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1MALLORY TECHNICAL SUPPORT (775) 882-6600 tech@mrgasket.com HYFIREfi V ELECTRONIC IGNITION CONTROL PART NO. 585 INSTALLATION INSTRUCTIONS FORM 1051 (REV. A) 10/01 Battery The HYFIRE fi V Series Ignition Control operates on any negative ground, 12 volt electrical system with a distributor. It will also work with 16 volt batteries and can withstand a momentary spike of 24 volts in case of jump starts. This system delivers full voltage with a supply of 10-18 volts, and operates with a supply voltage as low as 8 volts. If your application does not use an alternator, allow at least 15 amp/ hour for every half hour of operation. If you crank the engine with the same battery or other accessories, such as an electric fuel or water pump, increase the amp/hour rating Coils For optimum performance with your HYFIRE fi V Ignition Control, we recommend Mallorys PROMASTER fi Coil P/N 29440. Mallorys PROMASTERfi Coil P/N 29625 can also be used, as well as most stock coils or aftermarket coils designed as stock replacements. NOTE: Do not use Mallorys PROMASTERfi Coil P/N 28880. Tachometers The yellow wire on the HYFIREfi V Ignition Control provides a trigger signal for tachometers, shift lights, or other add-on RPM activated devices. This wire produces a 12 volts square wave signal with a 20% duty cycle. Some vehicles with factory tachometers may require a tach adapter to work with the HYFIRE fi V Ignition Control. If your GM vehicle uses an inline filter, it may cause the tach to drop to zero on acceleration. If this occurs, bypass the filter. For more information on tachometers, see page 4. Foreign Vehicles Because of modern fuel injection systems, some foreign vehicles may require a tachometer/fuel injection adapter to work with the HYFIRE fi V Ignition Control. NOTE: Do not install the HYFIRE fi V Ignition Control in any ve- hicle that is originally equipped with a CD ignition control. Spark Plugs Using the correct spark plug and heat range is important for optimum performance. Because there are so many variables to consider, we suggest starting with your engine manufacturers spark plug recom- mendation. From there, you can experiment with small changes in plug gap and heat range to obtain the best performance from your engine. We also recommend non-resistor spark plugs. Spark Plug Wires High quality, spiral wound wire and proper routing are essential to the operation of the HYFIRE fi V Ignition Control. This type of wire pro- vides a good path for the spark to follow while minimizing electromag- netic interference (EMI). NOTE: Do not use solid core spark plug wires with the HYFIRE fi V Ignition Control. Routing Wires should be routed away from sharp edges, moving objects, and heat sources. Wires that are next to each other in the engines firing order should be separated. For example, in a Chevy V8 with a firing order of 1-8-4-3-6-5-7-2, the #5 and #7 cylinders are positioned next to each other on the engine as well as in the firing order. Voltage from the #5 wire could jump to the #7 wire. This could cause detonation and engine damage. For added protection against cross-fire, Mallory offers PRO SHIELD insulated sleeving. PRO SHIELD is a glass woven, silicone coated protective sleeve that slides over your plug wires. It also helps reduce damage from heat and sharp objects.
1 HYFIRE
fi V Ignition Control 4 #10 Sheet Metal Screws
2 Wire Ties
2 Ring Terminals, Insulated
2 1/4" Tab Terminals 5 1/4" Male Disconnects 5 1/4" Female Disconnects
1 Rubber Grommet
2 Cable Clamps
1 Magnetic Pickup Extension
PARTS INCLUDED:
MALLORY IGNITION 550 MALLORY WAY, CARSON CITY, NV 897012 WIRE FUNCTIONS Power Leads The two heavy gauge wires (14 gauge) that deliver battery voltage to the ignition: Heavy Red Connects directly to the battery positive (+) terminal or to a positive battery junction. It could also be con- nected to the positive side of the starter solenoid. NOTE: Never connect this wire to the alternator. Heavy Black Connects to frame or chassis ground. Trigger and Coil Leads Small Red Connects to a switched 12 volt source, such as the ignition key. Orange Connects to the positive (+) terminal of the coil. NOTE: This is the only wire that makes electri- cal contact with the coil positive (+) terminal. Small Black Connects to the negative () terminal of the coil NOTE: This is the only wire that makes electri- cal contact with the coil positive () terminal. Trigger Wires Either of two circuits will trigger the HYFIRE fi V Igni- tion Control: a points circuit (white wire) or a mag- netic pickup circuit (violet and green wires). NOTE: The two circuits will never be used together. White Connects to points, electronic ignition amplifier out- put or to the green wire of a Mallory timing acces- sory. When this wire is used, the magnetic pickup connector is not used. Violet/Green These wires are routed together in one harness to form the magnetic pickup connector. The connector plugs directly into a Mallory distributor or crank trig- ger. It will also connect to factory magnetic pickups or other aftermarket pickups. The violet wire is posi- tive (+) and the green is negative (). When these wires are used, the white wire is not used. Consult the chart that shows the polarity of other common magnetic pickups Yellow Connects to the tachometer pickup wire. /K44/K49/K41/K47/K4E/K4F/K53/K54/K49/K43 /K4C/K45/K44 MISCELLANEOUS INFORMATION Sealing Do not attempt to seal the HYFIRE fi V Ignition Control. All of the cir- cuits of a HYFIREfi V receive a conformal coating of sealant that pro- tects the electronics from moisture. Sealing the HYFIRE fi V will not allow any moisture that seeps in through the grommets to drain and may result in corrosion. Welding To avoid any damage to the HYFIRE fi V Ignition Control when welding on the vehicle, disconnect the positive (red) and negative (black) power cables of the HYFIRE fi V Ignition Control. It is also a good idea to disconnect the tachometer ground wire as well. Distributor Cap and Rotor As with any high performance ignition system, we recommend install- ing a new distributor cap and rotor when installing the HYFIRE fi V Ignition Control. Be sure the cap is clean inside and out, especially the terminals and rotor tip. HYFIRE fi V Diagnostic LED On the end panel of your HYFIRE fi V Ignition there is a small hole. Behind this hole is a red LED indicator. The LED will flash when re- ceiving a proper trigger signal from the vehicle. If, after a normal power- up, the LED doesnt flash when cranking the engine, you should check your triggering circuit for problems. If the LED flashes when the en- gine is cranked, but there is still no spark, the problem lies some- where else. MOUNTING The HYFIRE fi V Ignition Control can be mounted in any position. If you mount it in the engine compartment, keep it away from moving objects and heat sources. Do not mount the unit in a closed area, such as the glovebox. When you find a suitable location to mount the unit, make sure all wires of the ignition reach their connections. Hold the ignition in place and mark the location of the mounting holes. Use a 1/8" drill bit to drill the holes. Use the supplied self-tapping screws to mount the box. WIRING Wire Length All of the wires of the HYFIRE fi V Ignition Control may be shortened as long as quality connectors are used or soldered in place. To lengthen the wires, use one size larger gauge wire (12 gauge for power leads, 16 gauge for all others). Use the proper connectors to terminate all wires. All connections must be soldered and sealed. Grounds A poor ground connection can cause many frustrating problems. When a wire is specified to go to ground, connect it to the chassis. Always connect a ground strap between the engine and chassis. Connect any ground wires to a clean, paint-free metal surface. Ballast Resistor If your vehicle has a ballast resistor in line with the coil wiring, it is not necessary to bypass it. This is because the HYFIRE fi V Ignition Con- trol receives its main power directly from the battery. FIGURE 1
3MALLORY TECHNICAL SUPPORT (775) 882-6600 tech@mrgasket.com /K46/K52/K4F/K4D /K48/K59/K46/K49/K52/K45/KAE/K56 /K57/K48/K49/K54/K45 /K42/K4C/K41/K43/K4B /K55/K53/K49/K4E/K47 /K54/K48/K45 /K4D/K41/K47/K4E/K45/K54/K49/K43 /K50/K49/K43/K4B/K55/K50 /K57/K49/K52/K45 /K54/K4F /K54/K52/K49/K47/K47/K45/K52 /K54/K48/K45 /K48/K59/K46/K49/K52/K45 /KAE/K56 /K55/K53/K49/K4E/K47 /K54/K48/K45 /K57/K48/K49/K54/K45 /K57/K49/K52/K45 /K54/K4F /K54/K52/K49/K47/K47/K45/K52 /K54/K48/K45 /K48/K59/K46/K49/K52/K45 /KAE/K56 /K43/K4F/K4E/K4E/K45/K43/K54/K53 /K54/K4F /K50/K55/K52/K50/K4C/K45/K42/K4C/K41/K43/K4B /K4D/K41/K47/K4E/K45/K54/K49/K43 /K50/K49/K43/K4B/K55/K50 /K50/K55/K52/K50/K4C/K45 /K47/K52/K45/K45/K4E PRESTART CHECKLIST The only wires connected to the coil terminals should be the or- ange connected to coil positive (+) and black connected to coil negative (). The small red wire is connected to a switched 12 volts source, such as the ignition key. Power leads are connected directly to the battery positive and nega- tive terminals. If youre not using an alternator, the battery should be connected and fully charged. The engine is equipped with at least one ground strap to the chassis. THEFT DETERRENT The HYFIREfi V Ignition Control provides an easy way to install a theft deterrent kill switch. See Figure 2. White Wire Trigger When using the white wire to trigger the HYFIREfi V Ignition Control, install a switch across the magnetic pickup violet wire to ground. When the violet wire is grounded, the vehicle will crank but will not start. Magnetic Pickup Trigger When using the mag pickup to trigger the HYFIRE fi V Ignition Control, install a switch to the white wire and the other side to ground. When the white wire is grounded, the vehicle will crank but will not start. FIGURE 2 ROUTING WIRES Route all wires away from heat sources, sharp edges, and moving objects. Route the trigger wires separate from the other wires and spark plug wires. If possible, route them along a ground plane, such as the block or firewall, which creates an electrical shield. The mag- netic pickup wires should be routed separately and twisted together to help reduce extraneous interference. COMMON COLORS FOR MAG PICKUP WIRES Distributor Mag + Mag Mallory Crank Trigger Purple Green Mallory Billet Competition Distributor, Series Nos. 81 and 84 Orange Purple Mallory COMP fi 9000 Series Nos. 96-99 Orange Purple Mallory Harness P/N 29040 Red Black MSD Orange/Black Violet/Black MSD Crank Trigger Orange/Black Violet/Black Ford Orange Purple Accel 46/48000 Series Orange/Black Violet/Black Accel 51/61000 Series Red Black Chrysler Orange/White Black TROUBLESHOOTING This section offers several tests and checks you can perform to en- sure proper installation and operation of the HYFIREfi V Ignition Con- trol. If you experience a problem with your HYFIREfi V, first check for proper installation and poor connections. You can eliminate many prob- lems by checking these items. If you have any questions concerning your HYFIRE fi V Ignition Control contact the Mallory Technical Ser- vice Department at 775-882-6600, Monday through Friday, 8:00 am to 5:00 pm Pacific time. Tach/Fuel Adapters If your tachometer does not operate correctly, you probably need a Mallory tach adapter. Consult the Tachometer Compatibility List at right for common tachometers and compatible tach adapters. No-Run on Foreign Vehicles Some foreign vehicles with fuel injection systems may require a ta- chometer/fuel injection adapter to run with the HYFIRE fi V Ignition Control. Often, the same trigger source is used to operate an ignition, tachometer, and fuel injection. This results in a voltage signal that is too low to trigger the fuel injection. A tach/fuel injection adapter will usually solve this problem. Inoperative Tachometers If your tachometer fails to operate with the HYFIRE fi V installed, you may need a Mallory tach adapter. Before purchasing a tach adapter, try connecting your tachometer trigger wire to the yellow wire of the HYFIREfi V Ignition Control. This output produces a 12 volt, square wave. If the tach still does not operate, you will need a tach adapter. Two different tach adapters are available: PN 29078 If you are using the magnetic pickup connector (green and violet wires) to trigger the HYFIRE fi V, you will need this adapter. PN 29074 If your tach was triggered from the coil negative termi- nal (voltage trigger) and you are using the white wire to trigger the HYFIRE fi V, you will need this adapter. Ballast Resistor If you have a current trigger tach (originally connected to coil (+) posi- tive) and use the white wire of the HYFIREfi V for triggering, you can purchase a Chrysler Dual Ballast Resistor (1973-76 applications). Wire it as shown in Figure 3.
PART No. 585 MICROPROCESSOR CONTROLLED IGNITION SYSTEMMICROPROCESSOR CONTROLLED IGNITION SYSTEM R /K59/K45/K4C/K4C/K4F/K57/K54/K4F /K54/K41/K43/K48/K4F/K4D/K45/K54/K45/K52 /K52/K45/K44 /K28/K4C/K41/K52/K47/K45 /K31/K34 /K47/K41/K29 /K54/K4F /K42/K41/K54/K54/K45/K52/K59 /K50/K4F/K53 /K28/K2B/K29 /K42/K4C/K41/K43/K4B /K28/K4C/K41/K52/K47/K45 /K31/K34 /K47/K41/K29 /K54/K4F /K42/K41/K54/K54/K45/K52/K59 /K4E/K45/K47 /K28/K96/K29 /K47/K52/K45/K45/K4E /K50/K55/K52/K50/K4C/K45 /K52/K45/K44 /K28/K53/K4D/K41/K4C/K4C /K31/K38 /K47/K41/K29 /K4D/K41/K47/K4E/K45/K54/K49/K43 /K50/K49/K43/K4B/K55/K50 /K4E/K4F/K54 /K55/K53/K45/K44 /K4F/K52/K49/K47/K49/K4E/K41/K4C /K43/K4F/K49/K4C /K28/K2B/K29 /K57/K49/K52/K45 /K53/K50/K4C/K49/K43/K45 /K48/K45/K52/K45 /K57/K48/K49/K54/K45 /K28/K96/K29 /K42/K4C/K41/K43/K4B /K28/K53/K4D/K41/K4C/K4C /K31/K38 /K47/K41/K29 /K41/K4D/K50/K4C/K49/K46/K49/K45/K52 /K4F/K52/K49/K47/K49/K4E/K41/K4C /K43/K4F/K49/K4C /K28/K96/K29 /K54/K45/K52/K4D/K49/K4E/K41/K4C /K46/K52/K4F/K4D /K41/K4D/K50/K4C/K49/K46/K49/K45/K52 /K54/K4F /K49/K47/K4E/K49/K54/K49/K4F/K4E /K53/K57/K49/K54/K43/K48 /K28/K2B/K29 /K4F/K52/K41/K4E/K47/K45 /K53/K50/K4C/K49/K43/K45 /K48/K45/K52/K45 /K53/K48/K52/K49/K4E/K4B /K54/K55/K42/K49/K4E/K47 /K49/K47/K4E/K49/K54/K49/K4F/K4E /K43/K4F/K49/K4C Installing the HYFIREfi V with a Typical Import Application FORM 1051 (REV. A) 10/01 Made in U.S.A. Printed in U.S.A. MALLORY IS A DIVISION OF THE MR. GASKET PERFORMANCE GROUP
550 MALLORY WAY, CARSON CITY, NEVADA 89701
(775) 882-6600 FAX (775) 887-4326 www.mrgasket.com FIGURE 22