Mallory Ignition 77141, 77142, 77143, 77144 User Manual

ACCEL DFI PRO RAM CHEVY

Installation Instructions.

INSTALLATION EQUIPMENT LIST

The Following is a partial list of the tools you may need for the installation of your
new system.

• Socket set, 3/8” Drive

• Open end wrenches

•Silicone Sealant

• Screw driver set

• Needle nose pliers • Gasket Scraper

• 1- 5/8” Green Lee Punch • hole saw

• Drain bucket

• Timing Light

• Torque Wrench

• Volt/Ohmmeter (example: Snap on MT406, Matco ET 856)

ADDITIONAL PARTS REQUIRED

Intake Manifold Gasket Set
S/B (Mr Gasket # 5820 STK – 5821 Standard Port– 5822 Med/Race Port).
B/B (Mr Gasket # 5827 Oval Port #5828 Rect Port.
Thermostat Housing Gasket # 738
3/8” Stainless Steel Braided Feed Fuel Line & Fittings
160 Degree Fahrenheit Thermostat # 4363 or 180 Deg # 4364

MANIFOLD INSTALLATION INSTRUCTIONS.

Warning: Read and follow instructions before, during and after installation
to preserve warranty. Also disconnect battery leads and drain engine
coolant prior to manifold installation.

In the vast majority of cases, the manifold may be installed without modifications,
if further port matching is required, material removal should be blended up at
least two inches into the runner.
Since the casting lines between the runners and the plenum floor are located
entirely outside of the runner entries, an ideal runner approach radius is insured
as cast.

Note: It may be necessary to purchase some of the parts listed (or the
equivalent) in order to properly complete the manifold installation. Also,
before moving the distributor, set the rotor to the number one cylinder.
Note: To reduce chances of engine contamination by dirt or other foreign
material, it is advisable to clean the engine exterior before starting the
manifolds change.

After removing the distributor and existing intake manifold, clean the gasket
surfaces prior to installing the Small Block Pro Ram system. It is recommended
at this point to use the Green Lee Punches or a hole saw to put a 1 5/8” hole in
the fire wall to accommodate the Main Wire Harness. (Remember to cover
engine completely when drilling through the firewall) Once the gasket surface has

been cleaned, apply a fine bead of silicone on the bottom sides of the
replacement intake gaskets and place on the heads.
Next, place a 1/4” bead of silicone on both ends of the engine block. With all the
intake gaskets in place, carefully place the assembled Small Block Single Plane
Multi Point System onto the engine. Be sure that the gaskets are still aligned with
the bolt holes and start to thread the intake bolts into the engine heads. Torque
the intake bolts first to 20 LB/ft. then to 30 LB/ft. Next install the distributor
making sure that the rotor is aligned properly with the No.1 cylinder cap tower
location.
The next step is to route the vacuum lines. The following items need to be
referenced to manifold vacuum:

1) Map sensor 2) Pressure regulator 3) Power brake booster 4) PCV 5)
Transmission kick-down Note: Never splice the Map Sensor or Pressure

Regulator vacuum lines.

MOUNTING THE ECM

The ECM comes with four mounting holes designed for a #8 screw. The ECM
should be mounted behind the passengers kick panel on the floor. If your kick
panel has an air vent incorporated into it, DO NOT mount the ECM here. This
enclosure is not waterproof and therefore needs a mounting place free of
moisture. The alternate location is in the dash board area behind the glove box;
you can also mount the ECM in the engine compartment although it is not
recommended since it is only moisture resistant and not water proof. .

MAIN WIRE HARNESS
ROUTING AND CONNECTIONS

BEFORE PROCEEDING DISCONNECT BOTH BATTERY TERMINALS FROM
THE BATTERY.

The System contains two (2) Wire Harnesses. A Main Wire Harness (this will be
referenced as the MWH in the following instructions) and an Injector Wire
Harness.
The harness can be routed and connected as follows: Begin by connecting the
MWH’s connectors to the ECM. Then route MWH leg through the firewall hole.
Continue pulling the harness leg through the firewall until the rubber grommet
seat the firewall.

Make sure to connect the +12 V switch (PINK) to the switched IGN accessory in the fuse
box. The switched ignition accessory must maintain 12 volts during cranking.
Connect + 12 V (3/8” ring terminal), and battery ground (3/8” ring terminal) connectors
directly to battery. (Do not connect to back of alternator) Then connect all sensors and
IAC (connectors are labeled).
Finally connecting the fuel pump; (Refer to fuel pump mounting) if you need to
lengthen the red/black 12 volt+ wire to the fuel pump, be sure to use at least a 14-gauge
wire.

DISTRIBUTOR SELECTION AND SETUP.

ACCEL DUAL SYNC
GM HEI