Edelbrock Pro-Tuner, Pro-Tuner Series, 3670, 3690 User Manual

Pro-Tuner Users Guide

Edelbrock Corporation 2700 California Street Torrance, CA 90503 Toll Free Tech Line: 800-416-8628 Office: 310-781-2222 Tech e-mail: edelbrock@edelbrock.com

Table of Contents

Part I

Part II

Part III

Introduction Kit Contents Installation and Setup

................................................................................................................................... 101 Engine Management Concepts

.......................................................................................................................................................... 12Strategies and Methods

................................................................................................................................... 152 Vehicle Installation

.......................................................................................................................................................... 22Fuel System Installation

.......................................................................................................................................................... 30ECU and Main Harness Installation

.......................................................................................................................................................... 36Component and Sensor Installation

......................................................................................................................................................... 37Distributor and Ignition

......................................................................................................................................................... 41Intake Air Temperature Sensor (IAT)

......................................................................................................................................................... 42Engine Coolant Temperature Sensor (ECT)

......................................................................................................................................................... 43Manifold Absolute Pressure Sensor (MAP)

......................................................................................................................................................... 45Idle Air Control Valve (IAC)

......................................................................................................................................................... 46Fuel Pressure Sensor (optional)

......................................................................................................................................................... 47Oil Pressure Sensor (optional)

......................................................................................................................................................... 48Mass Air Flow (MAF) Sensor (optional)

......................................................................................................................................................... 50Throttle Position Sensor (TPS)

......................................................................................................................................................... 51Main Wiring Harness and Engine Wiring

......................................................................................................................................................... 54Oxygen Sensors

......................................................................................................................................................... 59Malfunction Indicator Light

................................................................................................................................... 603 Installing and Configuring the Software

.......................................................................................................................................................... 62System Requirements

.......................................................................................................................................................... 64Installing the Software

.......................................................................................................................................................... 70Installing the Communications Hardware

......................................................................................................................................................... 72USB/Serial Converters

.......................................................................................................................................................... 80Connecting to the Vehicle

.......................................................................................................................................................... 87Application Settings and Preferences

5 7

Part IV

Basic Tuning with the Pro Tuner System

................................................................................................................................... 901 Setup Wizard

.......................................................................................................................................................... 94Scaling Setup - Custom Load and RPM Axis

................................................................................................................................... 962 Screens, Indicators and Tools

.......................................................................................................................................................... 99Dashboard

.......................................................................................................................................................... 101MAPs

.......................................................................................................................................................... 104Details

.......................................................................................................................................................... 105Status Bar

.......................................................................................................................................................... 106About

.......................................................................................................................................................... 107System Information

................................................................................................................................... 1083 Tuning Maps

.......................................................................................................................................................... 116Base Fuel Map

.......................................................................................................................................................... 118Volumetric Efficiency Map

.......................................................................................................................................................... 121Spark Advance Map

.......................................................................................................................................................... 124Target Air/Fuel Ratio Map

.......................................................................................................................................................... 128Accel / Decel Fuel Settings

.......................................................................................................................................................... 132Closed Loop Compensation (CLC) map

.......................................................................................................................................................... 135ECT Fuel Trim Table

.......................................................................................................................................................... 136A/C Load Compensation

.......................................................................................................................................................... 138IAT Fuel Trim Table

................................................................................................................................... 1394 3D Chart Manipulation

.......................................................................................................................................................... 140EDIT Chart Point

.......................................................................................................................................................... 142ROTATE

.......................................................................................................................................................... 144ZOOM chart

.......................................................................................................................................................... 145MOVE view

.......................................................................................................................................................... 146RESET View

................................................................................................................................... 1475 Logging and Data Viewing

................................................................................................................................... 1516 Initial Start Up and Idle Tuning

................................................................................................................................... 1557 TPS Set Points

................................................................................................................................... 1588 Ignition Sync Offset

................................................................................................................................... 1609 OFFLINE Mode

.......................................................................................................................................................... 164OFFLINE LOAD

.......................................................................................................................................................... 165OFFLINE SAVE AS

.......................................................................................................................................................... 167OFFLINE SAVE

.......................................................................................................................................................... 168OFFLINE SAVE and USE ONLINE

.......................................................................................................................................................... 169View Logger Data

3Contents

Part V

Part VI

Advanced Tuning with the Pro Tuner System

................................................................................................................................... 1721 Warm Up Fine Tuning

................................................................................................................................... 1742 Idle Fine Tuning

................................................................................................................................... 1773 Toggle Closed Loop

................................................................................................................................... 1784 VE Estimator Tool

................................................................................................................................... 1805 Adaptive Fuel "AutoTuning" Capabilities

................................................................................................................................... 1836 Oil Pressure Warning Set Points

................................................................................................................................... 1847 Coolant Fan Output

................................................................................................................................... 1858 Coolant Fan Set Points

................................................................................................................................... 1869 Fault Detection and Troubleshooting

................................................................................................................................... 18910 Reset ECU to last programmed setup

Features Available with Pro option only

................................................................................................................................... 1911 Additional Maps

................................................................................................................................... 2032 Flight Recorder

................................................................................................................................... 2063 Virtual Engine Simulator

................................................................................................................................... 2084 Base Fuel Pressure Set Point

................................................................................................................................... 2105 Adaptive Air "AutoTuning" Capabilities

171

190

Part VII

Appendices

................................................................................................................................... 2151 Engine Controller Pinout Sheets

214

................................................................................................................................... 2182 Frequently Asked Questions (FAQs)

................................................................................................................................... 2193 Trouble Codes/Faults

................................................................................................................................... 2224 Maintenance Procedures

.......................................................................................................................................................... 223TPS Replacement

................................................................................................................................... 2255 Glossary

................................................................................................................................... 2326 Additional Resources/Service

1 Introduction

Introduction 5

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Edelbrock Pro-Tuner Series Electronic Fuel Injection (EFI)

"Total Engine Management"

That’s the slogan for Edelbrock’s Pro-Tuner EFI Systems, powered by Mototron Electronic Control Units (ECU).

Pro-Tuner EFI Systems include everything needed to convert any engine to powerful electronic fuel injection; with user programmable features and full ignition control as well as fuel delivery. Two performance levels are available: Victor and Super Victor. Both versions include an Edelbrock Victor or Super Victor EFI intake manifold, fuel rails, throttle body, wiring harness, injectors, Pro-Tuner software, sensors, fuel pump regulator, and Mototron ECU with Power PC, 32-bit micro controller.

Victor Systems include a Mototron ECM for semi-sequential injection, while Super Victor Systems feature fully sequential operation and individual cylinder adjustment of spark and fuel for complete optimization, plus a software upgradeable Mototron PCM with advanced features - and expandability for exciting future options. Through your laptop computer, all critical aspects of engine tuning are adjustable to suit your application. The simplified user interface allows a tuner to dial-in the behavior of the state of the art control strategies running within the ruggedized Engine Control Module (ECM).

The proprietary Mototron ECU is extremely durable. It’s completely sealed making it waterproof and ideal for not only competition vehicles but for marine as well. Once up and running, Edelbrock’s Pro-Tuner EFI software offers easy-to-use, yet sophisticated tuning control with user-friendly pull down menus and screens.

Available separately, Edelbrock offers a Pro USB key which allows access to enhanced tuning parameters for more experienced calibrators. A Basic USB key is included standard.

Before reading this manual and installing your new system, it is important to understand that your Edelbrock EFI system is more than fuel injection. It is an Engine Management System. In addition to controlling the fueling of your engine, the system will also be controlling ignition, idle airflow, monitoring sensor health, and running other optional actuator outputs.

While every effort is made to simplify the installation and calibration process, the most important tool is the knowledge and experience of the person tuning the engine. Just as with carbureted engines; the tuner must know the fueling and ignition limits of the specific engine he or she is calibrating to avoid engine damage and provide the best reliability and drivability possible. In addition to reading this manual, there are many other sources of engine management theory, as well as experienced tuners and Edelbrock experts available to assist with questions that you have. See the “Additional Resources” section of this manual for more sources of EFI information. It is highly recommended that the Tuner educate themselves as much as possible in the area of electronic engine control and calibration theory and technique.

If you run into problems, you may contact our EFI Technical Hotline at 800-416-8628 from 7:00 am to 5:00 pm PST Monday through Friday. You may also contact us by email at: EFItech@edelbrock.com

READ THROUGH ENTIRE MANUAL BEFORE BEGINNING

•

SYSTEM INSTALLATION!

THIS CONTROL SYSTEM IS INTENDED FOR OFF-ROAD

•

APPLICATIONS ONLY. THE USER ASSUMES ALL RESPONSIBILITY FOR THE INSTALLATION AND APPLICATION OF THE SYSTEM AND MUST COMPLY WITH ALL APPLICABLE RULES AND REGULATIONS GOVERNING USAGE AND EMISSION REQUIREMENTS.

2 Kit Contents

Kit #3670 Contents:

Part No. Description Qty.

22-3601 Firewall Bulkhead Plate Kit 1

38-1515 Bulkhead Plates 2 68-0410 Self-Tapping Screws 4 72-1516 Grommet 1 3/4" O.D. 1

24-0301 Ignition Amplifier Kit 1

Introduction 7

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68-0410 Self-Tapping Screws 3

37-3517 Victor Pro-Tuner Kit 1

37-0004 RS485 Comms Cable 1 37-0006 USB Software Key (Basic Key) 1 37-0007 Controller ECM (48 Pin) 1 72-1517 ECM Rubber Grommet 3 82-0111 ECM Mounting Washers 3

82-3519 ECM Mounting Bushing 3 38-1600 Mounting Bracket for 48 pin PCM 1 68-4005 1/4-20 x 7/8" PCM Socket Head Screw 3

37-3545 Main Engine Harness w/ 2-Power Relays 1

N/A Padded J-Clamps 4 37-3546 Distributor Harness 1 37-3547 Fuel Pump Harness 1 63-3670 Instruction Sheet - Quick Start Guide 1

63-3615 Instruction Sheet - Distributor 1 63-0507 CD-ROM 1 37-3518 MAT Sensor GM (AC Delco #12160244) 1 72-9952 MAT Sensor Grommet 1 37-1520 Serial to USB Converter 1 63-91147Serial to USB Converter Instructions 1

37-3548 Malfunction Indicator Light w/ Clip 1 37-7119 1 Bar Map Sensor (Remove Orange Rubber) 1 38-3601 Gen III Map Sensor Bracket 1 37-3528 60 lb/hr High Impedance Injectors 8 67-1570 Injector O-ring Lube 1 37-3529 MSD Distributor w/ Cam Sync MSD PN 23451 1 37-3543 Temperature Sensor 1 37-3542 Oxygen Sensor Switching 1 52-9710 Oxygen Sensor Bung 1

Kit Contents 9

Kit #3690 Contents:

Part No. Description Qty.

22-3601Firewall Bulkhead Plate Kit 1

38-1515 Bulkhead Plates 2 68-0410 Self-Tapping Screws 4 72-1516 Grommet 1 3/4" O.D. 1

24-0301Ignition Amplifier Kit 1

68-0410 Self-Tapping Screws 3

37-3523Victor Pro-Tuner Kit 1

37-0004 RS485 Comms Cable 1 37-3524 USB Software Key (Pro Key) 1 37-0005 Controller PCM (80 Pin) 1 72-1517 PCM Rubber Grommet 3 82-0111 PCM Mounting Washers 3

82-3519 PCM Mounting Bushing 3 38-1601 Mounting Bracket for 80 pin PCM 1 68-4005 1/4-20 x 7/8" PCM Socket Head Screw 3

37-3550Main Engine Harness w/ 2-Power Relays 1

N/A Padded J-Clamps 4 37-3546 Distributor Harness 1 37-3547 Fuel Pump Harness 1 63-3670 Instruction Sheet - Quick Start Guide 1

3 Installation and Setup

Installation and Setup

In this section, you will have access to information on how to physically install the system in your vehicle, install the sensors and ECU, and begin the setup process to get your vehicle on the road!

BEFORE BEGINNING!

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A clean and trouble free installation of the Pro-Tuner System is greatly enhanced by taking the time to organize and plan your installation before beginning. Perform the following:

· Unpack and inventory the system to ensure that you have all the parts, sensors, and

wiring that are listed on the packing list

· Lay the harness and wiring out on a table or the floor to help visualize the placement of

the sensors, connectors and components

· Take your battery to a local auto parts store and have them test it for proper voltage

and current carrying capacity.

· Be sure your engine is in good mechanical condition. Fouled spark plugs, vacuum

leaks, etc. will prevent you from properly tuning your engine!

3.1 Engine Management Concepts

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Engine Management Concepts

In this section, we will discuss the general operation of the Engine Management system, including strategies, controls and methods used to enable the engine to be efficient,

Installation and Setup 11

clean, and reliable.

IMPORTANT!

TO AVOID SERIOUS OR FATAL INJURY, NEVER ATTEMPT

TO WORK WITH THE CALIBRATION LAPTOP COMPUTER

WHILE DRIVING VEHICLE.

NEVER PERFORM CALIBRATION ACTIVITIES ON PUBLIC

STREETS OR HIGHWAYS! DISTRACTION AND/OR

INADVERTENT CALIBRATION CHANGES COULD RESULT

IN SERIOUS ACCIDENTS.

Calibration Introduction

Calibration of an EFI system, presents many challenges and opportunities. The opportunities are to improve the throttle response, drivability, start ability, fuel economy, reliability, and reduce emissions of almost any engine. The challenge centers around optimizing a myriad of variables for every operating condition of the engine to achieve the desired results. While certain parameters can be “learned” by the engine control computer through various strategies and algorithms; it ultimately becomes the responsibility of the calibrator or tuner to decide what the ECM should learn, and to make critical decisions about how the particular engine he/she is calibrating will behave under various conditions. Just as it takes time and effort to become a proficient carburetion calibrator; so it will take as much or more time and practice to become a good EFI calibrator. Do not become discouraged or intimidated. Start with the basics of fuel and spark control, then gradually work up to cold starting, transient calibration, idle control, individual cylinder control, and advanced functions and setups. Always remember to start with conservative values for spark, fuel, etc. to avoid damaging the engine. (Minimal spark advance with fueling on the rich side of optimum)

Most tuners agree there is great personal satisfaction when an engine with their own “optimized” calibration is running well. This calibration guide assumes the reader to be familiar with general engine tuning and concepts, and experienced in the requirements and limits of the engine being calibrated. Since each engine and application differ; this manual does not attempt to dictate detailed tuning specifications (such as dictating "X degrees of spark advance at 5% load and 800 rpm”) rather; its purpose is to familiarize the calibrator with the interface software, techniques for tuning various strategies, and provide background information on how they are used. The user assumes all responsibility for the application and use of the information and Edelbrock system software & hardware.

While this guide should prove helpful; it is significantly condensed and simplified to allow the calibrator to quickly reference specific sections. Depending on your specific system

and the method of interfacing to the engine; some of the strategies described in this guide may not be visible or may be pre-calibrated for you. Systems also vary as to their configuration: mass airflow, speed density or speed-throttle, oxygen sensors, ECU, and so on – slightly altering the calibration process. Descriptions of the functions are usually available next to the item or in the header of the map to aid the calibrator. The “HELP” menu in the calibration software also contains much useful information; as well as the documentation for your system, and can be selected at any time during software usage. Always use the documentation for your exact system as the primary reference for system setup and questions.

Ideally, calibration is performed with the vehicle on a chassis dyno where all loads and speeds may be calibrated under controlled conditions. In cases where dynamometer running is not possible, the tuner should enlist the help of another to drive the vehicle while the tuner makes adjustments with the laptop between runs or make table adjustments based on recorded logger data. Vehicle calibration should ONLY be done

on a closed road-course or drag strip with helmets and all other proper safety gear in place. Be aware also that some adjustments may be necessary even after an engine is dyno tuned. Different engine dynos will load the engine differently and they do not always accurately simulate vehicle conditions. This is especially true for transient operation (throttle snaps, etc.).

3.1.1 Strategies and Methods

Strategies and Methods

Control System Concepts

The Engine Management System functions by receiving inputs from various sensors, making calculations and operational decisions, and sending appropriate instructions to outputs that control devices and actuators. In order to do this, the Engine Control Module (ECM) converts the analog inputs to digital signals and processes them within the 32 bit microprocessor. Outputs are conditioned as required for the assigned purpose.

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Your Edelbrock system is capable of three different fuel/timing control strategies. Modeled speed density uses sensor inputs along with a volumetric efficiency (VE) table

Installation and Setup 13

to estimate the airflow through the engine. The air fuel target table is used in conjunction with this calculated airflow to control the injector pulsewidth. The MAP-N strategy uses a base fuel map that varies as a function of engine speed and manifold pressure. The desired base injector pulsewidth is displayed in the table. The Alpha-N strategy uses a base fuel map that varies with engine speed and throttle position. The desired base injector pulsewidth is displayed in the table. The Alpha-N strategy works very well for engines with very large camshafts that exhibit very low idle vacuum. The table below summarizes the advantages and disadvantages to each control strategy.

Modeled Speed Density MAP-N Alpha-N

Advantages

Disadvantages

· If properly setup, does

not require tuning of temperature based trim tables

· Direct measurement of

engine load (assuming the VE table is accurately defined)

· Can adjust for changes in

engine tuning requirements if used with optional mass airflow sensor

· If properly setup, will be

more consistent as operating conditions change

· Requires an accurate

volumetric efficiency table

· Fuel control units more

difficult to understand

· Mass airflow sensor (if

used) difficult to retrofit onto older engines

· Relatively quick and easy to

tune

· Base fuel map in units of

injector pulsewidth

· Very common tuning method

used in many available aftermarket EFI systems.

· Works well and easy to tune

for boosted applications

· Easy to modify calibration if

larger injectors installed

· Does not work well with

large overlap camshafts due to low idle vacuum

· Requires temperature based

trim tables

· Indirect measurement of

load

· Calibration could be

inconsistent if trim tables are not properly tuned

· Works well for large overlap

camshafts Not affected by low idle vacuum signal

· Relatively quick and easy to

tune

· Base fuel map in units of

injector pulsewidth

· Easy to modify calibration if

larger injectors installed

· Idle mixture affected by

closed throttle TPS voltage drift

· Requires temperature based

trim tables

· Indirect measurement of load

· Does not work well with idle

air control motors.

· Calibration could be

inconsistent if trim tables are not properly tuned

The engine management system requires sensor data to maintain efficient operation under various conditions, and to provide feedback to the ECM regarding the current operating conditions. The sensors needed for basic operation include: ECT (Engine Coolant Temperature), IAT (Intake Air Temperature) or (Charge Air Temperature), TPS (Throttle Position Sensor), CTS (Crankshaft Trigger Sensor), MAP (Manifold Absolute Pressure) sensor, and O2 (oxygen sensor). Other sensors can be added for additional control information or data acquisition; however, the sensors listed are the minimum ones required for basic engine control with this system.

When calibrating an engine, the basic goals are to optimize torque and minimize fuel consumption at every speed and load point. However, there are limits to how

far one can go with this in actual application. In practice, you will be constrained by other factors and may be limited to values that insure running quality and reliability. This is called the “calibration window” for that condition. We will discuss cal windows later on. As you proceed, It is very important to understand that engines will attempt to run in

many conditions in which they should not be exposed – such as detonation or excessive temperatures. It is your job as a calibrator to balance all of the factors for your specific combination and program the best target values into the ECM that you can while keeping the engine in a safe operating window. There is a desired order in which an engine control system should be calibrated. A general order of activities is listed below:

1. Verify correct system installation and insure the method of wire and hose routing will prevent any chance of wear, fraying, or proximity to high temperatures. Insure software and communication to the ECM is functioning properly.

2. Perform preliminary calibration activities: load proper sensor and engine configuration calibrations and limits, set crank trigger offset (& cam offset if available), scale sensors and map ordinates. It is preferable if the tuner starts with a known calibration for a similar combination whenever possible; as it greatly speeds the setup and calibration process.

3. Calibrate under steady state conditions for every engine speed and throttle position (load) - while optimizing fuel, ignition timing, and airflow – and completing the various maps at each point.

4. Optimize starting, warm-up, and idle calibrations for various temperatures and conditions. (Cold starts, hot restart, etc.)

5. Calibrate transient fueling (acceleration and deceleration) parameters if needed to optimize fuel during non-steady state conditions.

Fundamental Steady-State Engine Calibration Goals

1. Minimize BSFC at part-throttle operating conditions.

2. Maximize Torque at WOT.

3. Stay within emissions constraints.

5. Stay within EGT limits

6. Minimize drastic or erratic map value changes between cells

The important thing to remember is to balance all of the factors to create the best compromise between them.

For example: as a calibrator, you may be personally focused on running quality. You may find that running quality continues to improve as you advance the spark at a particular operating point. Even though running quality may actually improve as spark is advanced into the knock region – one should not cross those limits in pursuit of optimizing one variable, because doing so could cause engine damage.

The best calibration attempts to keep each variable in the middle of the window for every operating point. While this may not always be possible due to operating conditions or engine hardware and design; every effort should be made to keep away from the edges of the window. For example, let’s say you calibrated your engine on the lean side of the wide open throttle air/fuel window to reduce fuel consumption during the race. While it may be OK for that specific combination at that time, you would have to ask yourself,

1.Is the calibration robust enough if my crew chief advances the cam 2 degrees?

2.Will the engine be OK if fuel quality varies?

3.Will the engine detonate if lugged in gear?

For these reasons and others, it is desirable to stay in the center of the variable’s window

whenever practical. Further calibration tips are contained within this manual and associated with the Pro

Tuner function or map that they correspond to.

3.2 Vehicle Installation

Installing the Victor System in the Vehicle

Installation and Setup 15

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Installing the Victor system in a vehicle is a straight-forward procedure that is not difficult; particularly if you have experience replacing intake manifolds and basic automotive electrical knowledge. During this stage, it is helpful to consult a factory service manual (if available) as well as your system documentation.

Since specific procedures may vary with application, a factory manual should be used to identify and assist in installation in those instances. Some items that may be unique depending on the applications are:

1.Firing order

2.Location of #1 cylinder

3.Proper idle vacuum, RPM and ignition timing

4.Ignition advance curve For proper system function and warranty coverage, it is very important that all

installation instructions be followed during installation and operation. If you do not understand a procedure, contact the Edelbrock hotline. If you do not have the necessary skill or tools to perform any of the operations, consult a professional dealer/installer for assistance.

CHEVROLET V8

System Components:

System ECU (ECM/PCM)

•

Software

•

Ignition Module

•

Wiring harness w/Fuel pump and Main Power relays

•

Fuel Pump harness

•

Ignition Harness

•

MSD/Edelbrock HEI distributor

•

Intake Manifold - Fuel Rail Assembly

•

Edelbrock High Flow 60 pph Fuel Injectors

•

Four barrel Throttle Body w/integrated TPS sensor & Idle Air Control valve

•

Heated Oxygen sensor w/mounting bung

•

1 bar Manifold Absolute Pressure (MAP) sensor

•

Intake Air Temperature (IAT) sensor

•

Engine Coolant Temperature (ECT) sensor

•

Firewall bulkhead grommet/cover plate assembly

•

Additional Hardware and Parts needed:

Intake Gaskets / other engine gaskets as required

•

Edelbrock/GM/or equivalent

•

5/16” steel tubing (approximate equal length to fuel pickup in tank)

•

Edelbrock Gasgacinch #9300

•

Loctite 598 OEM High Temperature Silicone gasket (O2 sensor compatible)

•

Radiator Coolant - Teflon paste thread sealant

•

Manifold bolt kit

•

Factory service manual & wiring diagrams

•

Preliminary Checklist:

CAREFULLY STUDY AND UNDERSTAND ALL INSTRUCTIONS.

•

Examine the system components and packaging for shipping damage. (If

•

damaged, contact your dealer immediately) Check all threaded manifold holes.

•

Check all internal manifold passages with a light and wire, making sure they are

•

clean and unobstructed. Check automatic transmission shift points before removal of the stock system, and

•

adjust linkage after Edelbrock manifold installation for same shift points if needed.

Determining Hood Clearance

1. CHECK HOOD CLEARANCE BEFORE REMOVING STOCK MANIFOLD.

2. Use modeling clay or putty to make five small cones 2-3” high.

3. Position cones on air cleaner at front, rear, each side, and on center stud.

4. Close hood fully and reopen.

5. The heights of the cones indicate the amount of clearance between the hood and

the air cleaner. Record the measurements.

Installation and Setup 17

AFTER MEASUREMENT:

COMPARING HEIGHT OF STOCK INTAKE ASSEMBLY AND VICTOR PRO TUNER ASSEMBLY.

1. Remove air cleaner from stock assembly.

2. Lay a straightedge across top of carburetor flange front to rear.

3. Measure from bottom of straightedge to manifold/block sealing surface of manifold at front and rear of engine. Record measurements (A & B).

4. Add “A” and “B” and divide by 2 to get average height.

5. Measure your Victor assembly using the same method.

6. Compare the measurements. If the Victor dimensions are taller, subtract the difference from the current hood clearance to determine the new hood clearance.

*CAUTION: You must maintain a minimum of ½” clearance between air cleaner and hood due to engine torque movement. If you have insufficient clearance, a low profile air cleaner may solve the problem.

EMISSION CONTROLS:

The Edelbrock Victor and Super Victor Engine Management Systems will not accept stock emission control systems. Check local laws for requirements before installing this system. Not legal on pollution controlled applications.

FUEL REQUIREMENTS:

Because the Victor and Super Victor systems use an oxygen sensor, you must use

unleaded fuel only to avoid damaging the sensor. If you use leaded fuel in your

application, do not install the O2 sensor and configure the system for no O2 sensors through the setup Wizard. Fueling will then be managed open loop.

The driver's side sensor is always the primary sensor. Always plug into the

driver side only when using a single sensor. If using dual sensors, the system will use the leanest bank's sensor to provide closed loop feedback.

AUTOMATIC TRANSMISSION CHECK:

For best performance, economy, and emissions, the shift points must be checked before and after the manifold change.

*NOTE: This check should only be performed on the drag strip or test track.

With the shifter in drive, accelerate to wide open throttle from a standing start. Hold in this position, noting speedometer reading when the transmission makes the 1-2 shift. Run the test again after the manifold change. The shift point should be the same. If the shift point is not the same – adjustment is necessary. We recommend use of the Edelbrock Throttle, Cruise control, & Transmission Kick-down Mounting Bracket #8031 or #8032 with Vortec heads. The Turbo 350 and Turbo 200 feature a window to accommodate user adjustment of shift points at WOT (Wide Open Throttle).

Installation and Setup 19

The 200R4 and 700R4 transmissions require precise adjustments. We recommend that you consult a reputable transmission shop for final adjustment once the Victor system has been installed.

INCORRECT SHIFT POINTS CAN RESULT IN TRANSMISSION DAMAGE!

ENGINE CLEANING:

Always perform the installation with a clean engine and engine compartment. Use utmost care in the cleanliness of ALL parts during the process.

EXHAUST MANIFOLD HEAT RISER:

If your vehicle is equipped with an exhaust manifold heat riser (typically located on the passenger side of the vehicle under the exhaust manifold), remove the valve for proper operation.

HEADERS:

For best performance, headers are recommended. Consult Edelbrock or your exhaust supplier for recommendations on header, pipe, and muffler specifications for your combination.

INSTALLING THE EFI INTAKE MANIFOLD:

The procedure for installing your new EFI manifold is nearly identical to installing a carbureted manifold. Always install new gaskets per manufacturer recommendation and follow the Edelbrock torque specifications for your particular manifold.

PRE-INSTALLATION

Before installing the induction system, take the following steps to ensure successful installation and performance:

1. Check all components thoroughly for damage when unpacking.

2. Make sure all throttle linkages open entirely and close freely.

3. Make sure all fuel inlet and vacuum ports are free from packing material.

4. Check the installation kit for proper parts.

REMOVING THE STOCK CARBURETOR AND MANIFOLD

1. Disconnect battery.

2. For ease of installation, keep all parts in order.

CAUTION: Do not remove manifold if engine is hot.

3. Drain radiator coolant (radiator drain plug is typically located on lower right facing engine).

4. Remove gas cap to relieve pressure. Disconnect fuel line and plug. Replace gas cap.

5. Disconnect all linkage from carburetor such as throttle, throttle springs, transmission, cruise control and automatic choke.

6. Tag and remove coil wires and sensor wires.

7. Remove previously marked vacuum lines.

8. Remove radiator hose, thermostat housing and thermostat, if mounted on manifold.

9. Remove all brackets from the manifold.

10.Loosen or remove valve cover bolts for manifold removal and replacement. It may be necessary to replace valve cover gaskets if broken, to prevent oil leakage.

PORT SURFACE CLEANING

1. When cleaning old gaskets from head surfaces, lay rags in the lifter valley and stuff paper into the ports, to prevent pieces of the old gasket from falling into ports and combustion chambers or valley.

2. When clean, remove paper, making sure that all particles fall on the rags in the lifter valley.

3. Remove rags, and wipe surfaces clean with rags soaked in lacquer thinner in order to remove oil or grease.

NOTE: This procedure is necessary to ensure proper sealing.

INSTALLING FITTINGS, PIPE PLUGS, AND STUDS

Do not over-tighten or cross-thread fittings, pipe plugs, studs, or bolts in your aluminum manifold. Damage to threads or a cracked mounting boss may result unless caution is used when installing accessories. Use Teflon sealant on all pipe threads.

GASKET SURFACE PREPARATION

CAUTION: Replace all gaskets as recommended. Do not use race-type nonembossed gaskets for street applications. Due to material deterioration under street driving conditions, internal vacuum and oil leaks may occur. We recommend Fel-Pro Printoseal gaskets or equivalent. Do not use Fel-Pro Perma torque Blue gaskets, which are designed for use on stock cast iron intake manifolds only.

1. Check gaskets on head surface and manifold to make sure they are correct. Embossed side faces up. NOTE: In some cases, there may be a different right and left side gasket. Make sure both are placed correctly.

2. Coat head surface and both sides of gaskets with Edelbrock Gasgacinch #9300.

3. Apply Loctite 598 OEM High Temperature Silicone Gasket around water passages on head surface.

4. Gaskets and surface will become tacky to the touch within a few minutes. Carefully place gaskets on head surface, aligning ports and bolt holes.

5. Edelbrock recommends the use of Loctite 598 OEM High Temperature Silicone Gasket instead of end seal gaskets. Apply a 1/4-inch thick bead of sealant across each end seal surface, overlapping the intake gasket at the four corners.

NOTE: Use the ONLY recommended O2 SENSOR SAFE sealer . Others may

damage the O2 sensor. This method eliminates end seal slippage and

deterioration. For ease of installation, we recommend using an Edelbrock Manifold Bolt and Washer Kit.

6. Apply Edelbrock Gasgacinch #9300 or equivalent to port surface of the manifold and to the head surfaces to ensure a good seal.

7. Apply RTV gasket sealer around water passages on the manifold.

8. Surfaces will become tacky to the touch within a few minutes.

INDUCTION SYSTEM INSTALLATION

1. Carefully position manifold and air valve on engine, centering bolt holes with the bolt holes in the head.

2. Apply thread sealer or Teflon tape to bolt threads where exposed to water or oil.

3. Hand tighten all bolts.

4. Torque all manifold bolts to Edelbrock specifications.

Installation and Setup 21

5. Re-connect throttle linkage and springs, transmission, cruise control, and fuel lines. Check all linkage for smooth throttle operation from idle to Wide Open Throttle (WOT).

Note: Do not install with a throttle rod, use a cable actuated throttle. Throttle rods can transfer engine movement to the throttle and possible lead to binding.

6. Re-tighten the valve cover bolts.

3.2.1 Fuel System Installation

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Fuel System

FUEL SYSTEM BASICS Because your Edelbrock Pro Tuner system controls fuel delivery very differently than a

carburetor, some conversions to your fuel system may be necessary. Victor/Super Victor Pro-Tuner electronic fuel injection requires high and constant fuel volume and fuel pressure. For this reason, a good primary fuel line is critical. A 3/8-inch (minimum) HIGH PRESSURE fuel line must be used as the primary fuel line.

The fuel that bypasses the injectors must be returned to the fuel tank via a return fuel line. If your vehicle is already equipped with a fuel pump bypass line, this line can be used as the return fuel line. If not, the original primary line may be used as the return line or a new return line plumbed with 5/16” ID steel or high pressure line.

Many late-model cars are equipped with an additional fuel line which runs to a charcoal canister mounted on the driver side of the vehicle. This line MUST be re-installed after the fuel system conversion and MUST NOT be used as the return fuel line.

FUEL SYSTEM PLUMBING

Edelbrock recommends parallel plumbing for performance applications. Parallel plumbing is accomplished by teeing the feed hose from the pump into both fuel rails and connecting the two outlets to the fuel pressure regulator. See Fig. 2 below. This gives twice the capacity of series configuration plumbing. It also reduces the fuel velocity in the fuel rail when compared to series plumbing. If the fuel velocity is too high it may cause flow disturbance in the fuel rails. A parallel configuration is recommended to achieve the best cylinder to cylinder distribution.

Installation and Setup 23

Figure 2

FUEL PUMP AND FILTER

The Victor/Super Victor Pro-Tuner system uses a single Edelbrock high-pressure electric fuel pump which is capable of pumping 50 or more psi (depending upon the pump). The pump relay will prime the system on key-up and shut down the pump if it does not receive an engine-run signal from the ECU, as in the case of a stall. This safety precaution is necessary when using a high-pressure fuel system. It is very important that the fuel flow capacity of the EFI pump exceed your peak demand by 20-25% to avoid engine damage due to loss of pressure. Electrical connectors should face the front of vehicle when mounting. Consult your Edelbrock representative for assistance in pump selection. A high pressure/high volume EFI fuel filter should be mounted between the engine compartment and the fuel pump. A high quality inlet filter should also be installed to protect the fuel pump from contamination. See Fig. 2. Consult your Edelbrock representative for assistance in filter selection. Use the mounting instructions for the pump and filters that you are using.

RECOMMENDED FUEL PUMP AND REGULATOR KITS

Up to 600 HP Edelbrock P/N 35943 - Kit includes fuel pump #3594 and regulator #1728

Up to 800 HP Edelbrock P/N 17903 - Kit includes fuel pump #1790 and regulator #1729

Up to 1500 HP Edelbrock P/N 17943 - Kit includes fuel pump #1794 and regulator #1729

FUEL PRESSURE REGULATOR

Fuel pressure is as important as fuel volume, particularly in fuel injection. The Victor/ Super Victor Pro-Tuner system requires that the fuel pressure regulator maintains a constant pressure at the injectors. It is recommended that Manifold Absolute Pressure references the regulator diaphragm to maintain constant pressure across all 8 injectors, regardless of fluctuating manifold pressure (vacuum) level. The fuel that is not injected is returned to the fuel tank via the return fuel line. Recommended pressure settings vary with application. Consult your Edelbrock representative for pressure recommendations. A typical regulator installation is shown in Figure 3.

FUEL LINE SIZES

A high pressure EFI system does not need the same size lines as a low pressure carbureted engine. A 3/8" diameter (-6 AN) is adequate for engines to at least 750 HP. A 1/2" diameter line should be used on engines over 750 HP.

RETURN FUEL LINE

There are three options for installing a bypass return line.

1. Use the 5/16 rubber fuel line provided with the system as the fuel return line.

Figure 3

Installation and Setup 25

2. Use the vehicle’s existing primary line as the fuel return line with modification to the pick up as described below.

3. Use the vehicle’s existing return line (if so equipped) as the fuel return line. This option applies only to vehicles previously equipped with fuel injection. If the vehicle is not already equipped with a return line, some fuel tank modifications are required for routing the return line through the sending unit plate back into the tank. The first two methods listed below require some welding and should be done by a professional radiator or fuel system repair shop.

RUBBER RETURN LINE METHOD

Drill a 5/16-inch hole in the sending unit plate adjacent to where the main line enters the tank. This will be the hole for your return line. Insert a short length of 5/16-inch hard line (available at most radiator shops) into the hole and weld it to the sending unit plate. The hard line should extend through the hole 1 to 2 inches on each side of the plate. Connect a length (at least 4 inches) of 5/16-inch rubber return line hose to the hard line that will extend into the tank. Connect the rubber line to the fuel pickup line using tie wraps.

BULKHEAD FITTING METHOD

Drill a 9/16-inch hole in the sending unit plate adjacent to where the main line enters the tank. This will be the hole for your return line. Insert a #6 AN bulkhead fitting (available at most radiator shops) into the hole, the narrow end of the fitting on the inside of the plate. Apply a rubber washer or RTV sealant and fasten the fitting to the plate with the

Figure 4

nut. Connect a length (at least 4 inches) of flexible return line (rubber or braided hose) to the fitting end. Connect the return line to the fuel pickup line using tie wraps.

NOTE: THIS METHOD REQUIRES NO WELDING OF THE FUEL SYSTEM. NOTE: Whichever method you use to install the return fuel line, be careful to keep

the end of the line away from the fuel pickup, as shown. Otherwise, aerated return fuel can be drawn into the pickup.

HARD RETURN LINE METHOD

Drill a 5/16-inch hole in the sending unit plate adjacent to where the main line, enters the tank. This will be the hole for your return line. Insert a length of 5/16-inch hard line (available at most radiator shops) into the hole and weld it to the sending unit plate. The hard line should extend through the hole 1 to 2 inches on the outside of the plate. On the inside of the plate, the hard line should follow the contours of the fuel pickup line. Bend the end of the return line away from the sock on the end of the fuel pickup line.

Figure 5

Installation and Setup 27

Figure 6

Solder or weld the return hard line to the fuel pickup line.

Figure 7 - Completed return line installation

FUEL SYSTEM INSTALLATION

1. Disconnect the vehicle battery.

2. Drain the fuel tank.

3. Remove all lines from the tank and carburetor.

4. Remove the fuel tank if sender plate is inaccessible. While fuel tank is removed from vehicle, it is recommended that it be professionally cleaned in order to remove any rust or dirt that may have accumulated inside which could damage the injectors.

5. Remove the sending unit from the fuel tank. Refer to RETURN FUEL LINE METHODS above for installing the bypass fuel return line.

6. Install the high pressure fuel line next to the original line, which may now serve as the return line. Use large radius bends. Avoid exhaust components, sharp edges, and possible wear points. Mount the lines firmly and high in the underbody to insure that they will not be exposed to ground clearance obstacles or road debris hazards that could catch or damage the line.

7. If you do not use the original fuel as the return line, route the return line directly alongside the provided primary fuel line.

8. Mount the fuel pump between the tank and the fuel filter as low and as close to the fuel tank as possible. The pump is directional. Electrical connectors should face the front of vehicle. The fuel pump needs to be at or below the level of fuel in the tank.

Installation and Setup 29

9. Mount the fuel filter between the fuel pump and the engine.

10.Re-install the modified sending unit plate to the clean fuel tank.

11.Reinstall the fuel tank.

12.Attach the primary line and return line to the sending unit plate on the tank.

13.Re-attach all other fuel lines at the tank (vapor purge lines, etc., if so equipped).

14.Secure the primary and return fuel lines with the provided tie-wraps, or with Adel clamps if available.

15.Re-attach all fuel lines to the induction system once it has been installed.

NOTE: REMOVE FUEL SENDING UNIT FROM TANK BEFORE MODIFYING. ALL WELDING AND SOLDERING OF THE FUEL SYSTEM MUST BE PERFORMED BY A PROFESSIONAL RADIATOR OR FUEL SYSTEM REPAIR SHOP.

INJECTOR INSTALLATION

DO NOT INSTALL FITTINGS WITH RAIL INSTALLED. TORQUE APPLIED TO THE ASSEMBLY COULD DAMAGE PARTS AND CAUSE FUEL LEAKS!

1. Fasten fuel rail stands (if applicable) to manifold per Edelbrock instructions; making sure the stands are parallel with the injector bosses in the manifold.

2. Lightly grease the injector O-rings at the top and bottom of injector per Figure 5. using supplied o-ring lube.

Figure 8

3. Install the top of each injector into the fuel rail; carefully inserting the injector to avoid pinching or damaging the sealing O-ring. Orient the injector so that the connector is facing outward. (The outside of the rail has the Edelbrock logo on the side).

4. Carefully insert the rail w/injectors into the manifold, insuring that each injector enters the manifold straight and lower O-rings do not get pinched or damaged.

5. Align mounting holes in rail with the rail mounts.

6. Install with hardware provided.

7. Remember to attach the coated injector harness clips to each rail mount, orienting so the clip is above the mounting hole.

NOTE: If O-rings are damaged even slightly, they MUST be replaced before pressurizing system!

Injectors should not bind in the ports. You should be able to rotate

them slightly.

A typical rail installation is illustrated in Figure 9.

3.2.2 ECU and Main Harness Installation

ECU and Main Harness

Figure 9

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