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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
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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
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Select the ignition type in the Systems screen under IGNITION TYPE
SELECTION.
FUEL PUMP MOUNTING.
The most important component of the high-pressure fuel system is the fuel pump.
The location and mounting of the pump is critical. The pump must be located at
the rear of the vehicle near the tank at a point below the fuel level in a protected
area. It can be mounted using a special fabricated bracket or with an ACCEL fuel
pump mounting bracket that is supplied.
The fuel pump requires a 12-volt source. If your vehicle already has an electronic
high pressure fuel pump, you still MUST connect the +12 VDC side of the fuel
pump to the
ACCEL main harness (red/black wire). The +12 VDC comes from the fuel pump
relay via the red/black wire in the main harness. The pump draws up to 30 amps
of current depending on size and fuel system pressure; the ground can be
connected to any clean, paint-free point on the chassis. Route and secure the
wiring from the pump into the engine compartment so that it does not hang below
the vehicle, interfere with rotating parts or become exposed to excess heat.
There seems to be a misunderstanding that a fuel pump “produces pressure”.
This is wrong. What actually happens is the pump produces fuel flow at a given
system pressure which is maintained by the pressure regulator. The pressure
regulator is a dynamic modulating devise, which regulates the fuel rail pressure
by either restricting or bypassing fuel back to the fuel tank.
MECHANICAL PUMP REMOVAL
Bypass or remove the mechanical engine driven fuel pump.
Cap the fittings or block off the opening to prevent leakage.
Mr. Gasket block off plate part number 1516 can be used to on a Chevy SB/BB
to do this.
HIGH PRESSURE FUEL FILTER MOUNTING
The high-pressure fuel filter (5 to 20 Microns) should be located between the
outlet of the high-pressure fuel pump and fuel rail. It is recommended to place a
fuel filter/strainer (100 Microns) between the fuel tank outlet and pump inlet.
Connect the filter to the fuel line using the ACCEL fittings supplied with the
system.
HIGH PRESSURE FUEL LINE INSTALLATION
The system comes with a high-pressure pump and fuel filter. These must be
used in conjunction with either 3/8” S.S. braided line or hard tubing to route the
fuel line from the tank outlet to the fuel rail inlet.
At this point, the high-pressure circuit of the fuel system can be plumbed. If the
existing fuel supply line cannot sustain 150-PSI pressure, then it must be
replaced with high-pressure fuel line/tubing. Remember that a carbureted system
operates at 6 PSI. Never take any chances. If in doubt, replace the hose. Use
only 3/8” diameter double braided stainless steel high-pressure gasoline hose
such as Mr Gasket Shadow Series or equivalent. Use this exclusively to connect
the fuel pump and filter to the balance of the fuel system along the entire length
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of the vehicle. ACCEL recommends supporting the fuel line/tubing every three (3) feet.
DUAL FUEL TANKS
It is important to note that for vehicles with either two tanks and/or class A RV s,
it is highly recommended that a boost pump be installed in each tank and fed
through a multi port switching valve when operating in hot climates. Boost pumps
used on such vehicles as a Ford 1985 F-250, 5.0L EFI, will work well for this type
of application. Also, the switching valve from a Ford 6.9L Diesel, 1984 or
Chevrolet 1986 C-10, 305 will work well in dual tank applications. Dual tank
equipped must be plumbed to return excess fuel to the tank, which is in use
supplying fuel to the EFI System to avoid tank overflow problems. The remotely
activated dual three way valves described above will work well in these
applications.
RETURN FUEL LINE INSTALLATION
If your car was originally equipped with a carburetor, a 1/4” diameter fuel line was
used to return the bypassed fuel back to the tank. This line is insufficient to return
the bypass fuel of the PRO RAM Injection System. Therefore ACCEL
recommends using a 5/16” diameter return line from the pressure regulator outlet
to the fuel tank. Be sure to route the return line in protected areas with restriction
free bends. For the tank connection, ACCEL recommends a 5/16” compression
fitting to 6AN `hose fitting.
SENDING UNIT MODIFICATION
To install a return line in your tank, remove the sending unit assembly from the
fuel tank. Have a gas tank repair shop install the return line through the lid on the
sending unit.
MOUNTING THE OXYGEN SENSOR
The PRO RAM Kit includes an oxygen sensor and a M18 x 1.5 hex nuts. This nut
should be welded to the passenger side header collector or exhaust pipe as
close to the connecting flange without interfering with the mounting of the
exhaust manifold or header. Prior to mounting the nut, drill an 11/16” diameter
hole in the exhaust pipe, the hole must be drilled perpendicular to the exhaust
pipe.
Now you are ready for pre-startup.
Refer to GEN 7 or THRUSTER Pre
Start & Tuning guide on CD-R disc.
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