Holley Fuel Rails for OE style LS intakes

Holley Fuel Rails for OE style LS intakes
Holley Fuel Rails
for OE style LS intakes
P/N 534-209 - Fits LS1, LS2, LS3, LS6, & L99 factory intakes
Includes (4) -6 to 3/4 -16 O-ring adapters
Fuel rails are machined to accept large -8 (3/4 -16) O-ring fittings (sold separately)
P/N 534-210 - Same as 534-209, but also includes:
6 feet -6 braided hose
(4) -6 90°
(2) -6 straight -6 hose ends
P/N 534-211 - Adapter kit, required when directly connecting Holley fuel rails to GM factory fuel line quick-connect. Includes (1) 3/4-16
O-ring port plug and (1) -6 to GM quick connect adapter.
P/N 534-212 - Bracket kit, required when upgrading to (EV1/Bosch style) performance injectors on LS2, LS3, LS6 or L99 applications
(not required to upgrade LS1 and LS6 applications).
GM 3/8” Quick-Connect Release Tool to disconnect the factory fuel line (these are inexpensive and available at the local auto parts
Installation should be performed by a qualified mechanic.
Read all instructions and warnings before beginning.
Installation of this product involves handling of gasoline.
Make certain there are no open flames in the area.
Use eye protection during installation to protect against gasoline spray.
NOTE: System fuel pressure must be relieved before proceeding with disassembly. Refer to the vehicle service manual for
procedures and precautions.
NOTE: 1997-98 LS1 applications utilizing a factory supply and return fuel line will require the addition of a fuel pressure
regulator when installing Holley fuel rails.
After the engine has cooled, disconnect the negative battery cable.
Disconnect the electrical connector at each injector. Note that the injector harness is specific to injector order. If the
harnesses are removed, they must be reinstalled on the correct engine side and to each injector.
Clean any dirt or debris near rail connections and injectors.
Relieve the fuel system pressure (refer to the vehicle service manual for procedures and precautions for this step).
Disconnect the fuel line/lines from the OEM fuel rails. A 3/8” quick-connect tool will be required (available at the local auto
parts store). Use clean shop towels to catch any gasoline that may escape and to prevent any contaminates from entering the
fuel lines.
Disconnect any wiring, vacuum lines, and throttle body components interfering with the installation process.
Remove the fuel rail mounting and related hardware (Figure 1).
Figure 1
Figure 2
Place clean shop towels around the injectors to catch any gasoline that escapes. Pull up on the OE rail assembly. The
injectors are sealed on both ends with O-rings. It is recommended the injectors remain sealed to the fuel rail during removal to
prevent large amounts of fuel from escaping onto the engine.
Remove injector retaining clips and then remove injectors. Pull straight down on the injectors while gently twisting them
(Figure 2).
10. Install the -6 O-ring fittings onto each end of the rails before installing the rails on the intake (Figure 3). Lubricate with clean
Figure 3
11. Install the appropriate brackets onto the Holley rails using the supplied M5 bolts and lock washers.
Use brackets 49R3142 for LS2, LS3, LS6 &
L99 applications (Figure 4 bracket placement)
Use brackets 49R3143 for LS1 & LS6
applications (Figure 4b bracket placement)
When using optional kit P/N 534-212 to allow the upgrade to tall
performance injectors (use Figure 4 bracket placement for
Use brackets 49R3141 for LS3, LS6 & L99 applications
Use brackets 49R3144 for LS2 applications
Use outer hole set.
Use inner hole set.
Figure 4 - Bracket placement
Figure 4b - Bracket placement
12. Make certain the injectors are free from debris. Inspect each injector O-ring for cracks, nicks, cuts, etc. Replace, if there is
any damage. Replacement O-rings are available at your local auto parts store.
If installing optional kit P/N 534-212, replace each injector’s intake side O-rings with the kit supplied larger O-rings.
13. Apply a light coat of clean oil to all O-rings, intake injector bores, and Holley rail bores for ease of installation.
14. Insert each injector into the fuel injector bore of the Holley rails or into the intake bores, whichever is easier for your particular
15. Install each of the fuel rail/injector assemblies onto the intake manifold. Make certain each of the O-rings is seated at both
ends and that none of the O-rings were cut (Figure 5).
Figure 5
NOTE: On many cars there is a bracket at the rear of one or both rails. If there is interference, the brackets will need to be
modified (Figure 6).
Figure 6
Figure 7
16. Reinstall the four rail mounting bolts. Add a grounding strap for each fuel rail from one of the intake bolts to a rail mounting
bolt (Figure 7).
17. Reinstall any intake bolts that were removed (refer to vehicle service manual for torque values and pattern for this step).
18. Make certain any spilled gasoline and shop towels are removed.
19. Reconnect any wiring, vacuum lines, and throttle body components that were removed.
20. Plumbing will vary per application. Below is an example of two configurations (Figures 8 & 9). Refer to appendix A and B for
hose assembly and routing instructions.
Figure 8
Figure 9
21. Reconnect the battery and turn the ignition to the ON position but do not start the vehicle. To purge air and build fuel
pressure, cycle the ignition from off to on several times, waiting at least 10 seconds with the ignition in the off position each
time. Inspect for leaks.
22. Start the engine and inspect for any fuel leaks around the fuel injectors, fuel rail fittings, fuel lines, etc. Take a brief test drive
and check again for any fuel leaks.
Holley® Performance Products, Inc.
1801 Russellville Road
Bowling Green, KY 42101
Technical Support: 1-866-GOHOLLEY
Phone: 1-270-781-9741
Fax: 1-270-781-9772
© 2011 Holley Performance Products, Inc. All rights reserved.
Revision Date: 8-15-12
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