INSTALLATION TUNING AND TROUBLESHOOTING MANUAL

1 Part Number s 504-13 Pro-Jection 4D, 650 CFM 504-12 Pro-Jection 4D, 700 CFM Part Number s 504-23 Pro-Jection 4Di, 650 CFM 504-22 Pro-Jection 4Di, 700 CFM 504-21 Pro-Jection 4Di, 900 CFM INSTALLATION TUNING AND TROUBLESHOOTING MANUAL NOTE: These instructions must be read and fully understood before beginning INSTALLATION . If this MANUAL is not fully understood, INSTALLATION should not be attempted. Failure to follow these instructions, including the pictures may result in subsequent system failure.

2 TABLE OF CONTENTS: 2 INTRODUCTION .. 4 CHOOSING THE RIGHT SYSTEM .. 4 WARNINGS, NOTES, AND NOTICES .. 5 PARTS IDENTIFICATION .. 5 ADDITIONAL PARTS REQUIRED FOR INSTALLATION .. 9 TOOLS REQUIRED FOR INSTALLATION .. 9 REMOVAL OF EXISTING FUEL SYSTEM .. 9 PRO-JECTION SYSTEM INSTALLATION .. 10 Throttle Body .. 10 Throttle Connections .. 10 Vacuum Line Connections .. 11 Fuel Pump INSTALLATION .. 11 Dual Tank INSTALLATION .

3 12 Fuel Pump Filter .. 14 Throttle Body Fuel Filter .. 14 Return Line INSTALLATION .. 14 Inlet Fuel Line INSTALLATION .. 15 Oxygen Sensor INSTALLATION .. 15 Oxygen Sensor Function, Theory, and Use .. 15 Oxygen Sensor Mounting Procedure .. 15 Electronic Control Unit (ECU) Mounting .. 16 Engine Wiring Harness .. 16 Coolant Temperature Sensor .. 16 Manifold Absolute Pressure (MAP) Sensor .. 17 ELECTRICAL CONNECTIONS .. 17 Air Charge Temperature Sensor .. 18 Coolant Temperature Sensor.

4 18 Throttle Position Sensor (TPS) .. 18 Idle Air Control (IAC) Motor .. 18 Injectors .. 18 Manifold Absolute Pressure (MAP) Sensor .. 18 Oxygen Sensor .. 18 Fuel Pump .. 18 Ignition/Spark Control .. 19 Fuel Pump and System Power Relays .. 19 System Power .. 19 Tachometer/Ignition .. 19 Oil Pressure Switch .. 20 MECHANICAL CHECKOUT BEFORE STARTING ENGINE .. 20 PRO-JECTION SYSTEM TUNING THEORY AND PHILOSOPHY .. 21 TUNING Goals.

5 21 Oxygen Sensor Effect on Performance .. 21 Engine Configuration Related Concerns .. 21 GETTING STARTED TUNING AND PROGRAMMING (D SYSTEM) .. 23 TUNING Tips .. 23 Calibration Module Controls .. 23 TUNING and Adjustment Procedures for a D System .. 23 TABLE OF CONTENTS: (cont.) GETTING STARTED TUNING AND PROGRAMMING (Di SYSTEM) .. 26 3 Software INSTALLATION and Software Operational Description .. 26 Windows 95 .. 26 Windows .. 26 Dos Install .. 27 Mapview .. 27 Data Monitor.

6 27 EEprom Programming .. 28 File .. 28 Edit .. 29 Graph .. 31 Print .. 31 Communications .. 32 TUNING Tips for a Di System .. 32 TUNING Tips for a Di System With an Oxygen Sensor (closed loop) .. 32 Other General TUNING Tips for a Di System (closed and open loop) .. 32 TUNING and Adjustment Procedures With a Di System .. 33 OPERATION OF THE PRO-JECTION SYSTEM .. 36 Normal Starting Procedure .. 36 Normal Operation and Use .. 36 MAINTENANCE AND STORAGE .. 36 GENERAL TROUBLESHOOTING .

7 37 Testing and Adjusting Fuel Pressure .. 38 TESTING AND TROUBLESHOOTING ELECTRICAL COMPONENTS .. 38 Testing Relays .. 38 Testing the Manifold Absolute Pressure (MAP) Sensor .. 38 Throttle Position Sensor (TPS) Adjustment .. 39 Testing Idle Air Control (IAC) Motor .. 40 Testing Coolant Temperature Sensor .. 40 Testing Air Charge Temperature Sensor .. 40 Testing the Oxygen Sensor .. 40 INTRODUCTION Holley Performance Products has written this MANUAL for the INSTALLATION of the PRO-JECTION 4D and 4Di fuel injection system.

8 This MANUAL contains all the information needed to install this system. Please read all the WARNINGS, NOTES, and TIPS, as they contain valuable information that can save you time and money. It is our intent to provide the best possible products for our 4 customer; products that perform properly and satisfy your expectations. Should you need information or parts assistance, please contact our technical service department at 1-270-781-9741, Monday through Friday, 7 to 5 Central Time. By using this number, you may obtain any information and/or parts assistance that you may require.

9 Please have the part number of the product you purchased when you call. WARNING! The PRO-JECTION 4D and 4Di systems consist of a number of sophisticated components. Failure of any one component does not constitute, nor does it justify, warranty of the complete system. Individual service items are available for replacement of components. If assistance is required or if you need further warranty clarification, you can call Holley Technical Service at the number shown above.

10 WARNING! To preserve warranty, these instructions must be read and followed thoroughly and completely before and during INSTALLATION . It is important that you become familiar with the parts and the INSTALLATION of the PRO-JECTION system before you begin. Failure to read and understand these instructions could result in damage to PRO-JECTION components that are not covered by the warranty and could result in serious personal injury and property damage.