Edelbrock 641563 User Manual
©2007 Edelbrock Corporation
Brochure #63-641560Page 1
Catalog #641560, 641563
Rev. 10/07 - AJ/mc
COMPLETE CHASSIS FUEL LINE KITS
For 1996-2000 Honda Civic Equipped with B-Series Engine
Catalog #641560, 641563
INSTALLATION INSTRUCTIONS
PLEASE study these instructions carefully before beginning this installation. Most installations can be accomplished with common tools and
procedures. However, you should be familiar with and comfortable working on your vehicle. If you do not feel comfortable performing this installation,
it is recommended to have the installation completed by a qualified mechanic. If you have any questions, please call our Technical Hotline at:
1-800-416-8628, 7:00 am - 5:00 pm, Pacific Standard Time, Monday through Friday or e-mail us at Edelbrock@Edelbrock.com
.
IMPORTANT NOTE: Proper installation is the responsibility of the installer. Improper installation
will void your warranty and may result in poor performance and engine or vehicle damage.
DESCRIPTION: This Russell Performance Complete Fuel Line kit includes all necessary parts to replace your factory fuel system with a high flow, high
performance fuel pump, fuel lines, fuel filter, fuel rail and fuel pressure regulator, while retaining the factory fuel tank. These kits feature a high
performance Edelbrock in-tank fuel pump, Edelbrock aluminum fuel rail, Edelbrock Adjustable Fuel Pressure Regulator, Russell Fuel Filter, Russell
Proflex or Proclassic hoses, and Russell AN fittings. The kit is designed to fit 1996-2000 Honda Civic chassis equipped with a Honda DOHC B-Series
engine, and will provide increased fuel flow for high performance applications. Kit #641560 features Proflex hoses and red and blue anodized fittings,
while kit #641563 features Proclassic hose and fittings with a black and clear finish.
KIT CONTENTS:
❑ 1 Fuel Rail. High Flow, Honda B-Series Engines (PN 4796)
❑ 1 Adjustable Fuel Pressure Regulator (PN 1728)
❑ 1 In-Tank Fuel Pump, 255 Liters/Hour (PN 17937)
❑ 1 Inline Fuel Filter, 10 Micron, -10AN In/Out
❑ 1 Inline Fuel Filter Mounting Clamp
❑ 16ft Proflex/Proclassic Braided Stainless Steel Hose (-6AN)
❑ 14ft Proflex/Proclassic Braided Stainless Steel Hose (-4AN)
❑ 3 Straight Hose End (-6AN)
❑ 1 Straight Hose End (-4AN)
❑ 2 90° Swivel Hose End (-6AN)
❑ 1 45° Swivel Hose End (-6AN)
❑ 1 8mm Fuel Tank Outlet to -6AN EFI Adapter Fitting
TOOLS REQUIRED:
❑ Hand Tools, Standard and Metric
❑ Standard and Metric Allen Keys
❑ Phillips Screwdriver
❑ Wire Stripping and Crimping Tool
❑ Pliers
❑ 2 -10AN to -6AN Adapter Fittings (with o-rings)
❑ 2 -8AN to -6AN Adapter Fittings (with o-rings)
❑ 2 -6AN Dry-Sump Fittings (with o-rings)
❑ 1 -6AN Block-Off Plug (with o-ring)
❑ 1 -6AN Female to -4AN Male Coupling
❑ 1 -6AN Female Coupling Nut
❑ 2 #4 Hose Clamp Cover (Chrome/Red Anodized)
❑ 1 #4 Hose Clamp
❑ 10 #4 Cushion Clamp
❑ 10 #6 Cushion Clamp
❑ 12 Tie-Wraps
❑ 1 Russell Assembly Lube/Sealant
❑ 1 Fuel Pressure Gauge
❑ AN Wrenches
❑ AN Fitting Assembly Lubricant
❑ Fuel Pressure Gauge (For Fuel Pressure Adjustment)
❑ Mounting Hardware for Regulator & Filter Bracket
WARNING: EXPOSED FUEL AND OIL WILL BE PRESENT DURING THIS INSTALLATION. WHEN WORKING AROUND
GASOLINE OR OIL, ALWAYS WORK IN A WELL VENTILATED AREA, AND KEEP ALL OPEN FLAMES, SPARKS, AND OTHER
SOURCES OF IGNITION AWAY FROM THE WORK AREA. FAILURE TO DO SO CAN RESULT IN A FIRE
OR EXPLOSION.
MAKE SURE TO DISCONNECT YOUR BATTERY TO AVOID THE POTENTIAL FOR SPARKS IN THE WORK AREA!
NOTE: Certain Honda vehicles have security protected audio systems. If your vehicle is equipped with a factory audio system, be
sure to have the security code written down prior to disconnecting the battery. See Honda Service Manual for additional details.
WARNING: SOME PROCEDURES IN THIS INSTALLATION WILL REQUIRE THE VEHICLE TO BE RAISED ON JACKSTANDS OR A LIFT. WHEN
RAISING A VEHICLE, MAKE SURE THE VEHICLE IS ON LEVEL GROUND AND SUPPORTED SECURELY BY JACKSTANDS.
NEVER WORK UNDER A VEHICLE THAT IS SUPPORTED BY A JACK ONLY!
BEFORE BEGINNING INSTALLATION
©2007 Edelbrock Corporation
Brochure #63-641560Page 2
Catalog #641560, 641563
Rev. 10/07 - AJ/mc
BEFORE BEGINNING INSTALLATION (Continued)
BEFORE BEGINNING: Someone who has a basic knowledge of automobile repair and modification and is familiar with and comfortable with working
on their vehicle can accomplish the mechanical installation of this kit using common tools and procedures. However, this kit is designed to allow you
to custom fit the fuel lines to your application, and will require that you cut hoses to fit and drill holes for Fuel Pressure Regulator mounting. If you do
not feel comfortable with any of the steps listed below, please consult a qualified professional installer. Make sure to read the instructions provided
with the supplied fuel rail and fuel pressure regulator. These will be referenced throughout this instruction sheet.
AFTER INSTALLATION, BEFORE STARTING THE VEHICLE: ALWAYS make sure to check for any leaks BEFORE starting the vehicle. Reconnect the
battery and turn the ignition key to the “on” position. This will activate the fuel pump and pressurize the fuel system. If any leaks are present, turn
the ignition “off”, disconnect the battery, and make the necessary corrections before continuing.
INSTALLATION PROCEDURE
UNDERHOOD DISASSEMBLY AND FUEL RAIL INSTALLATION
1. Make sure the vehicle is on level ground, and the gear selector is in
“Park” or in 1st gear. Set the parking brake or chock the wheels.
2. Disconnect the battery negative terminal
(See note on page 1
regarding Honda/Acura security protected audio systems)
.
3. Thoroughly clean the area surrounding the fuel injectors and the fuel
rail. This will prevent debris from entering the fuel system or the
intake manifold upon fuel rail removal.
4. Relieve any residual fuel pressure in the fuel system. Remove the
fuel filler cap, then relieve fuel pressure by loosening the banjo bolt
connecting the fuel line to the fuel filter. Place a shop towel or rag
over the wrench while loosening the banjo to soak up any fuel spray
(See Fig. 1)
. When loosening or tightening the banjo bolt on the
fuel filter can, use a 19mm wrench on the hex of the fuel filter can
to counteract the torque of loosening or tightening the banjo bolt.
This will prevent the fuel filter can and bracket from being
improperly loaded during loosening or tightening at the banjo bolt.
If your vehicle has a special banjo bolt at the fuel filter, which has a
service bolt in the top of the banjo bolt, use a box end wrench to
loosen the service bolt at the fuel filter while holding the banjo bolt
with another wrench. Keep the banjo or service bolt loose until all
pressure is relieved.
5. Remove the banjo bolt from the fuel filter and disconnect the fuel
supply line from the fuel filter. Using a small, fuel safe container,
allow the excess fuel to drain from the fuel line and fuel rail.
6. Disconnect the factory fuel return line from the steel tubing on the
firewall. Use rags or a small, fuel safe container to catch any spills.
7. Disconnect the wiring harness from the fuel injectors and from the
fuel rail. If your vehicle is equipped with a purge valve, disconnect
the wiring from the purge valve.
8. Remove the vacuum line from the factory fuel pressure regulator.
Refer to the instructions supplied with the 4796 fuel rail, and remove
the fuel rail, factory fuel pressure regulator, supply line, and return
line from the vehicle as one assembly. Use care when separating
the fuel rail from the fuel injectors.
9. Install the supplied -8AN to -6AN Adapter Fittings (with o-rings) into
the fuel rail using a bit of o-ring lube on the o-rings. Install the 1/8
NPT pipe plugs (supplied with fuel rail) if the gauge ports are not
being used (see fuel rail instructions).
10. Inspect the injectors and transfer them to the new fuel rail as
described in the fuel rail instructions.
11. Install the fuel rail / injector assembly on the intake manifold as
shown in the fuel rail instructions.
Vacuum
Fitting
-6 AN Block
Off Plug
Adjusting Screw.
Locknut and Washer
-6 AN Dry-
Sump Fittings
Figure 2 - Fuel Pressure Regulator Fitting Placement
Figure 1
©2007 Edelbrock Corporation
Brochure #63-641560Page 3
Catalog #641560, 641563
Rev. 10/07 - AJ/mc
Figure 3 - Cowl Cover Removed
FUEL PRESSURE REGULATOR MOUNTING:
1. Install the provided fittings into the fuel pressure regulator
(See Fig.
2)
. Install one -6AN Dry Sump Union in the inlet port and one in the
return port (located at the bottom of the regulator). Install the -6AN
block off plug in the fuel outlet port of the regulator. Slip the -6AN
Female coupling nut over the -6AN female to -4AN male coupling.
Install this assembly over the -6AN dry-sump fitting previously
installed in the return port of the regulator. Install the vacuum fitting
supplied with the regulator in the port on the top half of the
regulator. Install the pressure adjusting screw and jam nut at the
top of the regulator. See the instructions provided with the regulator
for more information.
2. Determine a location in the engine compartment to mount the fuel
pressure regulator. Make sure it is in a location that will provide
clearance to route the -4AN return line to the regulator, and that you
will be able to easily connect a length of -6AN hose between the fuel
rail and the regulator. We chose a location on the firewall.
3. To mount the regulator in this location you will need to remove the
cowl cover
(See Fig 3)
.
4. Following the instructions provided with the fuel pressure regulator,
use the provided bracket, and mark the location to drill the mounting
holes.
5. Mount the fuel pressure regulator to the bracket, and the
regulator/bracket assembly to the firewall
(See Fig. 4)
.
NOTE: You may need to bend/modify the supplied bracket in
order to mount the fuel pressure regulator in your desired
location.
6. Install the factory fuel pressure regulator vacuum line onto the fitting
on the fuel pressure regulator. You may need to replace or extend
this line, depending on where you are mounting the regulator.
FUEL TANK PREPARATION AND FUEL PUMP INSTALLATION:
WARNING: PROCEDURES IN THIS SECTION WILL REQUIRE
THE VEHICLE TO BE RAISED ON JACKSTANDS OR A LIFT.
WHEN RAISING A VEHICLE, MAKE SURE THE VEHICLE IS ON
LEVEL GROUND AND SUPPORTED SECURELY BY JACKSTANDS. NEVER WORK UNDER A VEHICLE THAT IS
SUPPORTED BY A JACK ONLY!
1. Fuel Tank Removal:
A. Remove the rear seat cushion to provide access to the top
of the fuel tank and fuel pump access panel.
B. Clean any dirt and debris away from the area and remove
the fuel pump access panel
(See Fig. 5)
.
Figure 4 - Regulator Mounted on Firewall
Figure 5 - Fuel Pump Access Cover Removed
C. Disconnect the electrical connectors from the top of the
fuel level sender and fuel pump assembly
(See Fig. 5)
.
D. Disconnect the fuel supply line from the top of the fuel
pump assembly. Use pliers to remove the hose clamp
from the fuel return hose and remove the return line. Use
rags to absorb any fuel spillage.
E. Raise the vehicle and drain the fuel tank of any remaining
fuel. Loosen the drain plug and drain fuel into clean, fuel
safe containers. Tighten the drain plug when empty.
F. Remove the section of exhaust pipe that runs partially
below the fuel tank
(See Fig. 6)
.
Figure 6 - Exhaust Midpipe Removal
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