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PRO-FLO XT 3527
User Manual
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Edelbrock PRO-FLO XT 3527, PRO-FLO XT 3528 User Manual

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Pro-Flo EFI Installation Instructions
©2008 Edelbrock Corporation
Brochure No. 63-3527
Catalog #3527, #3528 Rev. 8/08 - AJ/mc
TABLE OF CONTENTS
Part #3527 and #3528
INTRODUCTION
Thank you for selecting the Edelbrock Pro-Flo XT Fuel Injection System. This Multi-Point Fuel Injection System has been designed for 350 c.i.d. small-block Chevrolet engines, and is designed to provide excellent performance, fuel economy, and maintenance-free operation. Installation of the Edelbrock Pro-Flo XT Fuel Injection System involves modifications to the fuel system, ignition system, induction system, and possibly the valve train. Although there are steps that must take place before others, the modifications do not necessarily have to be performed in a particular order. Each modification is described in a separate section in this manual. Please study these instructions carefully before beginning installation of any part of the Pro-Flo XT system.
If you have any questions, do not hesitate to call our
EFI Technical Hotline at (800) 416-8628, 7am-5pm PST, Monday-Friday
E-mail: EFItech@edelbrock.com
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Pro-Flo EFI Installation Instructions
©2008 Edelbrock Corporation
Brochure No. 63-3527
Catalog #3527, #3528 Rev. 8/08 - AJ/mc
PRIMARY KIT COMPONENTS
❑ Electronic Control Unit/System ECU ❑ Fuel filter ❑ Calibration Module ❑ Fuel rail assembly ❑ Distributor conversion kit ❑ Fuel pressure regulator ❑ Fuel injectors ❑ High pressure fuel pump ❑ ECU power relay/Fuel pump relay ❑ Intake manifold ❑ Manifold Absolute Pressure (MAP) Sensor ❑ Four barrel air valve ❑ Manifold Air Temperature (MAT) Sensor ❑ Idle Air Control (IAC) solenoid, integrated with air valve ❑ Coolant Temperature Sensor (CTS) ❑ Main system harness ❑ Throttle Position Sensor (TPS), integrated with air valve ❑ Fuel pump harness ❑ Oxygen (O
2
) sensor ❑ Installation package
❑ USB/Serial Converter ❑ Ignition Harness ❑ Software CD ❑ MSD Blaster Coil ❑ Mallory Distributor
Many Pro-Flo XT components, including the Manifold Absolute Pressure sensor, fuel pressure regulator, Coolant Temperature sensor, and the fuel filter are standard OEM pieces. In the event that one of these parts needs to be replaced, you are likely to find a replacement at your local parts supplier, in addition to your local Edelbrock dealer or directly from Edelbrock. For a list of part numbers, refer to the PART NUMBERS section at the back of this manual.
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Pro-Flo EFI Installation Instructions
©2008 Edelbrock Corporation
Brochure No. 63-3527
Catalog #3527, #3528 Rev. 8/08 - AJ/mc
TOOLS AND EQUIPMENT
Use the following checklist for items needed.
❑ Box and open end wrenches
❑ Socket set
❑ Distributor wrench
❑ Pliers (channel locks and hose clamp)
❑ Screwdrivers (regular and Phillips)
❑ Torque wrench
❑ Hammer
❑ Gasket scraper or putty knife
❑ Timing light
❑ Vacuum gauge
❑ Rags
❑ Water bucket
❑ Drill and bits
❑ Hole saw (1 1/4-inch or 1 3/4-inch)
❑ Tubing wrenches
❑ Tubing cutter
PRELIMINAR
Y CHECKLIST
1. CAREFULLY STUDY AND UNDERSTAND ALL INSTRUCTIONS, BEFORE BEGINNING THIS INSTALLATION.
NOTE: This installation can be accomplished using common tools and procedures. However, you should have a basic
knowledge of automotive repair and modification and be familiar with and comfortable working on your vehicle. If you do
not feel comfortable working on your vehicle, it is recommended to have the installation completed by a professional
mechanic.
2. Examine the Pro-Flo XT system for possible shipping damage. If damaged, contact your dealer immediately.
3. The 3527 & 3528 kits are designed for use with a standard Small Block Chevy V8 firing order.
4. Check all threaded manifold holes.
5. Check all internal manifold passages with a light and wire, making sure they are clean and unobstructed.
6. Check automatic transmission shift points before removal of your stock manifold and adjust linkage after Edelbrock
manifold installation for same shift points (if needed).
NOTE::We recommend that you refer to this checklist again after installation to be sure that you have completed all steps.
HARDWARE AND PARTS RECOMMENDED
Use the following checklist for items needed.
❑ Intake gasket; #3527 kits use Edelbrock gaskets #7201; #3528
kits use gaskets #7235
❑ Pipe plugs, if needed
❑ 5/16-inch steel tubing (approximate equal length to fuel pickup
line in tank)
❑ Edelbrock Gasgacinch #9300
❑ Loctite 598 OEM High Temperature Silicone Gasket (O
2
Sensor
Compatible)
❑ Radiator coolant
❑ Wiring diagram for your vehicle
❑ Teflon tape or liquid Teflon thread sealer
❑ Manifold bolt kit; #3527use #8504; #3528 uses #8516
❑ 195° Thermostat
❑ Resistor type spark plugs (Use correct heat range for your
particular application
❑ Set of low-resistance spark plug wires with high EMI suppression
(DO NOT use solid core spark plug wires)
❑ Dynojet wideband commander (Optional, not included)
❑ DB9 Serial cable (Optional, not included)
❑ Late model low profile water neck such as Trans-Dapt #9229 or
GM #12342034 (chrome)
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Pro-Flo EFI Installation Instructions
©2008 Edelbrock Corporation
Brochure No. 63-3527
Catalog #3527, #3528 Rev. 8/08 - AJ/mc
MANIFOLD & CARBURETOR HEIGHT VS. PRO-FLO XT HEIGHT
1. Lay a straightedge (such as a yardstick) across the top of the air cleaner from front to back.
2. Measure from block and manifold end seal surfaces to straightedge.
3. Record these measurements (height A and height B).
4. Add height A and height B and divide by two to get the average height.
5. The Pro-Flo XT manifold is 9” tall at the center and 9.125” at the throttle body flange.
6. Compare this to your original measurements. If the Pro-Flo XT unit is taller, subtract this amount from the hood clearance figure to determine new hood clearance.
CAUTION: You must maintain at least 1/2-inch clearance between the hood and manifold because of engine torque. If you have insufficient clearance, a hood scoop may solve the problem.
EMISSION CONTROLS
The Edelbrock Pro-Flo XT system will not accept stock emissions control systems. Check local laws for requirements before installing the Pro-Flo system. Not legal on pollution-controlled motor vehicles.
DETERMINING HOOD CLEARANCE
NOTE: Check hood clearance before removing stock manifold.
1. Use modeling clay or putty to make five small cones, two or three inches high.
2. Position cones on air cleaner at front, rear, each side, and on center stud.
3. Close hood to locked position and re-open.
4. The height of the cones indicate the amount of clearance between the hood and the air cleaner. Record these measurements.
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Pro-Flo EFI Installation Instructions
©2008 Edelbrock Corporation
Brochure No. 63-3527
Catalog #3527, #3528 Rev. 8/08 - AJ/mc
FUEL REQUIREMENTS
Because the Pro-Flo XT system uses an Oxygen sensor, you must use unleaded fuel only. Leaded fuels will damage the O2sensor. If you do use leaded fuel in your vehicle, do not install the O2sensor and do not operate the vehicle in the closed loop fuel mode.
AUTOMATIC TRANSMISSION CHECK
For best performance, economy, and emissions, the shift point must be checked before and after the manifold change.
NOTE: This check should be performed ONLY at a sanctioned 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 MPH when the transmission makes the first 1-2 shift. After the Pro-Flo XT system has been installed, make the same test, again noting MPH of this first shift.
The transmissions in certain vehicles require precise adjustments. We recommend that you consult a reputable transmission shop for final adjustments once the Pro-Flo system has been installed. Incorrect shift points can result in transmission damage.
ENGINE CLEANING
Edelbrock recommends that the Pro-Flo XT system be installed on a clean engine in order to prevent dirt from falling into the engine lifter valley or intake ports.
1. Cover ignition. Use engine degreaser and a brush to thoroughly clean the manifold and the area between the manifold and valve covers.
2. Rinse with water and blow dry.
EXHAUST MANIFOLD HEAT RISER VALVE
If your vehicle is equipped with an exhaust manifold heat riser valve (typically located on the passenger side of the vehicle below the exhaust manifold), remove the valve for proper operation. If applicable, any air injection tubes must be removed and holes in the exhaust manifold plugged for proper operation.
HEADERS
For best performance, headers are recommended. For this application, header primary tube diameter should be 1-3/4 inch, approximately 31 inches long and terminating into a 3 inch collector. The remainder of the exhaust system should consist of dual exhaust and tail pipes, at least 2­1/4 inches in diameter with low back pressure mufflers.
COOLING SYSTEM
The minimum requirements for the thermostat are 180° but the ideal thermostat is 195°. When the vehicle is at 175 or below, system will stay in cold start mode and not perform properly.
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Pro-Flo EFI Installation Instructions
©2008 Edelbrock Corporation
Brochure No. 63-3527
Catalog #3527, #3528 Rev. 8/08 - AJ/mc
FUEL SYSTEM
Because your Edelbrock Pro-Flo XT system controls fuel delivery very differently than a carburetor, some conversions to your fuel system are necessary. Pro-Flo XT electronic fuel injection requires high and constant fuel volume and fuel pressure. For this reason, a good primary fuel line is critical. The Pro-Flo XT system includes a 3/8-inch high pressure fuel line which 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. If desired, a 15 foot length of 3/8” ID Pro Classic hose is supplied for use as the return 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.
Tank Side
Engine Side
FUEL PUMP AND FILTER
The Pro-Flo XT system uses a single Edelbrock high-pressure electric fuel pump which is capable of pumping 50 psi. The pump relay will 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 line. The provided fuel filter should be mounted between the engine compartment and the fuel pump to allow fuel to be pushed through the filter rather than drawn through. Electrical connectors should face the front of vehicle. Make sure the fuel pump is mounted at or below the bottom of your fuel tank. If the pump is mounted above this point, fuel pump failure will occur.
FUEL PRESSURE REGULATOR AND FUEL SUPPLY LINE
Fuel pressure is as important as fuel volume, particularly in fuel injection. The Pro-Flo XT fuel pressure regulator maintains a constant pressure at the injectors with a spring loaded by-pass to the return fuel line. 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.
RETURN FUEL LINE
Due to the high fuel pressure used by the Pro-Flo system, the supplied 3/8-inch Pro Classic high pressure fuel line MUST be used as the primary fuel line, and a bypass fuel return line must be installed. There are three options for installing a bypass return line.
1. Use the 3/8” Pro Classic rubber fuel line provided with the system as the fuel return line.
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.
Return Side
Supply Side
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.
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Pro-Flo EFI Installation Instructions
©2008 Edelbrock Corporation
Brochure No. 63-3527
Catalog #3527, #3528 Rev. 8/08 - AJ/mc
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 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. Solder or weld the return hard line to the fuel pickup line.
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Pro-Flo EFI Installation Instructions
©2008 Edelbrock Corporation
Brochure No. 63-3527
Catalog #3527, #3528 Rev. 8/08 - AJ/mc
BULKHEAD FITTING METHOD
HARD RETURN LINE METHOD
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Pro-Flo EFI Installation Instructions
©2008 Edelbrock Corporation
Brochure No. 63-3527
Catalog #3527, #3528 Rev. 8/08 - AJ/mc
NOTE: ALL WELDING AND SOLDERING OF THE FUEL SYSTEM MUST BE PERFORMED BY A PROFESSIONAL RADIATOR AND/OR FUEL SYSTEM REPAIR SHOP.
FUEL SYSTEM INSTALLATION
1. Drain the fuel tank.
2. Remove all fuel lines from the tank and from the carburetor.
3. Remove the fuel tank.
NOTE: While the fuel tank is removed from the car, it is recommended that it be professionally cleaned in order to remove any rust or dirt that may have accumulated inside and which could damage the injectors.
4. Remove the sending unit from the fuel tank. Refer to the RETURN FUEL LINE methods above for installing the bypass fuel return line.
5. Install the provided 3/8-inch primary fuel line directly above the original line, which may now serve as a return line. Use large radius bends. Avoid the exhaust pipe and any sharp edges.
NOTE: The 3/8” Pro Classic high pressure fuel line supplied with the Pro-Flo system must be used as the primary fuel line. See the following section for assembly instructions.
6. If you do not use the original fuel as the return line, route the return line directly alongside the provided 3/8-inch primary fuel line.
7. 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 bottom of the fuel tank.
8. Mount the fuel filter between the fuel pump and the engine.
9. Re-install the modified sending unit plate to the clean fuel tank.
10. Reinstall the fuel tank.
11. Attach the primary line and return line to the sending unit plate on the tank.
12. Re-attach all other fuel lines at the tank (vapor purge lines, etc., if so equipped).
13. Secure the primary and return fuel lines with the provided tie-wraps, or with Adel clamps if available.
14. Re-attach all fuel lines to the induction system once it has been installed.
15. Use the 10-foot wiring harness to connect the fuel pump to the Main System Harness. Route the harness away from the exhaust pipe and any sharp edges. This harness may be cut to length. Replacement terminals are provided with the Pro-Flo XT system. Cover the connection to the positive terminal with the sleeve and tie wrap provided. Refer to the MAIN SYSTEM HARNESS section of this manual for details.
16. Before starting the engine, turn the ignition key to the ON position 4 or 5 times to prime the electric fuel pump, fuel lines, and fuel rails. You should hear the pump run for approximately 2 seconds each time. Check the entire fuel system for leaks. Refer to the SYSTEM START-UP section of this manual for details.
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Pro-Flo EFI Installation Instructions
©2008 Edelbrock Corporation
Brochure No. 63-3527
Catalog #3527, #3528 Rev. 8/08 - AJ/mc
INDUCTION SYSTEM
The Edelbrock Pro-Flo XT system delivers fuel and air to the engine via the induction system consisting primarily of a manifold, 90mm air valve, fuel rails, and fuel injectors. The induction system is fully assembled, tested, seal checked, and flowed at the factory and is as easy to install as a manifold. DO NOT DISASSEMBLE any of these components during installation.
INTAKE MANIFOLD
The new Edelbrock Pro-Flo XT manifold has been designed specifically
for electronic fuel injection applications.
90mm THROTTLE BODY
The Pro-Flo XT system uses a throttle body with 90mm air valve. The
air valve can flow up to 1000 cfm at 1.5" of mercury when wide open.
FUEL INJECTORS
The Pro-Flo XT #3527 & #3528
systems use high impedance pintle-
type fuel injectors. The injectors are capable of flowing 29 lbs./hr. at 50 psi. The injectors mount directly onto the manifold, one at each port,
for fuel delivery that is precisely
controlled and instantaneously
injected.
FUEL RAILS
The extruded aluminum rail assembly routes the high pressure fuel to the injectors. Aluminum rails have an advantage over soft rails both in
terms of style and safety.
ASSEMBLING PRO-CLASSIC HOSE
Step One: Cut hose to length,
as straight and square as possible, with razor blade-type hose cutter or shears.
Step Two: Unscrew socket from hose end. Push hose into socket, turning counter­clockwise, until hose is seated against step in socket. Make sure rubber part of hose does not protrude into socket threads.
Step Three: Apply Russell assembly lube to threads on nipple assembly and in socket. Insert nipple into socket/hose and start threads by hand (clockwise).
Step Four: Hold socket/hose in vise. Turn nipple with wrench until there is less than 1/16" between nipple hex and socket. Repeat Steps 1-3 for other end of hose. Then, flush hose assembly with solvent or soapy water and blow clean with compressed air or let air dry.
11
Pro-Flo EFI Installation Instructions
©2008 Edelbrock Corporation
Brochure No. 63-3527
Catalog #3527, #3528 Rev. 8/08 - AJ/mc
PRE-INSTALLATION
Before installing the induction system, take the following steps to ensure successful installation and performance
1. Check all components thoroughly for damage.
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
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. When clean, remove paper, making sure that all particles fall on the rags in the lifter valley. 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 high quality pipe thread sealant on all threads. Install fittings from your stock manifold.
NOTE: Vortec blocks (1996 & later) do not have an internal coolant bypass to the water pump. The Vortec Pro-Flo XT kit includes a fitting, hose, and threaded orifice at the front of the manifold to connect an external bypass to the water pump. Standard blocks (1995 & earlier) using Vortec cylinder heads should plug this port. Do not use this port for a coolant temperature sensor since the reduced orifice size may prevent an accurate reading.
12
Pro-Flo EFI Installation Instructions
©2008 Edelbrock Corporation
Brochure No. 63-3527
Catalog #3527, #3528 Rev. 8/08 - AJ/mc
GASKET SURFACE PREPARATION
CAUTION: Replace all gaskets as recommended. Do not use race-type non-embossed gaskets for street applications. Due to material
deterioration under street driving conditions, internal vacuum and oil leaks may occur. We recommend Edelbrock gasket #7201 for kit #3527 and #7235 for kit #3528. Do not use Fel-Pro Permatorque 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 recommended silicon sealer. Others may damage the O2 sensor. This method eliminates end seal slippage and deterioration. For ease of installation, we recommend using Edelbrock Manifold Bolt and Washer Kit #8564.)
.
6. Apply Edelbrock Gasgacinch #9300 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 25 ft/lbs. Torque in the sequence illustrated.
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.
Note: Do not install with a throttle rod, use a cable actuated throttle. See Throttle Cable Installation section for further details.
6. Re-tighten the valve cover bolts.
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Kit #3527
Kit #3528
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