Mallory Ignition Mallory HIGH VOLUME FUEL RAILS 4311M - Manual

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INSTALLATION INSTRUCTIONS
®
FORM 1532 (REV. A) 8/01
HIGH VOLUME FUEL RAILS
FOR GM TPI
Part No. 4311M
2) 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.
3) 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 damag-
ing the o-rings.
4) Install the rail assembly (with injectors) onto the lower mani-
fold. 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.
5) Connect the cold start injector (if applicable).
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.
8) Use one of the extra ports on the regulator to connect a pres-
sure gauge (if desired).
9) 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.
10) Turn the pump on and check for leaks.
NOTE: If the system will not prime properly, remove the ad-
justment screw from the regulator until the system is primed.
11) Reinstall the upper manifold, runner, and any other compo-
nents that were removed earlier.
12) Set the fuel pressure. Loosen the jam nut on the regulator
and turn the adjustment screw while the pump is running to
adjust fuel pressure. Clockwise increases pressure. The best
fuel pressure depends on many variables. However, a start-
ing point of about 45 psi (with the vacuum line disconnected)
is usually close.
APPLICATIONS: Small Block Chevy V8 with TPI or Accel Super Ram
Electronic Fuel Injection.
GENERAL INFORMATION
A factory repair manual should be referred to during installation.
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.
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 larger-
than-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.
NOTE: These instructions show installation on an F-body
(Camaro/Firebird). Installation on a Corvette is similar, how-
ever, the routing of the fuel lines and the mounting location of
the regulator may be different.
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
“-8AN port to cold start adapter” in the end of the driver’s side
rail. If a cold start injector is not used, install a -8AN port plug
in the end of the rail.
4) O-rings are supplied for the crossover tubes. Be sure to lubri-
cate o-rings with oil before pressing the tubes into the rails.
5) Connect the hoses to the rails and regulator, but leave the
fittings loose until the rails are installed on the engine. This
makes it easier to route the hoses around obstructions.
6) The extra ports on the regulator can be plugged with supplied
plugs or used for gauge ports or used to supply fuel for a
nitrous system. Be sure to use thread sealer on any tapered
NPT fittings.
INSTALL RAIL ASSEMBLY ON THE ENGINE
See Photo 3 and Photo 4
1) Remove the upper manifold, runners, and stock fuel rails
(consult a repair manual for more information).
PARTS LIST:
1
Driver’s side fuel rail
1 Passenger side fuel rail
1 Hose, -6AN braided 90°
1 Hose, -6AN braided 90°/45°
1 Pressure regulator
1 Regulator bracket
2 Regulator bracket screws
2 Crossover tubes
2 O-rings for crossover tubes
3 Fittings, -8AN port to –6AN male
2 Fittings, -8AN port plug
1 Fitting, -8AN port to –6AN female
1 Fitting, -8AN port to cold start adapter
6 O-rings, for –8AN ports
2 Fittings, brass 3/8NPT plug
1 Fitting, -6AN to 3/8 Saginaw
1 Fitting, -6AN to 5/16 Saginaw
1 Nut, 8mm x 1.25
1 Lockwasher, 8mm