switches is a number indicator. It has markings of 1000 and 100 along with markings of
8, 4, 2 and 1. Switches of each limiter are set ON to add combinations of 1, 2, 4 and 8 of
each switches hundred and thousand sections. Notice that the switches are marked ON in
their corner.
EXAMPLE: If you want to set the engine protection at 7,300 RPM, set the HIGH SIDE
switches thousand section to 8-off, 4-ON, 2-ON and 1-ON (4+2+1=7 thousand). Similarly,
set the HIGH SIDE switches hundred section to 8-off, 4-off, 2-ON and 1-ON (2+1=3
hundred). As stated earlier, if you are not going to use the engine protection RPM limiter, set
the RPM value higher than your engine will normally run (up to 12,000 RPM).
EXAMPLE: If you want to set the staging control at 5,600 RPM, set the STAGE switches
thousand section to 8-off, 4-ON, 2-off and 1-ON (4+1=5 thousand). Similarly, set the STAGE
switches hundred section to 8-off, 4-ON, 2-ON and 1-off (4+2=6 hundred). The staging
control RPM limiter is triggered by applying 12 volts to the ORANGE WIRE. Connect the
ORANGE WIRE to 12-volt/line-lock, trans-brake wire or manual/toggle switches.
NOTE: The RPM limiting systems will not work properly with odd-fire V6 applications. The
RPM limiting systems are not recommended as an engine speed governor. Similarly, forcing
engine RPM past the RPM limiter continuously for long intervals can cause problems
resulting from fuel build up in the exhaust system that may adversely affect exhaust oxygen
sensors (if used) and cause severe backfiring.
STAGE
ON
HIGH SIDE
ON
ADD FOR TOTAL RPM ADD FOR TOTAL RPM
8000
4000
2000
1000
800
400
200
100
ON ON
STAGING
RPM
EXAMPLE:
5,600 RPM
ENGINE
PROTECTION
RPM
EXAMPLE:
7,300 RPM
OPTIONAL IGNITION ACCESSORIES
Single Stage High Speed Retard  Part No. 618-1
Mallorys Single Stage High Speed Retard is a finger tip adjustable ignition timing retard
control. The adjustment knob provides full adjustment range of 0°-15°. This retard is designed
with matching mating plugs so it can to be added between the HYFIRE®IV Electronic Ignition
Control and the Ignition Control Harness.
Multi Stage High Speed Retard  Part No. 618-3
This is a finger tip adjustable 3-stage timing retard control with an adjustment range for the first
and second stage of 0°-15° and a range of 0°- 20° for the third stage. Each succeeding stage
overrides the previous stage to allow you to reduce (or add) ignition timing on a succeeding
stage. This retard is designed with matching mating plugs so it can to be added between the
HYFIRE®IV Electronic Ignition Control and the Ignition Control Harness.
Mallory Electronic Advance Computer  Part Nos. 600-04, 600-06 and 600-08
This is a user programmable advance curve system using a CMOS microprocessor for
advance calculations. This allows you to select from 256 different advance curve combinations!
It is designed with matching mating plugs so it can to be added between the HYFIRE®IV
Electronic Ignition Control and the Ignition Control Harness.
Mallory Remote Timing Control  Part No. 631
Mallorys Remote Timing Control allows you to change the ignition timing as you drive for
maximum performance, for better fuel economy or to avoid engine knock.
NOTE: The accessories listed above will not work properly with odd-fire V6
applications or point trigger distributors. They are not designed for marine use.
Mallory RPM Activated Switch  Part No. 627A
This device is programmable from 3,000-10,800 RPM in increments of 100 RPM. It features
integral 5 amp relay contacts to operate 12-volt or ground circuits with connections for normally
open and normally closed operation. It works with any 8, 6 (includes odd-fire, semi-even fire,
and even-fire V6 engines), or 4 cylinder application and triggers from the tach output terminal
on the HYFIRE®IV Electronic Ignition Control.
Mallory Fuel Injection and Tachometer Adapter  Part No. 29074 and 29078
Some applications with fuel injection or a tachometer need a voltage spike signal from the
negative side of the coil before they will operate properly. This signal changes once the
HYFIRE®IV Electronic Ignition Control is installed. Mallorys adapter provides the proper
signal to trigger most fuel injection systems and voltage/current triggered tachometers.
FIGURE 19

12
BYPASS CONNECTOR
The Bypass Connector (standard ignition bypass) fits into the mating plug of the Ignition
Control Harness to convert back to standard ignition. If you use the Bypass Connector, use
ignition ballast resistors designed for the particular distributor and coil in the wire from the
ignition switch. DO NOT put the Bypass Connector into the mating plug of a Mallory
HYFIRE®IV RPM Limiting Adapter, or Single or Multi Stage High Speed Retard. DO NOT
put the Bypass Connector into the mating plug of a Mallory Electronic Advance Computer or
Remote Timing Control. Use the Power Plug to convert back to standard ignition.Also, if you
are using a Mallory Fuel Injection/Tachometer Adapter (Part No. 29074), disconnect it (and
its diode if used) as part of converting back to standard ignition. The Bypass Connector
(standard ignition bypass method to convert back to standard ignition) does not work with
magnetic pickup distributors or crank trigger ignition.
MALLORY IS A DIVISION OF THE MR. GASKET PERFORMANCE GROUP
550 MALLORY WAY, CARSON CITY, NEVADA 89701
[phone] FAX [phone]
www.mrgasket.com
FORM 1351
(REV. E) 10/99
Made in U.S.A.
Printed in U.S.A.
0.6"
0.6"
0.6"
0.6"
0.6"
0.6"
0.6"
0.6"
HYFIRE®IVA IGNITION SYSTEM
HYFIRE®IVC IGNITION SYSTEM
(BOTTOM PLATE)
MOUNTINGTEMPLATE
MAKE PROVISIONS 1" OUTSIDETHIS AREA
FORTHEWIRES COMING FROMTHIS ENDPLATE
HYFIRE
®
IGNITION
CONTROL OUTLINE
CENTER PUNCH
(4 LOCATIONS)
FIGURE 21
FIGURE 20