Avenger 550-400 User manual

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AVENGER EFI
4 BBL TBI SYSTEMS
550-400 (700 CFM – 65 lb/hr injectors) up to 400 HP
550-401 (900 CFM – 75 lb/hr injectors) up to 525 HP
550-402 (900 CFM – 85 lb/hr injectors) up to 600 HP
TBI HARDWARE
INSTALLATION MANUAL – 199R10552
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.
NOTE: Fits all standard square flange intake manifolds.

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TABLE OF CONTENTS:
1.0 INTRODUCTION ..................................................................................................................................................................... 3
2.0 CHOOSING THE RIGHT SYSTEM: ........................................................................................................................................ 3
3.0 WARNINGS, NOTES, AND NOTICES .................................................................................................................................... 4
4.0 PARTS IDENTIFICATION ....................................................................................................................................................... 4
5.0 ADDITIONAL ITEMS REQUIRED FOR INSTALLATION ......................................................................................................... 7
6.0 TOOLS REQUIRED FOR INSTALLATION .............................................................................................................................. 7
7.0 COOLANT TEMPERATURE SENSOR INSTALLATION ......................................................................................................... 7
8.0 REMOVAL OF EXISTING FUEL SYSTEM .............................................................................................................................. 7
9.0 AVENGER EFI TBI SYSTEM INSTALLATION ........................................................................................................................ 8
9.1 Throttle Body........................................................................................................................................................................ 8
9.2 Throttle Connections ............................................................................................................................................................ 8
9.3 MAP Sensor Installation and Vacuum Line Connections..................................................................................................... 9
9.4 Fuel Pump, Fuel Line, and Filter Installation ....................................................................................................................... 9
9.5 Return Line Installation ...................................................................................................................................................... 11
9.6 Oxygen Sensor Installation ................................................................................................................................................ 12
9.6.1 Oxygen Sensor Mounting Procedure .......................................................................................................................... 12
9.6.2 ECU Mounting ............................................................................................................................................................. 13
10.0 WIRING ............................................................................................................................................................................... 13
10.1 Important Wiring “Do’s and Don’ts” ................................................................................................................................. 13
11.0 WIRING HARNESS INSTALLATION .................................................................................................................................. 13
12.0 PRIMARY HARNESS INSTALLATION AND SENSORS CONNECTION ............................................................................ 14
12.1 ECU Connectors ............................................................................................................................................................... 14
12.2 Harness Routing ............................................................................................................................................................... 14
12.3 Sensor Connections ......................................................................................................................................................... 14
12.3.1 Throttle Position Sensor (TPS) .................................................................................................................................. 15
12.3.2 Manifold Air Pressure Sensor (MAP) ......................................................................................................................... 15
12.3.3 Coolant Temperature Sensor (CTS) .......................................................................................................................... 15
12.3.4 Manifold Air Temperature Sensor (MAT) ................................................................................................................... 15
12.3.6 Wide Band Oxygen Sensor (WB02) .......................................................................................................................... 15
12.3.7 Fuel Pressure (Fuel) .................................................................................................................................................. 16
12.3.8 Oil Pressure (Oil) ....................................................................................................................................................... 16
12.3.9 CANbus – Handheld (CAN) ....................................................................................................................................... 16
12.3.10 Knock Sensor (Knock) ............................................................................................................................................. 16
12.3.11 Ignition (IGN) – ........................................................................................................................................................ 17
13.0 PRIMARY OUTPUTS .......................................................................................................................................................... 17
13.1 Idle Air Control (IAC) ........................................................................................................................................................ 17
13.2 Fuel Injector Outputs (Injectors) ...................................................................................................................................... 17
14.0 LOOSE WIRES ................................................................................................................................................................... 17
15.0 IGNITION/ENGINE SPEED INPUT ..................................................................................................................................... 18
16.0 WIRING ............................................................................................................................................................................... 19
17.0 ADDITIONAL OUTPUTS ..................................................................................................................................................... 22
APPENDIX 1.0.............................................................................................................................................................................. 23
Pinout ........................................................................................................................................................................................ 23

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1.0 INTRODUCTION
Holley Performance Products has written this manual for the installation of the AVENGER EFI TBI fuel injection system. This
manual contains the information necessary for the hardware installation. 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 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, 8 a.m. to 5 p.m. Central Time. By
using this number, you may obtain any information and/or parts assistance that you may require. Please have the part number
of the product you purchased when you call.
NOTE: This manual is for the hardware installation of a Holley Throttle Body Fuel Injection System and instructions
specific to it. Instructions on using the Avenger Handheld to set up and tune your engine are contained in the
Avenger tuning manual (included with this kit).
WARNING! The AVENGER EFI 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.
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
AVENGER EFI system before you begin. Failure to read and understand these instructions could result in
damage to AVENGER EFI components that are not covered by the warranty and could result in serious
personal injury and property damage.
WARNING! The oxygen sensor in this kit is recommended for use with ONLY unleaded fuel. Use of leaded fuels will
degrade the oxygen sensor and will result in incorrect exhaust gas oxygen readings and improper fuel
delivery. Failure to follow these directions does not constitute the right to a warranty claim.
WARNING! Failure to follow all of the above will result in an improper installation, which may lead to personal injury,
including death, and/or property damage. Improper installation and/or use of this or any Holley product
will void all warranties.
WARNING! Use of some RTV silicone sealers will destroy the oxygen sensor used with this product. Ensure the RTV
silicone sealant you use is compatible with oxygen sensor vehicles. This information should be found on
the RTV package.
2.0 CHOOSING THE RIGHT SYSTEM:
To ensure that you have purchased the correct AVENGER EFI kit for your application, check to be sure that the kit you
purchased is listed beside your engine’s horsepower.
HORSEPOWER KIT PART NUMBER
Up to 400 hp ..................................550-400 AVENGER EFI TBI, 700 CFM 65 lb/hr injectors
Up to 525 hp ..................................550-401 AVENGER EFI TBI, 900 CFM 75 lb/hr injectors
Up to 600 hp ..................................550-402 AVENGER EFI TBI, 900 CFM 85 lb/hr injectors

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3.0 WARNINGS, NOTES, AND NOTICES
WARNING! For the safety and protection of you and others, only a trained mechanic having adequate fuel system
experience must perform the installation, adjustment, and repair. It is particularly important to remember
one of the very basic principles of safety: fuel vapors are heavier than air and tend to collect in low places
where an explosive fuel/air mixture may be ignited by any spark or flame resulting in property damage,
personal injury, and/or death. Extreme caution must be exercised to prevent spillage and thus eliminate
the formation of such fuel vapors.
WARNING! This type of work MUST be performed in a well-ventilated area. Do not smoke or have an open flame
present near gasoline vapors or an explosion may result.
4.0 PARTS IDENTIFICATION
ITEM DESCRIPTION QTY SERVICE PART
1 TBI Assembly 700 CFM 65 lb/hr Complete 1 534-172
TBI Assembly 900 CFM 75 lb/hr Complete 1 534-187
TBI Assembly 900 CFM 85 lb/hr Complete 1 534-173
2 Avenger EFI ECU and Handheld 1 554-116
3 Main Power Harness 1 558-308
4 Avenger EFI TBI Wiring Harness 1 558-100
5 Inline Pump 1 N/A
6 Metal Fuel Filter 1 562-1
7 Fuel Filter (WIX 33033) 1 N/A
8 Fuel Filter Clamp 1 N/A
9 Fuel Pump Block-Off Plate & Gasket 1 12-813
10 Wide Band Oxygen Sensor 1 554-101
11 MAP Sensor 1 538-24
12 Coolant Temperature Sensor 1 534-2
13 Air Cleaner Adapter 1 17-14
14 Air Cleaner Gasket 1 108-4
15 Flange Gasket 1 108-10
16 Manifold Flange Studs 4 N/A
17 Heat Insulator Gasket 1 108-12
18 Oxygen Sensor Weld Ring 1 534-49
19 40 AMP Relay (Pre-Installed in harness) 1 534-26
20 Throttle Bracket 1 N/A
21 Throttle and Cruise Control Stud 1 N/A
22 Throttle Lever Ball 1 N/A
23 Throttle Lever Bracket 1 N/A
24 Ford kick down return spring 1 N/A
25 Throttle Lever Stud 1 N/A
26 Transmission Kickdown Stud 1 N/A
27 Hose Clamp 8 N/A
28 Grommet 1 N/A
29 Cable Ties 12 N/A
30 Tube Cap 1 N/A
31 Lockwasher 2 N/A
32 1/4-28 Nut 2 N/A
33 5/16-24 Nut 4 N/A
34 5/16" Vacuum Line 1 N/A
35 Ignition Adapter 1 N/A
TBI Service Parts:
Air Charge Temperature Sensor 1 534-46
Fuel Injector 700 CFM 65 lb/hr (requires purchase of 4) 1 522-54
Fuel Injector 900 CFM 75 lb/hr (requires purchase of 4) 1 522-80
Fuel Injector 900 CFM 85 lb/hr (requires purchase of 4) 1 522-43
Fuel Pressure Regulator Diaphragm 1 512-1
Idle Air Control (IAC) Motor 1 543-105
Throttle Position Sensor (TPS) 1 543-29
Optional Parts:
Small Cap GM HEI Ignition Adapter 1 558-304
Ford TFI Ignition Adapter 1 538-305

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Item 1 Item 2 Item 3
Item 4 Item 5 Item 6
Item 7 Item 8 Item 9
Item 10 Item 11 Item 12
Item 13 Item 14 Item 15

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Item 16 Item 17 Item 18
Item 19 (Pre-Installed in Harness) Item 20 Item 21
Item 22 Item 23 Item 24
Item 25 Item 26 Item 27
Item 28 Item 29 Item 30 Item 31
Item 32 Item 33 Item 34 Item 35

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5.0 ADDITIONAL ITEMS REQUIRED FOR INSTALLATION
 3/8" fuel hose (must meet SAE J30)  5/16" fuel hose (must meet SAE J30)
 5/16" steel fuel line (must meet SAE J526)
A 0-30 psi fuel gauge and tee fitting for fuel gauge is recommended to check for proper fuel pressure. PN 554-102 is a 0-100
PSI pressure sensor that can be purchased as well that will plug into the Avenger harness to check and monitor fuel pressure.
It requires a 1/8” NPT port for installation.
In addition to the above list, the engine must be equipped with a four barrel intake manifold and the vehicle must be in good
operating condition.
6.0 TOOLS REQUIRED FOR INSTALLATION
 Standard wrench set  Small blade screwdriver  5/32” Allen wrench
 Medium blade screwdriver  #2 Phillips screwdriver  Digital Volt-Ohm meter
 Drill and assorted bit sizes  Hole saw (2”)  Terminal crimping tool
 Utility knife  Factory Service Manual for your vehicle
An assistant is necessary for some installation and adjustment procedures and should be present for safety reasons.
7.0 COOLANT TEMPERATURE SENSOR INSTALLATION
The coolant temperature sensor (item 12) must be installed in a coolant passage in either the intake manifold or cylinder head.
The sensor has 3/8” NPT threads. If only a ½” NPT port is available, an adapter will have to be used. It is best to drain the
some of the coolant before the sensor is installed.
8.0 REMOVAL OF EXISTING FUEL SYSTEM
1. Disconnect the battery and remove the air cleaner.
2. Before disconnecting any vacuum hoses, it is a good idea to sketch out the vacuum hose routing. Using masking tape and
a permanent marker, mark all the vacuum hoses, vacuum sources, and ports before removing the old fuel delivery system.
3. Remove and discard the fuel line that connects the fuel delivery system from the fuel pump. This will not be needed in the
installation.
4. Disconnect and plug the inlet fuel line that runs from the gas tank to the fuel pump. This will prevent fuel spillage and
foreign matter or dirt from entering the fuel line.
DANGER! Before disconnecting or removing fuel lines, ensure the engine is cold. Do not smoke. Extinguish all open
flames. An open flame, spark, or extreme heat near gasoline can result in a fire or explosion causing
property damage, serious injury, and/or death.
5. The fuel delivery system can now be removed. Holley recommends removing the mechanical fuel pump, if so equipped,
and blocking-off the fuel pump mount using the provided fuel pump block off plate. The AVENGER EFI system kit includes
a block-off plate that will fit small and big block Chevrolet and Chrysler engines. If the block-off plate does not fit your
engine, a block-off plate may have to be purchased from a local performance parts supplier.
6. If required, replace the intake manifold at this time. Proceed to step seven if this is not required. A 4-BARREL STOCK
OR AFTERMARKET SQUARE FLANGE INTAKE MANIFOLD IS REQUIRED FOR THE INSTALLATION OF THE
HOLLEY AVENGER EFI TBI system.
7. Place clean shop towels or rags into the manifold opening to prevent dirt or debris from entering the engine. Keep
exposed ends of the vacuum and fuel lines free from dirt.
WARNING! Failure to cover the intake opening with a clean towel could result in dirt or debris entering the engine.
Dirt or debris in the induction system can cause engine damage, which may necessitate in a complete
engine overhaul.
8. Remove all traces of the old gasket material from the TBI mounting flange. DO NOT gouge the intake manifold sealing
surface during removal of old gasket material. Failure to remove all traces of the old gasket material will result in vacuum
leaks that will be difficult to detect later. Sealing flanges must be clean and dry before installation.

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9. Remove the shop towels from the intake and vacuum out the intake channel to ensure no dirt or debris is left in the intake
system. Place a shop towel over the entire intake opening until you are ready to install the new AVENGER EFI TBI.
9.0 AVENGER EFI TBI SYSTEM INSTALLATION
9.1 Throttle Body
NOTE: A 4 barrel intake is required for the installation of the Holley AVENGER EFI TBI system.
NOTE: Some GM and Chrysler engines require the use of a manifold adapter Holley Part Number 17-6. This adapts the
spread bore carburetor manifold to the Holley square flange.
1. Install the heat insulating gasket (Item 17) between the manifold and the 4 barrel throttle body injection unit. Check for
sufficient thread engagement of the throttle body hold down studs and nuts. It may be necessary to purchase and install
longer studs in the manif old for proper nut engagement. Gasket sealant may be used to ensure that no vacuum leaks
occur.
NOTE: If using this heat insulating gasket, the flange gasket is not required.
DANGER! Check for proper clearance between engine components, such as the distributor, coil, etc., and the throttle
body. If any interference is found, correct the condition before continuing. Failure to do so can result in
damage to the engine components or the throttle body.
DANGER! Check for proper clearance between the air cleaner and the engine compartment cover hood. If any
interference is found, correct the condition before continuing. Failure to do so can result in damage to the
compartment cover or engine components.
2. Place the throttle body in position over the manifold flange studs with the IAC motor facing the front of the vehicle and the
regulator/fuel connections towards the rear of the vehicle.
3. Tighten the throttle body down in a criss-cross pattern being careful not to over-tighten. Proper torque is 5-7 ft lbs.
WARNING! Over tightening the TBI manifold flange hold-down-nuts may result in a warped or cracked throttle body.
The TBI hold down nuts should be tightened down progressively in a criss-cross pattern to 5-7 ft./lbs., to
prevent leaks and avoid causing damage to the throttle body. A TBI that has been damaged due to
negligence of the owner will void the warranty.
9.2 Throttle Connections
1. Measure the length of the throttle lever arm on the
carburetor removed from the vehicle. Compare the
length of the existing throttle lever arm with the one
on the AVENGER EFI throttle body. If the two
throttle lever arms are similar in length (within 1/2”
of each other), the throttle lever arm hole on the
AVENGER EFI throttle body can be used without
the extension bracket. Use the throttle lever arm
extension bracket, if the old throttle lever arm is
significantly longer than the new throttle lever arm.
Before installation of the bracket, check the
diameter of the throttle cable stud. Some systems
may use a 1/4” stud that will require drilling of the
appropriate hole in the extension bracket to a 1/4”
diameter. Attach the extension bracket using two
fillister head screws as shown in Figure 1. The
extension lever length can be adjusted using the
four sets of holes.
2. Attach throttle linkage and have an assistant get in
the vehicle and fully actuate the throttle controls.
Make the necessary adjustments to the throttle
linkage to ensure that the throttle plates are vertical
when the throttle control is wide open. Work the
throttle linkage back and forth several times to
ensure it operates smoothly with no binding or sticking. Figure 1

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DANGER! Sticking throttle may result in uncontrolled engine or vehicle speed. This could cause property damage,
personal injury, or death. A sticking throttle may be caused by improperly installed throttle cables, lack of
clearance for any of the throttle linkage, or by a binding throttle linkage. Check all throttle cables for
proper installation and alignment and actuate the throttle to check for any potential binding or clearance
problems. Repair any problems before continuing.
3. Locate the 1/4-28 throttle stud from the parts provided and attach to the throttle lever with the nut provided. Connect the
accelerator linkage to the throttle stud on the throttle body. If the vehicle is equipped with an automatic transmission,
connect the transmission kickdown rod to the linkage on the throttle body. The transmission kickdown may have to be
adjusted. Follow the vehicle manufacturer’s procedure for the correct adjustment procedure.
NOTE: On late model GM and Ford overdrive transmissions with a lockup torque converter, make sure the lockup function is
properly retained. Failure to do so will result in premature transmission failure.
NOTE: On Chrysler vehicles, a lever extension will be needed, Holley Part Number 20-7. Van applications may require the
use of throttle lever extension Holley Part Number 20-14.
4. Attach throttle linkage and throttle return spring. Have an assistant get in the vehicle and fully depress the accelerator
pedal. Make the necessary adjustments to the throttle linkage to insure that the throttle reaches wide-open position when
the accelerator is depressed. Work throttle linkage back and forth several times to ensure that it operates smoothly with
no binding or sticking.
DANGER! Failure to attach the throttle return spring or a sticking throttle may result in uncontrolled engine or vehicle
speed, which could cause personal property damage, serious injury, or death.
9.3 MAP Sensor Installation and Vacuum
Line Connections
1. The MAP sensor must be installed as close to the
vacuum source it is connected to as possible. It must
be connected to a “full manifold vacuum” port. This is a
vacuum source below the throttle body plates. The
throttle body has a full manifold port that the sensor can
be connected to (see Figure 2). It is best not to “tee”
multiple items into the port that supplies the MAP
sensor. The sensor should be mounted such that the
vacuum port on the sensor is pointed at some
downward angle above the vacuum source so that
moisture does not collect in the sensor itself.
NOTE: Make sure the MAP sensor is installed in a manner
such that the vacuum hose fitting is pointing at a
downward angle. Failure to do so can allow fuel
and condensation to run into the sensor and cause
failure. I
2. Install vacuum hoses to the appropriate port on the
throttle body. Use the diagrams made during removal of
the existing fuel system to locate the correct port. The
vacuum ports of the throttle body are labeled in Figure 2. Figure 2
9.4 Fuel Pump, Fuel Line, and Filter Installation
NOTE: If you have dual fuel tanks, you must purchase Holley PN 534-38.
The following section covers the installation of an in-line pump. Holley in-line fuel pump PN 12-920 is included with this kit.
Holley includes both a pre and post filter with the AVENGER TBI system. Both of these filters have “barbed” ends and are
designed to connect to an EFI pressure rated rubber hose. They are not designed for “AN” style plumbing. AN style fittings are
available for this pump from Holley if AN plumbing is used (PN 26-160 for -6, PN 26-180 for -8).
1. Do not mount the fuel pump higher than the lowest point of the fuel tank.
2. Make sure fuel tank is properly vented.
DANGER! Never get under a vehicle supported only by a jack. Serious injury or death can result from vehicles falling
off of jacks. Before working underneath a vehicle, support it solidly with jack stands.

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3. Mount the electric fuel pump as close to the fuel tank outlet as possible with the bracket provided. Mounting the fuel pump
in this manner will insure that the pump will prime easily and purge fuel vapors in the TBI quickly to ensure faster starts.
DANGER! Take precautions to ensure that all fuel line routings are away from heat sources, such as the engine or
exhaust pipes. A fire or explosion hazard could cause serious injury or death.
DANGER! Ensure that the fuel pump mounting location will not interfere with any under the vehicle components,
especially at the extreme limits of the suspension travel. A fire or explosion hazard could cause serious
injury or death.
Figure 3
4. There are two metal filters included with the system. The filter marked “33033” MUST be installed between the fuel tank
and the fuel pump inlet (unless an in-tank pump is used). The purpose of this filter is to protect the fuel pump from
particles of dirt or other foreign material. The filter should be installed with the arrow on the filter pointing in the direction of
the fuel flow.
5. The other metal fuel filter that is included with the EFI TBI system should be installed between the electric pump outlet and
TBI unit. This is a 10 micron EFI filter. Position the filter, so the fuel hoses can be routed without kinks or sharp bends.
The filter should be installed with the arrow on the filter pointing in the direction of the fuel flow. A clamp is provided to
assist with mounting this filter in the kit.
WARNING! Ensure both filters are installed in the proper direction. A flow direction arrow is stamped on the side of
the filter to indicate the direction of fuel flow. Failure to do so will result in a system malfunction.
DANGER! Take precautions to ensure all fuel line routings are away from heat sources, such as the engine or exhaust
system. A fire or explosion hazard could cause property damage, serious injury, and/or death.
6. Plumbing must now be installed to connect the
fuel tank to the filters, pump, and TBI unit. It is
recommended to use steel hard line or stainless
braided hose with AN fittings. If AN plumbing is
used, the appropriate fittings must be purchased
for the pump and TBI unit. Filters must have AN
style fittings as well. The thread in the inlet and
outlet fittings of the TBI unit is ¼” NPT.
7. 3/8” line should be used on the feed/pressure
side of the system (the filters included are
designed for 3/8” line). If using steel line, rubber
hose (rated for use with fuel injection) can be
used to connect the steel line to the pump and
filters. You should not connect a rubber hose
directly to a steel line unless the end of the line
has a “bead/nipple” or barb that retains the hose
(similar to the ends of the fuel filters). If the steel
line is just cut off, purchase a compression fitting
that a barbed hose end can be installed on, or
use a tool to roll a bead/nipple on the end of the
steel line. Install hose clamps on all of these
junctions (8 are included in the kit). All fuel
hoses used must meet SAE J30 performance
standards. All steel fuel line must meet SAE
J526 standards. Figure 4