Avenger 550-400 Bedienungsanleitung

AVENGER EFI

4 BBL TBI SYSTEMS

550-400 (700 CFM – 65 lb/hr injectors) up to 400 HP

550-401 (900 CFM – 75 lb/hr injectors) up to 525 HP

550-402 (900 CFM – 85 lb/hr injectors) up to 600 HP

TBI HARDWARE

INSTALLATION MANUAL – 199R10552

NOTE: These instructions must be read and fully understood before beginning installation. If this manual is not fully

understood, installation should not be attempted. Failure to follow these instructions, including the pictures

may result in subsequent system failure.

NOTE: Fits all standard square flange intake manifolds.

TABLE OF CONTENTS:

1.0 INTRODUCTION ..................................................................................................................................................................... 3

2.0 CHOOSING THE RIGHT SYSTEM: ........................................................................................................................................ 3

3.0 WARNINGS, NOTES, AND NOTICES .................................................................................................................................... 4

4.0 PARTS IDENTIFICATION ....................................................................................................................................................... 4

5.0 ADDITIONAL ITEMS REQUIRED FOR INSTALLATION ......................................................................................................... 7

6.0 TOOLS REQUIRED FOR INSTALLATION .............................................................................................................................. 7

7.0 COOLANT TEMPERATURE SENSOR INSTALLATION ......................................................................................................... 7

8.0 REMOVAL OF EXISTING FUEL SYSTEM .............................................................................................................................. 7

9.0 AVENGER EFI TBI SYSTEM INSTALLATION ........................................................................................................................ 8

9.1 Throttle Body........................................................................................................................................................................ 8

9.2 Throttle Connections ............................................................................................................................................................ 8

9.3 MAP Sensor Installation and Vacuum Line Connections..................................................................................................... 9

9.4 Fuel Pump, Fuel Line, and Filter Installation ....................................................................................................................... 9

9.5 Return Line Installation ...................................................................................................................................................... 11

9.6 Oxygen Sensor Installation ................................................................................................................................................ 12

9.6.1 Oxygen Sensor Mounting Procedure .......................................................................................................................... 12

9.6.2 ECU Mounting ............................................................................................................................................................. 13

10.0 WIRING ............................................................................................................................................................................... 13

10.1 Important Wiring “Do’s and Don’ts” ................................................................................................................................. 13

11.0 WIRING HARNESS INSTALLATION .................................................................................................................................. 13

12.0 PRIMARY HARNESS INSTALLATION AND SENSORS CONNECTION ............................................................................ 14

12.1 ECU Connectors ............................................................................................................................................................... 14

12.2 Harness Routing ............................................................................................................................................................... 14

12.3 Sensor Connections ......................................................................................................................................................... 14

12.3.1 Throttle Position Sensor (TPS) .................................................................................................................................. 15

12.3.2 Manifold Air Pressure Sensor (MAP) ......................................................................................................................... 15

12.3.3 Coolant Temperature Sensor (CTS) .......................................................................................................................... 15

12.3.4 Manifold Air Temperature Sensor (MAT) ................................................................................................................... 15

12.3.6 Wide Band Oxygen Sensor (WB02) .......................................................................................................................... 15

12.3.7 Fuel Pressure (Fuel) .................................................................................................................................................. 16

12.3.8 Oil Pressure (Oil) ....................................................................................................................................................... 16

12.3.9 CANbus – Handheld (CAN) ....................................................................................................................................... 16

12.3.10 Knock Sensor (Knock) ............................................................................................................................................. 16

12.3.11 Ignition (IGN) – ........................................................................................................................................................ 17

13.0 PRIMARY OUTPUTS .......................................................................................................................................................... 17

13.1 Idle Air Control (IAC) ........................................................................................................................................................ 17

13.2 Fuel Injector Outputs (Injectors) ...................................................................................................................................... 17

14.0 LOOSE WIRES ................................................................................................................................................................... 17

15.0 IGNITION/ENGINE SPEED INPUT ..................................................................................................................................... 18

16.0 WIRING ............................................................................................................................................................................... 19

17.0 ADDITIONAL OUTPUTS ..................................................................................................................................................... 22

APPENDIX 1.0.............................................................................................................................................................................. 23

Pinout ........................................................................................................................................................................................ 23

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,

as they contain valuable information that can save you time and money. It is our intent to provide the best possible products for

our 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 EFI systems consist of a number of sophisticated components. 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 you use is compatible with oxygen sensor vehicles. This information should be found on

the RTV package.

2.0 CHOOSING THE RIGHT SYSTEM:

To 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 lb/hr 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 lb/hr 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 eliminate

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 QTY SERVICE PART

1 TBI Assembly 700 CFM 65 lb/hr Complete 1 534-172

TBI Assembly 900 CFM 75 lb/hr Complete 1 534-187

TBI Assembly 900 CFM 85 lb/hr Complete 1 534-173

2 Avenger EFI ECU 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 N/A

6 Metal Fuel Filter 1 562-1

7 Fuel Filter (WIX 33033) 1 N/A

8 Fuel Filter Clamp 1 N/A

9 Fuel Pump Block-Off Plate & Gasket 1 12-813

10 Wide Band Oxygen Sensor 1 554-101

11 MAP Sensor 1 538-24

12 Coolant Temperature Sensor 1 534-2

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 N/A

17 Heat Insulator Gasket 1 108-12

18 Oxygen Sensor Weld Ring 1 534-49

19 40 AMP Relay (Pre-Installed in harness) 1 534-26

20 Throttle Bracket 1 N/A

21 Throttle and Cruise Control Stud 1 N/A

22 Throttle Lever Ball 1 N/A

23 Throttle Lever Bracket 1 N/A

24 Ford kick down return spring 1 N/A

25 Throttle Lever Stud 1 N/A

26 Transmission Kickdown Stud 1 N/A

27 Hose Clamp 8 N/A

28 Grommet 1 N/A

29 Cable Ties 12 N/A

30 Tube Cap 1 N/A

31 Lockwasher 2 N/A

32 1/4-28 Nut 2 N/A

33 5/16-24 Nut 4 N/A

34 5/16" Vacuum Line 1 N/A

35 Ignition Adapter 1 N/A

TBI Service Parts:

Air Charge Temperature Sensor 1 534-46

Fuel Injector 700 CFM 65 lb/hr (requires purchase of 4) 1 522-54

Fuel Injector 900 CFM 75 lb/hr (requires purchase of 4) 1 522-80

Fuel Injector 900 CFM 85 lb/hr (requires purchase of 4) 1 522-43

Fuel Pressure Regulator Diaphragm 1 512-1

Idle Air Control (IAC) Motor 1 543-105

Throttle Position Sensor (TPS) 1 543-29

Optional Parts:

Small Cap GM HEI Ignition Adapter 1 558-304

Ford TFI Ignition Adapter 1 538-305

Item 1 Item 2 Item 3

Item 4 Item 5 Item 6

Item 7 Item 8 Item 9

Item 10 Item 11 Item 12

Item 13 Item 14 Item 15

Item 16 Item 17 Item 18

Item 19 (Pre-Installed in Harness) Item 20 Item 21

Item 22 Item 23 Item 24

Item 25 Item 26 Item 27

Item 28 Item 29 Item 30 Item 31

Item 32 Item 33 Item 34 Item 35

5.0 ADDITIONAL ITEMS REQUIRED FOR INSTALLATION

 3/8" fuel hose (must meet SAE J30)  5/16" fuel hose (must meet SAE J30)

 5/16" steel fuel line (must meet SAE J526)

A 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 port 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 Phillips 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 safety reasons.

7.0 COOLANT TEMPERATURE SENSOR INSTALLATION

The coolant temperature sensor (item 12) must be installed in a coolant passage in either the intake manifold or cylinder head.

The sensor has 3/8” NPT threads. If only a ½” NPT port is available, an adapter will 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, it is a good idea to sketch out the vacuum hose routing. Using masking tape and

a permanent marker, mark all 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 fit small and big block 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. A 4-BARREL STOCK

OR 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 all 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 all 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.

9. Remove the shop towels from the intake and vacuum out the intake channel to ensure no dirt or debris is left in 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 Throttle Body

NOTE: A 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. Install 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

occur.

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, coil, 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

regulator/fuel connections towards the rear of the vehicle.

3. Tighten the throttle body down in a criss-cross pattern being careful not to over-tighten. Proper torque is 5-7 ft lbs.

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./lbs., 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

on the AVENGER EFI throttle body. If the two

throttle lever arms are similar in length (within 1/2”

of each other), the throttle lever arm hole on the

AVENGER EFI throttle body can be used without

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

may use a 1/4” stud that will require drilling of the

appropriate hole in the extension bracket to a 1/4”

diameter. Attach the extension bracket using two

fillister head screws as shown in Figure 1. The

extension lever length can be adjusted using the

four sets of holes.

2. Attach 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 throttle 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. Figure 1

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 premature transmission failure.

NOTE: On 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 return spring. Have an assistant get 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

no 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 it is connected to as possible. It must

be connected to a “full manifold vacuum” port. This is a

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). It is best not to “tee”

multiple items into the port that supplies the MAP

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 itself.

NOTE: Make sure the MAP sensor 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. I

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 12-920 is included with this kit.

Holley includes both a 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 “AN” 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. Do 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 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.

Figure 3

4. There are two metal filters included with the system. The filter 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 filter should be installed with the arrow on the filter pointing in the direction of

the fuel flow.

5. The other metal fuel filter 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 filter. 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 kit.

WARNING! 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. A 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. It is

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 TBI unit. Filters must have AN

style fittings as well. The thread in the inlet and

outlet fittings of the TBI unit is ¼” NPT.

7. 3/8” line should be used on the feed/pressure

side of the system (the filters included are

designed for 3/8” line). If using steel line, rubber

hose (rated for use with fuel injection) can be

used to connect the steel line to the pump and

filters. You should not connect a rubber hose

directly to a steel line unless the end of the line

has a “bead/nipple” or barb that retains the hose

(similar to the ends of the fuel filters). If the steel

line is just cut off, purchase a compression fitting

that a barbed hose end can be installed on, or

use a tool to roll a 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

hoses used must meet SAE J30 performance

standards. All steel fuel line must meet SAE

J526 standards. Figure 4

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