Hy re 6EZ and 6EZ RPML
Instruction Manual
Part#: 6855M, 6856M
FORM 1604 03/04
INSTALLATION INSTRUCTIONS
HYFIRE
®
6EZ and 6EZ
RPML SERIES
ELECTRONIC IGNITION
CONTROL
PART
NOS. 6855M (6EZ) and 6856M (6EZ
RPML)
PLEASE READ THESE INSTRUCTIONS COMPLETELY BEFORE STARTING THE INSTALLATION
PARTS INCLUDED:
1 HYFIRE
®
6EZ Ignition
Control
1 ProMaster
e
Performance
Coil
1
Coil
Wire Kit
8
#10 Sheet Metal
Screws
4
10-32 X 7/8
Screws
4
10-32
nuts
2
Ring
Terminals, Insulated
GENERAL
INFORMATION
The features of the HYFIRE
®
6EZ and HYFIRE
®
6EZ RPML are
the same, with one exception: the HYFIRE
®
6EZ RPML includes
a single stage RPM limiter. You can set various RPM limits using
switches that are accessible through the rectangular cut-out in
the end bracket. See page 4 of this instruction form for more
information about the rev limiting features of the HYFIRE
®
6EZ RPML.
Battery
The HYFIRE
®
6EZ 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
The ProMaster
®
e
Performance Coil will deliver optimum
performance with your HYFIRE
®
6EZ Ignition Control. The stock
coil on the vehicle is also retained.
Spark Plugs and Wires
High quality, spiral wound wire and proper routing are essential
to the operation of the HYFIRE
®
6EZ Ignition Control. This type of
wire provides a good path for the spark to follow while minimizing
electromagnetic interference (EMI).
NOTE: Do not use solid core spark plug wires with the
HYFIRE
®
6EZ 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
engine’s 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.
MISCELLANEOUS
INFORMATION
Sealing
Do not attempt to seal the HYFIRE
®
6EZ Ignition Control. All of the
circuits of a HYFIRE
®
6EZ receive a conformal coating of sealant
that protects the electronics from moisture. Sealing the HYFIRE
®
6EZ will not allow any moisture that seeps in through the
grommets to drain and may result in corrosion.
NOTE: Do not install the HYFIRE
®
6EZ Ignition Control in any
vehicle that is originally equipped with a CD ignition control.
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Mallory-Ignition.com
Welding
To avoid any damage to the HYFIRE
®
6EZ Ignition Control when
welding on the vehicle, disconnect the positive (red) and negative
(black) power cables of the HYFIRE
®
6EZ Ignition Control. It is also
a good idea to disconnect the tachometer ground wire
as well.
Distributor Cap and Rotor
We recommend installing a new distributor cap and rotor when
installing the HYFIRE
®
6EZ Ignition Control. Be sure the cap is
clean inside and out, especially the terminals and rotor tip. On
vehicles with smaller caps, it is possible for the air inside the cap
to become electrically charged causing crossfire which can result
in misfire. You can prevent this by drilling a couple of vent holes
in the cap. Drill the holes between terminals at rotor height, facing
away from the intake. If needed, place a small piece of screen
over the holes to act as a filter.
Hyfire
®
6EZ Diagnostic LED (Not available with rev limiting
ignition 6EZ RPML). On the end panel of your Hyfire 6EZ ignition
there is a small hole. Behind this hole is a red LED indicator.
The LED will flash when receiving a proper trigger signal from
the vehicle. If, after a normal power-up, the LED doesn’t flash
when cranking the engine, you should check your triggering
circuit for problems. If the LED flashes
when the engine is cranked, but there
is still no spark, the problem lies
somewhere else.
Hyfire
®
6EZ Cylinder Selection
Your HYFIRE
®
6EZ Ignition comes from
the factory set up for 8 cylinder
operation. If you want to use this
ignition with a 4 or 6 cylinder engine,
you must first remove the four screws
that hold the endplate with the LED hole. Once
the endplate is removed, you’ll see the end of the
circuit board. Look for the two-section switch. To select
4 cylinder mode, move the switch marked "1" to the "ON"
position. To select 6 cylinder mode, move the switch marked "2"
to the "ON" position. If both switches are "OFF", or both are
"ON", the ignition will run in the 8 cylinder mode. See Figure 1.
DIAGNOSTIC
LED
LABELS FOR
"CYLINDER SELECT"
ON CIRCUIT BOARD
MOUNTING
The HYFIRE
®
6EZ 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.
The ProMaster
®
e
Performance Coil can be mounted in any
position. We recommend placing it within 24" of the distributor
for ease of wiring.
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Mallory-Ignition.com
RED (LARGE 14 GA)
TO BATTERY POS (+)
BLACK (LARGE 14 GA)
TO BATTERY NEG (-)
PART No. 6855
®
COIL WIRE
NEW COIL
NEW COIL WIRE
TO DISTRIBUTOR
STOCK COIL
WIRING
See Figure 2
Remove the factory coil wire and set it aside. Leave all other
wiring on the distributor and coil in place. Connect one of the 2
supplied coil wires from the factory coil tower to the high tension
tower on the end of the HYFIRE
®
6EZ Ignition Control.
Take the other supplied coil wire and connect it from the new
Mallory coil to the distributor.
Connect the Red wire from the harness to the battery positive
(+) terminal.
Connect the Black wire from the harness to the battery negative
(-) terminal.
Plug the harness connector into the matching connector on the
ignition control.
Note: All of the wires of the HYFIRE
®
6EZ Ignition Control may
be shortened as long as quality connectors are used or sol-
dered in place.
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 connected to the positive side of
the starter solenoid.
NOTE: Never connect this
wire to the alternator.
Heavy Black
Connects directly to the battery negative (-)
Orange/Black
Plugs into the coil connector. These are the
Connector
only wires that make electrical contact with the
ProMaster
®
e
Performance Coil.
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 magnetic pickup wires should be routed separately and
twisted together to help reduce extraneous interference.
WARNING: The HYFIRE
®
6EZ Ignition Control is a capacitive
discharge ignition. High voltage is present at the coil primary
terminals. Do not touch these terminals or connect test
equipment to them.
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Mallory-Ignition.com
RPM Limiter Settings 6EZ RPML Only
See Figure 3
Note the sticker attached to the end plate of the HYFIRE
®
6EZ
RPML. This sticker shows settings for number of cylinders and
RPM limits. In case the sticker becomes damaged or otherwise
unreadable, the settings are shown at right.
Setting Switch #4 Not used
FIGURE
3
Rotary
Switch
Position
0
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
Number
of
Cylinders
4
6
8
Switch
#1
DOWN
4,500
4,750
5,000
5,250
5,500
5,750
6,000
6,250
6,500
6,750
7,000
7,250
7,500
7,750
8,000
8,250
Switch
#2
UP
Down
Down
Switch
#1
UP
8,500
8,750
9,000
9,250
9,500
9,750
10,000
10,250
10,500
10,750
11,000
11,250
11,500
11,750
12,000
NO
LIMIT
Switch
#3
Down
UP
Down
PRESTART CHECKLIST
• The only wires connected to the new coil terminals should be
the orange connected to coil positive (+) and black connected
to coil negative (–).
• Power leads are connected directly to the battery positive and
negative terminals.
• Both coil wires are seated into place.
• The engine is equipped with at least one ground strap to the
chassis.
TROUBLESHOOTING
This section offers several tests and checks you can perform to
ensure proper installation and operation of the HYFIRE
®
6EZ
Ignition Control. If you experience a problem with your HYFIRE
®
6EZ, first check for proper installation and poor connections.
You can eliminate many problems by checking these items. If
you have any questions concerning your HYFIRE
®
6EZ Ignition
Control contact the Mallory Technical Service Department at
216.688.8300, Monday through Friday, 8:30 am to 5:30 pm
Eastern time.
Misses and Intermittent Problems
Experience has shown that if your engine is misfiring or hesitating
at higher RPM, it is usually not an ignition problem. Most common
causes include a coil or plug wire failure, arcing from the cap or
boot plug to ground or spark ionization inside the cap. Perform the
following checks:
• Inspect the plug wires at the cap and at the spark plug for a
tight connection. Visually inspect for cuts, abrasions, or burns.
The higher energy of the new ignition can create an arching
problem if the spark plug wires have deteriorated. This will
make the engine miss.
• Inspect the primary coil wire connections. Because the
HYFIRE
®
6EZ Ignition Control receives a direct 12 volt source
from the battery, there will not be any voltage at the coil
positive (+) terminal, even with the key turned on. During
cranking, or while the engine is running, very high voltage
will be present and no test equipment should be connected.
WARNING: Do not touch the coil terminals during cranking or
while the engine is running.
• Make sure that the battery is fully charged and the connec-
tions are clean and tight. If you are not running an alternator,
this is an imperative check. If the battery voltage drops below
10 volts during a race, the HYFIRE
®
6EZ Ignition Control output
voltage will drop.
• Is the engine running lean? Inspect the spark plugs and the
entire fuel system.
• Check all wiring connections for corrosion or damage.
Remember to use proper connections followed by soldering,
then seal the connections completely.
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