FORM 1532 (REV. A) 8/01 INSTALLATION INSTRUCTIONS ® HIGH VOLUME FUEL RAILS FOR GM TPI Part No. 4311M APPLICATIONS: Small Block Chevy V8 with TPI or Accel Super Ram Electronic Fuel Injection. PARTS LIST: 1 1 1 1 1 1 2 Drivers side fuel rail Passenger side fuel rail Hose, -6AN braided 90° Hose, -6AN braided 90°/45° Pressure regulator Regulator bracket Regulator bracket screws 2 2 3 2 1 1 6 Crossover tubes O-rings for crossover tubes Fittings, -8AN port to 6AN male Fittings, -8AN port plug Fitting, -8AN port to 6AN female Fitting, -8AN port to cold start adapter O-rings, for 8AN ports 2 1 1 1 1 Fittings, brass 3/8NPT plug Fitting, -6AN to 3/8 Saginaw Fitting, -6AN to 5/16 Saginaw Nut, 8mm x 1.25 Lockwasher, 8mm GENERAL INFORMATION A factory repair manual should be referred to during installation. 2) Mallory fuel rails can be used on stock engines. However, the adjustable, high flow, remote mount regulator makes this kit ideal for high performance engines using high flow fuel pumps. 3) Adapter fittings and 6AN lines are supplied which allow Mallory fuel rails to be connected to the stock fuel line and return line. However, applications over 500 horsepower should use largerthan-stock lines. Mallory fuel rails and regulator accept 8AN for those applications over 500 hp. Recommended line and pump sizes are listed after the installation portion of this form. 4) NOTE: These instructions show installation on an F-body (Camaro/Firebird). Installation on a Corvette is similar, however, the routing of the fuel lines and the mounting location of the regulator may be different. 5) Remove the injectors from the stock fuel rails by removing the small metal clips near the top of each injector. Save these clips they must be re-used. 6) Using the nut and washer supplied, mount the regulator to the stud on the shock tower (see photo). 7) Connect the factory fuel line to the Mallory hose with the -6AN to 3/8 Saginaw fitting. Connect the factory return line to the return port on the bottom of the regulator. Use one of the extra ports on the regulator to connect a pressure gauge (if desired). ASSEMBLE THE FUEL RAILS AND REGULATOR See Photos 1 and 2 1) Make sure to install the supplied o-rings on all -8AN port fittings before installing the fittings into the rails and regulator. 2) The supplied -8AN port plugs may be hex or button head. 3) Engines equipped with a cold start injector will use the 8) -8AN port to cold start adapter in the end of the drivers side rail. If a cold start injector is not used, install a -8AN port plug 9) in the end of the rail. 4) O-rings are supplied for the crossover tubes. Be sure to lubricate o-rings with oil before pressing the tubes into the rails. Re-install the metal clips onto the injectors. Lubricate injector o-rings with oil. Press the injectors into the Mallory rails. NOTE: The clips must be on the injectors to prevent the injectors from extending too deep into the rails and damaging the o-rings. Install the rail assembly (with injectors) onto the lower manifold. Oil on the lower o-rings will help the injectors press into the mainfold easier. The stock bolts can be re-used to hold the rails to the lower manifold. Connect the cold start injector (if applicable). Find the vacuum hose that was originally connected to the stock fuel pressure regulator. Connect this hose to the small barb on the Mallory regulator. Because the regulator is mounted remotely, an additional length of vacuum hose will be needed. Connect the hoses to the rails and regulator, but leave the 10) Turn the pump on and check for leaks. fittings loose until the rails are installed on the engine. This NOTE: If the system will not prime properly, remove the admakes it easier to route the hoses around obstructions. justment screw from the regulator until the system is primed. 6) The extra ports on the regulator can be plugged with supplied 11) Reinstall the upper manifold, runner, and any other compoplugs or used for gauge ports or used to supply fuel for a nents that were removed earlier. nitrous system. Be sure to use thread sealer on any tapered NPT fittings. 12) Set the fuel pressure. Loosen the jam nut on the regulator and turn the adjustment screw while the pump is running to INSTALL RAIL ASSEMBLY ON THE ENGINE adjust fuel pressure. Clockwise increases pressure. The best See Photo 3 and Photo 4 fuel pressure depends on many variables. However, a starting point of about 45 psi (with the vacuum line disconnected) 1) Remove the upper manifold, runners, and stock fuel rails is usually close. (consult a repair manual for more information). 5) www.mrgasket.com 1 FIGURE 1 RIGHT RAIL (PASSENGER SIDE) REGULATOR LEFT RAIL BRACKET (DRIVER'S SIDE) REGULATOR FITTING (3/8NPT PLUG) CROSSOVER TUBES ADJUSTMENT FITTING BARB (8AN PORT TO SCREW 6AN FEMALE) HOSE L STAMP R STAMP (6AN 90°) FITTING R L INJECTORS FITTING (6AN TO 3/8 (NOT INCLUDED) SAGINAW) (8AN PORT TO 6AN MALE) FITTING (6AN TO 5/16 SAGINAW) FITTING (8AN PORT TO 6AN MALE) HOSE (6AN 90°/45°) FIGURE 2 DRIVER'S SIDE RAIL PASSENGER SIDE RAIL CROSSOVER TUBE FITTING COLD START INJECTOR AND (8AN PORT PLUG) BUTTON HEAD STYLE SHOWN HARD LINE (NOT INCLUDED) INJECTOR (NOT INCLUDED FITTING (8AN PORT TO COLD START ADAPTER) NOTE: USE 8AN PORT PLUG IF COLD START INJECTOR IS NOT USED 2 www.mrgasket.com FIGURE 3 METAL INJECTOR CLIPS MUST BE IN PLACE BEFORE INSERTING INJECTORS INTO MALLORY RAILS. GAUGE LINE (IF DESIRED) FIGURE 4 SHOCK TOWER VACUUM HOSE RETURN LINE FUEL LINE www.mrgasket.com 3 FUEL LINE SIZE Fuel line size is determined by the horsepower of the engine. Up to 350 HP 5/16" or 4AN Up to 500 HP 3/8" or 6AN Up to 700 HP 1/2" or 8AN Up to 1200 HP 5/8" or 10AN RETURN LINE SIZE Return line size is determined by the output of the fuel pump. Up to *29 gal/hr (110 liters/hr) 1/4" or 3AN Up to *45 gal/hr (170 liters/hr) 5/16" or 4AN Up to *90 gal/hr (340 liters/hr) 3/8" or 6AN Up to *180 gal/hr (680 liters/hr) 1/2" or 8AN *Pump output @ 45psi PUMP SIZE Pump size is determined by the horsepower of the engine. Horsepower x .083 = gallons per hour @ 45 psi Example: 500hp x .083 = 42 gal/hr or Horsepower x .314 = liters per hour @ 45 psi Example: 500hp x .314 = 157 liters/hr NOTE: add 25% to pump size for supercharged applications. MALLORY IS A DIVISION OF THE MR. GASKET PERFORMANCE GROUP 550 MALLORY WAY, CARSON CITY, NEVADA 89701 (775) 882-6600 FAX (775) 887-4326 4 www.mrgasket.com FORM 1532 (REV. A) 8/01 Made in U.S.A. Printed in U.S.A.