Installation Instructions for 550-400
Contents
1. 271R961A HOLLEY EFI 4BBL TBI HARNESS HED HARNESS ONLY SALES P N 558 100 amp amp e EB ds GRE Fue PP RED DEE o e uw aT Estar Goose 6 grt TER I 5 E Bur DB OB HB 8 ours promus mmm gt e 4 DESCRIPTION COLOR WIRE GAUGE PIE m LOOSE BLACK 2D ga 25 PIB 271R961A NIEOTORS HOLLEY EFI 4BBL TBI HARNESS HARNESS ONLY SALES PIN 558 100 IGNITION INPUTS OUTPUTS LOOSE LEADS a2. PIA Connector P1B Connector Pin Function Pin Function A1 Coil Input BI A2 Fuel Pump Out 12v B2 B3 Fan 2 Output ground A4 t B4 Injector F Output A5 TPS Input B5 Injector G Output A6 B6 Injector H Output AT WB1 COMPR2 B7 injector E Output WB1 Shield B8 lACBLo A9 WB HTR B9 IACBHi 10 Switched 12v Input B10 Fan 1 Output ground AM Manifold Air Temp Input gu 12 x Bi2 AC Shutdown 12 A13 B13 Injector D Output A14 CamiGrank Ground A15 Gauge Digital Output gis A16 WB1 COMPRI B16 A17 WB VS IP A18 Sensor Ground A19 Engine Coolant Temp Input B19 Injector A Output A20 Oil Pressure Input B20 EST 12V Output A21 E B21 A22 Cam Sync Input Ignition Bypass Output Bo A23 Map Sensor Input B23 A24 CAN Lo B24 7 A25 WB1 VS B25 Injector C Output A26 Sensor Sv B26 Injector B Output A27 NOT USED A28 EST Spout Output A29 A30 Crank Speed Input A31 Fuel Pressure Input A32 CAN Hi A33 Wei IP A34 WB HTR 23 Holley Performance Products 1801 Russellville Road Bowling Green KY 42101 Technical Service 1 270 781 9741 Fax 1 270 781 9772 For online help please refer to the Technical Information section of our website www holley com 199810552 wi Date 5 10 11 24
3. bead nipple on the end of the steel line Install hose clamps on all of these junctions 8 are included in the kit All fuel Init or Fuel Pump sie hoses used must meet SAE 430 performance standards All steel fuel line must meet SAE 1526 standards Figure 4 10 8 The TBI unit has an inlet and an outlet fiting The inlet fitting is designed for a 3 8 hose and is on the drivers side linkage side of the throttle body The return line designed for a 5 16 hose is on the passenger side side with the TPS 8 Ifyou plan to install fuel pressure gauge do so at this time The 4 bbl TBI systems are designed for an operating pressure of 21PSI Although this is factory pre set it is ideal that be checked The TBI units have an 1 8 NPT plug an the drivers side that can be used to temporarily install a gauge this location will interfere with the throttle cable on a permanent install to set the pressure Holley also sells a 0 100 PSI pressure transducer PN 554 102 that plugs into the fuel connector on the main harness This sensor be installed anywhere between the fuel pump and the TBI unit It has a 1 8 NPT male thread 10 If using the existing fuel lines inspect and replace any hose clamps or fuel line showing ANY sign of aging DANGER Failure to use a fuel hose that meets SAE J30 standards could result a fire or explosion hazard which could cause serious injury death fuel leaks A fuel leak may result
4. must be installed in a coolant passage in either the intake manifold or cylinder head The sensor has 3 8 NPT threads If only 7 NPT port is available an adapter wil have to be used It is best to drain the some of the coolant before the sensor is installed 8 0 REMOVAL OF EXISTING FUEL SYSTEM 1 Disconnect the battery and remove the air cleaner 2 Before disconnecting any vacuum hoses itis a good idea to sketch out the vacuum hose routing Using masking tape and a permanent marker mark the vacuum hoses vacuum sources and ports before removing the old fuel delivery system 3 Remove and discard the fuel line that connects the fuel delivery system from the fuel pump This will not be needed in the installation 4 Disconnect and plug the inlet fuel line that runs from the gas tank to the fuel pump This will prevent fuel spillage and foreign matter or dirt from entering the fuel line DANGER Before disconnecting or removing fuel lines ensure the engine is cold Do not smoke Extinguish all open flames An open flame spark or extreme heat near gasoline can result in a fire or explosion causing property damage serious injury and or death 5 The fuel delivery system can now be removed Holley recommends removing the mechanical fuel pump if so equipped and blocking off the fuel pump mount using the provided fuel pump block off plate The AVENGER EFI system kit includes a block off plate that will ft small and big bl
5. 5124 Idle Air Control Motor 1 543 105 Throttle Position Sensor TPS 1 543 29 Optional Small Cap GM HEI Ignition Adapter 1 568 304 Ford TFI Ignition Adapter 1 538 305 15 He Item 19 Pre installed in Harness 20 21 ose 34 35 5 0 ADDITIONAL ITEMS REQUIRED FOR INSTALLATION 3 8 fuel hose must meet SAE J30 5 16 fuel hose must meet SAE 430 5 16 steel fuel line must meet SAE J526 0 30 psi fuel gauge and tee fitting for fuel gauge is recommended to check for proper fuel pressure PN 554 102 is a 0 100 PSI pressure sensor that can be purchased as well that will plug into the Avenger harness to check and monitor fuel pressure It requires a 1 8 NPT for installation In addition to the above list the engine must be equipped with a four barrel intake manifold and the vehicle must be in good operating condition 6 0 TOOLS REQUIRED FOR INSTALLATION Standard wrench set Small blade screwdriver 5 32 Allen wrench Medium blade screwdriver 2 Philips screwdriver Digital Volt Ohm meter Drill and assorted bit sizes Hole saw 2 Terminal crimping tool Utility knife Factory Service Manual for your vehicle An assistant is necessary for some installation and adjustment procedures and should be present for safely reasons 7 0 COOLANT TEMPERATURE SENSOR INSTALLATION The coolant temperature sensor item 12
6. DESCRPTEN OLEN FUEL Poms ouor HH SE nh 1 199810552 wf Date 5 10 11
7. length of wire on for the features you wish to use The following indicates proper wiring for these features AIC Shutdown This output will provide a 12 volt output a defined throttle position This output can be used to trigger a relay that deactivates the at higher throttle positions This may require the installation of a 5 pole relay in the existing A C wiring This wire is located in pin E of the 8 pin Input Output connector and is Grey with a Yellow stripe Electric Fan 1 output This output will provide a ground output to trigger a relay used for a cooling fan This output should never be directly connected to a fan but the relay that powers the fan It should be connected to the ground trigger of the relay This wire is located in pin G of the 8 pin Input Output connector and is Grey with a Black stripe Electric Fan 2 output This output will provide a ground output to trigger a relay used for a cooling fan This output should never be directly connected to a fan but the relay that powers the fan It should be connected to the ground trigger of the relay This wire is located in pin G of the 8 pin Input Output connector and is Grey with a Green stripe Figure 34 22 APPENDIX 1 0 Pinout The following shows pins that are used on Avenger systems Pins that are not used on Avenger systems but may have wires populated in the harness are denoted with an asterisk 7
8. premature transmission failure NOTE Chrysler vehicles a lever extension will be needed Holley Part Number 20 7 Van applications may require the use of throttle lever extension Holley Part Number 20 14 4 Attach throttle linkage and throttle retum spring Have an assistant gat in the vehicle and fully depress the accelerator pedal Make the necessary adjustments to the throttle linkage to insure that the throttle reaches wide open position when the accelerator is depressed Work throttle linkage back and forth several times to ensure that it operates smoothly with binding or sticking DANGER Failure to attach the throttle return spring or a sticking throttle may result in uncontrolled engine or vehicle speed which could cause personal property damage serious injury or death 9 3 MAP Sensor Installation and Vacuum Line Connections 1 The MAP sensor must be installed as close to the vacuum source itis connected to as possible must be connected to a manifold vacuum port This is Vacuum source below the throttle body plates The throttle body has a full manifold port that the sensor can be connected to see Figure 2 Itis best not to lee multiple items into the port that supplies the sensor The sensor should be mounted such that the vacuum port on the sensor is pointed at some downward angle above the vacuum source so that moisture does not collect in the sensor ils NOTE Make sure the MAP sen
9. ARNING Ensure both filters are installed in the proper direction A flow direction arrow is stamped on the side of the filter to indicate the direction of fuel flow Failure to do so will result in a system malfunction DANGER Take precautions to ensure all fuel line routings are away from heat sources such as the engine or exhaust system fire or explosion hazard could cause property damage serious injury and or death 6 Plumbing must now be installed to connect the fuel tank to the filters pump and TBI unit Itis Air Tampaatue Sensor recommended to use steel hard line or stainless braided hose with AN fittings If AN plumbing is used the appropriate fittings must be purchased for the pump and unit Filters must have style fittings as well The thread in the inlet and outlet fittings of the TBI unit is 7 NPT ressure Port Plug 2 etn Side 7 38 line should be used on the feed pressure Side of the system the filters included s Retur Line designed for 3 8 line If using steel line rubber Re Tan hose rated for use with fuel injection can be used to connect the steel line to the pump and fiters You should not connect a rubber hose directly to a steel line unless the end of the line has a beadinipple or barb that retains the hose similar to the ends of the fuel fiters If the steel line is just cut off purchase a compression fiting that a barbed hose end can be installed on or use a tool to
10. AVENGER EFI 4 BBL TBI SYSTEMS 550 400 700 CFM 65 Ib hr injectors up to 400 HP 550 401 900 CFM 75 Ib hr injectors up to 525 HP 550 402 900 CFM 85 Ib hr injectors up to 600 TBI HARDWARE INSTALLATION MANUAL 199R10552 ad and fully understood before lion als not fully pted Failure ns including the pict NOTE Fits all standard square flange intake manifolds 1 TABLE OF CONTENTS 1 0 INTRODUCTION 2 0 CHOOSING THE RIGHT SYSTEM 3 0 WARNINGS NOTES AND NOTICES 4 0 PARTS IDENTIFICATION 5 0 ADDITIONAL ITEMS REQUIRED FOR INSTALLATION 60 TOOLS REQUIRED FOR INSTALLATION 7 0 COOLANT TEMPERATURE SENSOR INSTALLATION 8 0 REMOVAL OF EXISTING FUEL SYSTEM 90 AVENGER EFI TBI SYSTEM INSTALLATION 9 1 Throttle Body 92 Throttle Connections 93 MAP Sensor Installation and Vacuum Line Connections 94 Fuel Pump Fuel Line and Filter Installation 95 Return Line Installation 9 6 Oxygen Sensor Installation 8 6 1 Oxygen Sensor Mounting Procedure 8 62 ECU Mounting 100 WIRING 10 1 Important Wiring Do s and Don s 11 0 WIRING HARNESS INSTALLATION 12 0 PRIMARY HARNESS INSTALLATION AND SENSORS CONNECTION 12 1 ECU Connectors 12 2 Harness Routing 12 3 Sensor Connections 123 1 Throttle Position Sensor TPS 123 2 Manifold Air Pressure Sensor 123 3 Coolant Temperature Sensor CTS 123 4 Manifold Air Temperature Sensor MAT 123 6 Wide Band Oxygen Sensor WB02 123 7 Fuel Pressure Fuel 123 8 Oil P
11. ECU Connectors AVENGER The AVENGER ECU has two main connectors BIA The first connector next to the USB connector is the connector 34 pin This connector is primarily an Input connector It contains all the sensor inputs and wide band oxygen sensor control 1 The second connector is the P1B connector 26 pin This connector is the output connector It has amp injector outputs and outputs for other devices BAROMETRIC PRESSURE SENSOR no connection pedet Figure 10 USB is not used on Avenger EFI 12 2 Harness Routing Ifthe ECU is mounted in the interior it will have to be routed through the firewall into the engine compartment Use a 2 hole saw to create a hole in a desired location if no other point of access available A grommet is supplied for a 2 hole to seal this area ifthe ECU is mounted in the engine compartment the hand held tuning module cable will have to be routed lo Ihe CAN connector on the main harness located near the ECU connector main connector This wil require routing 1 x 4 connector Somewhere through the firewall Connect the and P1B connectors of the main harness into the ECU About 12 from the ECU main connectors is a 40A Relay This powers the injectors and fuel pump 12 3 Sensor Connections amp Outputs The following indicates the primary sensors that are required to be connected Each connector the main harness is labeled wit
12. Handheld 12 3 10 Knock Sensor Knock The knock sensor connector is NOT used on Avenger systems Figure 20 Knock 16 12 3 11 Ignition IGN There is a 10 pin connector marked This is to connect to various ignition systems This is not required for some applications See section 16 0 below for proper ignition wiring Figure 21 GN 13 0 PRIMARY OUTPUTS 13 1 Idle Air Control IAC Connect to the idle control motor which is installed in the throttle body 13 2 Fuel Injector Outputs INJ Connect the fuel injector harness on the TBI unit to the injector connector on the main harness Figure 22 IAC Figure 23 INJ 14 0 LOOSE WIRES Figure 2t The following loose wires in the main wiring harness should be connected as follows on all systems All of these wires come out of the hamess about 40 from the ECU connectors except for the 12V Switched wire 12V Switched Color Red White Should be connected to a clean 12 volt power source Power source should only be active when the ignition is on Make sure source has power when engine is cranking as well check with voltmeter Not all sources apply power when the ignition switch is in cranking position This wire is located approximately 7 from the ECU connectors Refer to Figure 24 12 Battery Color Red Should be connected directly to the battery This powers the fuel pump and fuel i
13. LEr on the hand held display This will not cause any issues Connect to the transducer if installed 12 3 8 Oil Pressure Oil pressure transducer connector is pre installed in the main harness The system is plug and play configured for a Holley 100 PSI pressure transducer can be purchased under PN 554 102 If these are not connected to a pressure transducer the Fuel and Oil Pressure will read LEr on the hand held display This will not cause any issues Connect to the transducer if installed Le Figure 16 Fuel Figure 17 Oll 12 3 9 CANbus Handheld CAN The handheld controller is used for create of an initial calibration for the system allows for simple tuning changes to be performed and is also used to view various information of the system It should be installed such the handheld controller be easily used in the passenger compartment The handheld has two loose wires and one connector with orange wires Plug the connector into the main wiring harness into the plug marked CAN This plug is located about inches from the ECU connector The handheld controller also has a white and a black wire The black wire should be run to a sound vehicle ground The white wire should be connected to a 12 volt source switched ignition source The handheld does not have to be powerediinstalled after the vehicle is up set up and running properly Figure 18 Harness to Handheld Figure 19
14. alf of the exhaust tubing with the angle shown above being greater than 10 The picture above indicates that the sensor can be mounted on either side of the exhaust tubing 2 Drill a 7 8 hole in the location picked for the sensor Weld the threaded boss into the 7 8 hole Weld all the way around the boss to insure a leak proof connection Install oxygen sensor into the threaded boss and tighten securely Itis good idea to add anti seize to the threads to aid in removal 3 On vehicles equipped with an AIR pump the oxygen sensor must be mounted before the AIR injection into the exhaust or the AIR pump must be disconnected Holley recommends that if the AIR is injected into both exhaust manifolds mount the oxygen sensor into the pipe immediately after the exhaust manifold Disconnect the AIR pump tube from the exhaust manifold and plug both ends Check with local ordinances for the legality of this procedure in your area n WARNING Failure to disconnect the AIR pump or locating the oxygen sensor downstream from All result in an extremely rich mixture which could cause driveability problems and severe engine damage WARNING It is important that the distribution ring is properly installed and fastened to the throttle body Failure to do so will cause an inadequate seal between the throttle body and air cleaner and may be a fire hazard in the event of a backtire Fire hazard can result in property damage serious injur
15. dy down in a criss cross pattern being careful not to over tighlen Proper torque is 5 7 ft Ibs WARNING Over tightening the TBI manifold flange hold down nuts may result in a warped or cracked throttle body The TBI hold down nuts should be tightened down progressively in a criss cross pattern to 5 7 ft bs to prevent leaks and avoid causing damage to the throttle body A TBI that has been damaged due to negligence of the owner will void the warranty 9 2 Throttle Connections 1 Measure the length of the throttle lever arm on the carburetor removed from the vehicle Compare the length of the existing throttle lever arm with the one Extension bracket on the AVENGER EFI throtle body I the unig tis throttle lever arms are similar in length within 1 2 Attach ball stud in of each other throttle lever arm hole on the remaining hole in AVENGER EFI throttle body can be used without bracket the extension bracket Use the throttle lever arm extension bracket if the old throttle lever arm is significantly longer than the new throttle lever arm Before installation of the bracket check the diameter of the throttle cable stud Some systems use 1 4 stud that will require drilling of the appropriate hole in the extension bracket fo a 1 4 diameter Attach the extension bracket using two filister head screws as shown in Figure 1 The extension lever length can be adjusted using the four sets of holes 2 At
16. e Body NOTE 4 barrel intake is required for the installation of the Holley AVENGER EFI TBI system NOTE Some GM and Chrysler engines require the use of a manifold adapter Holley Part Number 17 6 This adapts the spread bore carburetor manifold to the Holley square flange 1 Instali the heat insulating gasket Item 17 between the manifold and the 4 barrel throttle body injection unit Check for sufficient thread engagement of the throttle body hold down studs and nuts It may be necessary to purchase and install longer studs in the manif old for proper nut engagement Gasket sealant may be used to ensure that no vacuum leaks NOTE If using this heat insulating gasket the flange gasket is not required DANGER Check for proper clearance between engine components such as the distributor coll etc and the throttle body If any interference is found correct the condition before continuing Failure to do so can result in damage to the engine components or the throttle body DANGER Check for proper clearance between the air cleaner and the engine compartment cover hood If any interference is found correct the condition before continuing Failure to do so can result in damage to the compartment cover or engine components 2 Place the throttle body in position over the manifold flange studs with the IAC motor facing the front of the vehicle and the regulatorituel connections towards the rear of the vehicle 3 Tighten the throttle bo
17. h the sensor The name on this label for each sensor is in parenthesis below m 12 3 1 Throttle Position Sensor TPS Connect to the TPS which is located on the throttle body 12 3 2 Manifold Air Pressure Sensor MAP Bar MAP sensor is provided with all Holley EFI systems Connect to the MAP sensor Make sure that a vacuum line was connected to the MAP sensor in previous steps d Figure 11 TPS Figure 12 MAP 12 3 3 Coolant Temperature Sensor CTS Connect to the Coolant Temperature sensor which should have been installed in an engine coolant passage 12 3 4 Manifold Air Temperature Sensor MAT Connect to the Air Temperature Sensor This is located in the throttle body unit Figure 13 CTS Figure 14 MAT 12 3 6 Wide Band Oxygen Sensor WB02 Connect to the oxygen sensor connector to the oxygen sensor previously installed If you need an extension cable one is available from Holley P N 534 199 The Avenger systems are intended to be used with a Bosch wide band oxygen sensor supplied by Holley Make sure yours is the same as the picture below Figure 15 WBOZ 15 12 3 7 Fuel Pressure Fuel A fuel pressure transducer connector is pre installed in the main harness The system is plug and play configured for a Holley 100 PSI pressure transducer can be purchased under PN 554 102 If these are not connected to a pressure transducer the Fuel and Oil Pressure will read
18. in DANGER Failure to use a steel fuel line that meets SAE J526 standards could result in fuel leaks A fuel leak may result in a fire or explosion hazard which could cause serious injury or death DANGER Take precautions to ensure that all fuel line routings are away from heat sources such as the engine exhaust pipes A fire or explosion hazard could cause serious injury or death DANGER Rigid fuel line tubing should be used for under vehicle runs such as along vehicle frame rails or under floor pans Failure to do so is a potential fire or explosion hazard which could cause serious injury or death 11 Anchor fuel lines securely to solid chassis members at 1 Vs foot intervals using rubber coated steel clamps Use of only approved steel fuel line tubing wil afford maximum fuel line protection against road hazards and premature wearing due to flexing temperature extremes road salt weather ete 9 5 Return Line Installation Holley AVENGER EFI TBI system requires a return fuel line to the fuel tank Some late model vehicles that were originally equipped with a throttle body injection system may already have a return line to the fuel tank that can be utilized If a return fuel line must be installed a minimum size of 5 16 LD is recommended The retur line is on the passenger side of the TBI unit The fiting on the TBI unit is designed for a 5 16 line If larger line is used use an appropriate fitting on the thrott
19. le body The return line must not present a pressure restriction to the return fuel flow There should never be more than approximately 3 PSI of pressure in the retum line A line that is too small has restrictions will cause tuning problems with the system DANGER Do not use the vapor canister lines as a fuel return line Possible fuel leaks may create a fire or explosion hazard causing serious injury or death WARNING Use only approved steel fuel line The return fuel line should e unit flange or at the filler neck The filler neck or sending perform this operation r the fuel tank at the fuel level sending must be removed from the tank to DANGER Proper installation of the fuel return line may necessitate complete removal of the fuel tank This work should be done by a fuel tank specialist who regularly does this work and is familiar with safety regulations and precautions necessary to do this work If a person attempts this work who is not far with the safety regulations and precautions an explosion hazard may result causing serious injury or death YOR RETURN UNE ap gm Figure 5 n 9 6 Oxygen Sensor Installation The oxygen sensor should be mounted at a point where it can read a good average of the cylinders on one bank This would be slighty ater all the cylinders merge Do NOT mount the sensor far back in fne exhaust as this wil negatively impac
20. lete 1 534 187 TBI Assembly 900 85 Ib hr Complete 1 534 173 9 Avenger EFI and Handheld 1 554 116 3 Main Power Harness 1 558 308 4 Avenger EFI TBI Wiring Harness 1 558 100 5 Inline Pump 1 6 Metal Fuel Filler 1 562 1 7 Fuel Filter WIX 33033 1 8 Fuel Filter Clamp 1 9 Fuel Pump Plate 8 Gasket 1 12 813 10 Wide Band Oxygen Sensor 1 554 101 11 MAP Sensor 1 538 24 12 Coolant Temperature Sensor 1 5342 13 Air Cleaner Adapter 1 17 14 14 Air Cleaner Gasket 1 108 4 15 Flange Gasket 1 108 10 16 Manifold Flange Studs 4 17 Heat Insulator Gasket 1 108 12 18 Oxygen Sensor Weld Ring 1 534 49 19 40 Relay Pre Installed in harness 1 534 26 20 Throttle Bracket 1 21 Throttle and Cruise Control Stud 1 22 Throttle Lever Ball 1 28 Throttle Lever Bracket 1 24 Ford kick down return spring 1 25 Throttle Lever Stud 1 26 Transmission Kickdown Stud 1 27 Hose Clamp 8 28 Grommet 1 29 Cable 12 Tube 1 31 Lockwasher 2 32 1 4 28 Nut 2 33 5 16 24 Nut 4 34 5 16 Vacuum Line 1 35 Ignition Adapter 1 TBI Service Parts Charge Temperature Sensor 1 53446 Fuel Injector 700 CFM 68 lb hr requires purchase of 4 1 522 54 Fuel Injector 900 75 Ibihr requires purchase of 4 1 522 80 Fuel Injector 900 85 lb hr requires purchase of 4 1 522 43 Fuel Pressure Regulator Diaphragm 1
21. njectors This Wire is protected by a fuse in a sealed fuse holder The fuse holder is located about 9 from the ECU connector A fuse is pre installed 20A 32V Fuel Pump Color Green Used to directly power a fuel pump 12 volt Do not use this wire to power fuel pumps that Tequire over 10 12 Amps For high current pumps use this wire to trigger a separate relay and use larger gauge wire to feed the pump 10 gauge is recommended The pump that include with Avenger systems draws less than 10 Amps and can be powered directly by this wire The fuel pump also requires a ground wire Run a wire from the negative side of the fuel pump marked on the Holley pump in this kt Connect it to a solid chassis trame ground Figure 25 Points Output Color White This wire is NOT used with the Avenger system Tape up the end or install heat shrink in it Chassis Ground Color Black Connect to a chassis ground point that has excellent connectivity with both the engine and Yellow See section 15 0 below This is an RPM input wire used for some applications 15 0 IGNITION ENGINE SPEED INPUT The most important signal for the ECU is the Engine Speed input It is critical that this is configured and wired correctly or poor performance will result There are 3 engine speed options on the Avenger systems Each one is wired differently If these are wired incorrectly it is easily possible to permanently damage the ECU
22. ock Chevrolet and Chrysler engines If the block off plate does not fit your engine a block off plate may have to be purchased from a local performance parts supplier 6 If required replace the intake manifold at this time Proceed to step seven if this is not required 4 BARREL STOCK AFTERMARKET SQUARE FLANGE INTAKE MANIFOLD IS REQUIRED FOR THE INSTALLATION OF THE HOLLEY AVENGER EFI TBI system 7 Place clean shop towels or rags into the manifold opening to prevent dirt or debris from entering the engine Keep exposed ends of the vacuum and fuel lines free from dirt WARNING Failure to cover the intake opening with a clean towel could result in dirt or debris entering the engine Dirt or debris in the induction system can cause engine damage which may necessitate in a complete engine overhaul 8 Remove traces of the old gasket material from the TBI mounting flange DO NOT gouge the intake manifold sealing surface during removal of old gasket material Failure to remove traces of the old gasket material will result in vacuum leaks that will be difficult to detect later Sealing flanges must be clean and dry before installation 8 Remove the shop towels fram the intake and vacuum out the intake channel to ensure no dirt or debris is left the intake system Place a shop towel over the entire intake opening until you are ready to install the new AVENGER EFI TBI 9 0 AVENGER EFI TBI SYSTEM INSTALLATION 9 1 Throttl
23. ou use is compatible with oxygen sensor vehicles This information should be found on the RTV package 2 0 CHOOSING THE RIGHT SYSTEM ensure that you have purchased the correct AVENGER EFI kit for your application check to be sure that the kit you purchased is listed beside your engine s horsepower HORSEPOWER KIT PART NUMBER Up to 400 hp 550 400 AVENGER EFI TBI 700 CFM 65 lbhr injectors Up to 525 hp 550 401 AVENGER EFI TBI 900 CFM 75 lb hr injectors Up to 600 hp 550 402 AVENGER EFI TBI 900 CFM 85 lbihr injectors 3 0 WARNINGS NOTES AND NOTICES WARNING For the safety and protection of you and others only a trained mechanic having adequate fuel system experience must perform the installation adjustment and repair It is particularly important to remember one of the very basic principles of safety fuel vapors are heavier than air and tend to collect in low places where an explosive fuel air mixture may be ignited by any spark or flame resulting in property damage personal injury and or death Extreme caution must be exercised to prevent spillage and thus elimi the formation of such fuel vapors WARNING This type of work MUST be performed in a well ventilated area Do not smoke or have an open flame present near gasoline vapors or an explosion may result 4 0 PARTS IDENTIFICATION ITEM DESCRIPTION ary SERVICE PART 1 TBI Assembly 700 65 lb hr Complete 1 534 172 TBI Assembly 900 75 Ibihr Comp
24. r Controlled Distributor Small and Big Block Chevy engines use a small cap GM computer controlled distributor that was available factory GM vehicles from the 1980 s through mid 1990 s This distributor provides an engine speed signal to the EFI as well as allowing the EFI to control the ignition timing Figure 26 Distributor and Close Up of Distributor 16 0 WIRING OPTION 1 Option one uses the Yellow Wire for engine speed input The yellow wire is loose wire located 40 from the ECU connectors It is bundled with several other loose wires The following two diagrams show how to wire to the two most common applications which are 1 Any General Motors engine equipped with a factory large distributor equipped with mechanicalivacuum advance Figure 27 2 Any engine equipped with a factory mechanical advance distributor and separate canister style coil This would include any points style distributor Figure 28 Figure 27 below shows how to connect to large cap distributor HOLLEY EFI TO GM HEI USING MECHANICAL AND VACUUM ADVANCE 4 PIN MODULE DISTRIBUTOR ECU NOT CONTROLLING IGNITION TIMING connect TO YELLOW COIL WRE ON EFI HARNESS BROWN FACTORY HARNESS suce SOS DISTRIBUTOR BROWN FACTORY HARNESS TO TACHOMETER RED SWITCHED POWER Figure 27 19 Figure 28 below shows how to connec
25. ressure Oil 123 9 GANbus Handheld 123 10 Knock Sensor Knock 123 11 Ignition IGN 130 PRIMARY OUTPUTS 13 1 Idle Air Control IAC 132 Fuel Injector Outputs Injectors 140 LOOSE WIRES 150 IGNITIONENGINE SPEED INPUT 160 WIRING 170 ADDITIONAL OUTPUTS APPENDIX 1 0 Pinout 1 0 INTRODUCTION Holley Performance Products has written this manual for the installation of the AVENGER EFI TBI fuel injection system This manual contains the information necessary for the hardware installation Please read all the WARNINGS NOTES and TIPS they contain valuable information that can save you time and money It is our intent to provide the best possible products for customer products that perform properly and satisfy your expectations Should you need information or parts assistance please contact our technical service department at 1 270 781 9741 Monday through Friday 8 a m to 5 p m Central Time By Using this number you may obtain any information and or parts assistance that you may require Please have the part number of the product you purchased when you call NOTE This manual is for the hardware installation of a Holley Throttle Body Fuel Injection System and instructions specific to it Instructions on using the Avenger Handheld to set up and tune your engine are contained in the Avenger tuning manual included with this kit WARNING The AVENGER systems consist of a number of sophisticated componen
26. so pay close attention to proper wiring These options are described below and wiring diagrams are supplied below the descriptions OPTION 1 Coil engine speed input Use this if You are using a stock type mechanical advance distributor with a stock inductive ignition coil Examples of this would be any older style points distributor a 1974 1981 GM large cap Do NOT use this input if you are using an aftermarket Capacitive Discharge CD ignition system such as a MSD Mallory or others The ECU will be damaged you connect to a capacitive discharge type ignition coil NOTE Using this input the EFI will NOT control the ignition timing of the engine The timing will be based on the distributor initial mechanical and vacuum advance just like it did with a carburetor OPTION 2 Tach Out engine speed input Ifyou are using an aftermarket Capacitive Discharge CD ignition system such as a MSD Mallory others you need to connect to the Tach connection or wire these systems provide This is a 12 volt square wave output CAUTION NEVER NEVER connect any of the EFI wires to the coil on any CD type ignition system The ECU will be permanently damaged 18 NOTE Using this input the EFI will NOT control the ignition timing of the engine The timing wil be based on the distributor initial mechanical and vacuum advance just like it did with a carburetor OPTION 3 GM Small Cap HEI Compute
27. sor is installed in a manner such that the vacuum hose fitting is pointing at a downward angle Failure to do so can allow fuel and condensation to run into the sensor and cause failure 2 Install vacuum hoses to the appropriate port on the throttle body Use the diagrams made during removal of the existing fuel system to locate the correct port The vacuum ports of the throttle body are labeled in Figure 2 Figure 2 9 4 Fuel Pump Fuel Line and Filter Installation NOTE If you have dual fuel tanks you must purchase Holley PN 534 38 The following section covers the installation of an in line pump Holley in line fuel pump PN 12 820 is included with this kit Holley includes both pre and post filter with the AVENGER TBI system Both of these filters have barbed ends and are designed to connect to an EFI pressure rated rubber hose They are not designed for style plumbing AN style fittings are available for this pump from Holley if AN plumbing is used PN 26 160 for 6 PN 26 180 for 8 1 not mount the fuel pump higher than the lowest point of the fuel tank 2 Make sure fuel tank is properly vented DANGER Never get under a vehicle supported only by a jack Serious injury or death can result from vehicles falling off of jacks Before working underneath a vehicle support it solidly with jack stands 3 Mount the electric fuel pump as close to the fuel tank outlet as possible with the bracket provided Mounting
28. t Closed loop operation response If you have long tube headers mount the sensor approximately 1 10 after the collector or in the header collector itself Avenger systems come with a Bosch wideband oxygen sensor Make sure your sensor looks like Figure 6 Figure 6 9 6 1 Oxygen Sensor Mounting Procedure NOTE Never run the engine with the oxygen sensor installed if it is not plugged in and powered by the ECU or it will be damaged If you need to plug the hole temporarily use an O2 sensor plug or a spark plug with an 18mm thread NOTE Someone with experience in welding exhaust systems should install the oxygen sensor boss Any competent exhaust shop wil be able to perform this task at a minimum cost WARNING Use of leaded fuel will degrade an oxygen sensor Prolonged use is not recommended unless periodic replacement is performed WARNING Use of some RTV silicone sealers will destroy the oxygen sensor used with this product Ensure the RTV silicone sealant you use is compatible with oxygen sensor vehicles This information should be found on the RTV package 1 Locate a position for the oxygen sensor as close to the engine as possible If your vehicle has catalytic converters the oxygen sensor MUST be located between the engine and the catalylic converters Figure 7 NOTE The oxygen sensor should be mounted in such a way that the condensation in the exhaust tubing will not enter the sensor Mount the O sensor in the upper h
29. t to a factory style ignition with a canister style col cot av Loose YELLOW WIRE FROM WIRE HARNESS cot tj GROUND DISTRIBUTOR Figure 28 OPTION 2 Tach If using an aftermarket Capacitive Discharge CD ignition system you need to connect to the Tachometer Output connection on the ignition box To do so you need to install the included ignition adapter that comes with your kit This adapter will have a single yellow black wire yellow wire with a black stripe tat you wil connect to the tach out the ignition box This output usually is typically a spade type connector on the side of the box or a wire coming out of the box This adapter looks like this Connect it to the main hamess to the connector marked IGN Ignition Connect the yellowiblack wire to the tach out connection on your ignition box If you don t know what wire this is contact the tech service department for the ignition system you purchased Figure 30 20 OPTION 3 GM Small Cap Computer Controlled Distributor An ignition adapter to connect to a computer controlled small cap HE distributor is included with all Small and Big Block Chevy multi port Avenger EFI kits This adapter looks like Figure 31 Connect this adapter to the main EFI harness to the connector marked IGN Ignition Connect the other end to the 4 pin connector on the HE distributor You will need to supply the wiring
30. tach throttle linkage and have an assistant get in the vehicle and fully actuate the throttle controls Make the necessary adjustments to the throttle linkage to ensure that the throtll plates are vertical when the throttle control is wide open Work the throttle linkage back and forth several times to ensure it operates smoothly with no binding or sticking DANGER Sticking throttle may result in uncontrolled engine or vehicle speed This could cause property damage personal injury or death A sticking throttle may be caused by improperly installed throttle cables lack of clearance for any of the throttle linkage or by a binding throttle linkage Check all throttle cables for proper installation and alignment and actuate the throttle to check for any potential binding or clearance problems Repair any problems before continuing 3 Locate the 1 4 28 throttle stud from the parts provided and attach to the throttle lever with the nut provided Connect the accelerator linkage to the throttle stud on the throttle body If the vehicle is equipped with an automatic transmission connect the transmission kickdown rod to the linkage on the throttle body The transmission kickdown may have to be adjusted Follow the vehicle manufacturer s procedure for the correct adjustment procedure NOTE On late model GM and Ford overdrive transmissions with a lockup torque converter make sure the lockup function is properly retained Failure to do so will result in
31. the fuel pump in this manner will insure that the pump will prime easily and purge fuel vapors in the TBI quickly to ensure faster starts DANGER Take precautions to ensure that all fuel line routings are away from heat sources such as the engine or exhaust pipes A fire or explosion hazard could cause serious injury or death DANGER Ensure that the fuel pump mounting location will not interfere with any under the vehicle components especially at the extreme limits of the suspension travel A fire or explosion hazard could cause serious injury or death Fuel Tank Figure 3 4 There are two metal filters included with the system The fiter marked 33033 MUST be installed between the fuel tank and the fuel pump inlet unless an in tank pump is used The purpose of this filter is to protect the fuel pump from particles of dirt or other foreign material The fitter should be installed with the arrow on the filter pointing in the direction of the fuel flow 5 The other metal fuel fiter that is included with the EFI TBI system should be installed between the electric pump outlet and TBI unit This is a 10 micron EFI fier Position the filter so the fuel hoses can be routed without kinks or sharp bends The filter should be installed with the arrow on the filter pointing in the direction of the fuel flow A clamp is provided to assist with mounting this filter in the W
32. to connect the distributor to the coil Figure 32 shows how to wire when NOT using an aftermarket CD box Figure 33 Shows how to wire when using an aftermarket CD box HOLLEY EFI TO GM HEI IGNITION USING COMPUTER CONTROLLED DISTRIBUTOR EXTERNAL COIL ECU CONTROLLING TIMING 2 SWITCHED POWER epit lo ol INDUCTIVE COL FOLEY ADAPTER BLACK BANG OR RED DISTRIBUTOR SHIELD EAM HOLLEY PIN 890 160 EY FEL ERAN MSD PIN Figure 32 21 4 Figure 33 17 0 ADDITIONAL OUTPUTS There are 3 optional outputs available on the system that can be use for the following features Air Conditioning Shutdown at wide open throttle Electric Fan 1 output Electric Fan 2 output There outputs are located in the Input Output connector This connector is located about 27 inches from the ECU connector and contains pins 3 of these are used for the features mentioned above harness is available to plug into this connector under Holley PN 558 400 that provides a mating plug in connector and additional harness length If you wish to not purchase this mating harness bul want to use these options you can remove a single wire from the main harness Input Output connector and solder an additional
33. ts Failure of any one component does not constitute nor does it justify warranty of the complete system Individual service items are available for replacement of components If assistance is required or if you need further warranty clarification you can call Holley Technical Service at the number shown above WARNING To preserve warranty these instructions must be read and followed thoroughly and completely before and during installation It is important that you become familiar with the parts and the installation of the AVENGER EFI system before you begin Failure to read and understand these instructions could result in damage to AVENGER EFI components that are not covered by the warranty and could result in serious personal injury and property damage WARNING The oxygen sensor in this kit is recommended for use with ONLY unleaded fuel Use of leaded fuels will degrade the oxygen sensor and will result in incorrect exhaust gas oxygen readings and improper fuel delivery Failure to follow these directions does not constitute the right to a warranty claim WARNING Failure to follow all of the above will result in an improper installation which may lead to personal injury including death and or property damage Improper installation and or use of this or any Holley product will void all warranties WARNING Use of some RTV silicone sealers will destroy the oxygen sensor used with this product Ensure the RTV silicone sealant y
34. ts and wiring especially secondary ignition wiring plug wires ignition boxes and associated wiring Properly solder and heat shrink any wire connections tis critical that the engine has a proper ground connection to the battery and chassis DON TS NEVER run high voltage or noisy dirty wires in parallel bundlefloam together with any EFI sensor wiring If wires need to cross try to do so at an angle Do not use the electric fan outputs to directly power a fan They must only trigger a relay Do not use improper crimping tools Don t use things like taps etc Use solder and heat shrink Itis never recommended to splice share signal wires such as TPS etc between different electronic control units 11 0 WIRING HARNESS INSTALLATION 11 1 Main Power Battery Connection The AVENGER ECU has a main battery power and ground connector on the right side of the The bottom position Terminal A is the ground The upper position Terminal is the positive terminal Always use the fused power cable with the proper connectors supplied by Holley only Figure 8 13 12 0 PRIMARY HARNESS INSTALLATION AND SENSORS CONNECTION These sections review the Main Harness installation and all of the sensor connections that must be completed The Main is the primary harness that supports all he primary engine sensors fuel and ignition There are two main connectors for this harness that plug into the ECU Figure 9 12 1
35. y andior death 9 6 2 ECU Mounting The ECU can be mounted inside the passenger compartment preferable location or in the engine compartment mounted in the engine compartment follow these guidelines The ECU should be located such that it isn t being directly hit by water or road debris also be located such that it isn t extremely close to exhaust manifolds or headers It should be mounted such that it is as far away from spark plug wires CD ignition boxes or other electrically noisy devices as is reasonable possible The ECU comes with mounting hardware and vibration absorbers Mount the vibration absorbers between the feet and the mounting location Do not over lighlen the mounting hardware if the ECU is not mounted on a flat surface 10 0 WIRING The following overviews how to properly install wiring hamesses for this system 10 1 Important Wiring Do s and Don ts An EFI system depends heavily on being supplied a clean and constant voltage source The grounds of an electrical system ara just as important as the power side Avenger ECU s contain multiple processing devices that require clean power and ground sources The wiring hamesses for them must be installed in such a manner that they are separated from dirty power and ground sources Do s Install the main power and ground directly to the battery Keep sensor wiring away from high voltage or noisy dirty componen
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