Powerjection III EFI System Installation Guide

Welcome to the comprehensive installation guide for your Professional Products Powerjection III Fuel Injection System. This manual will walk you through every step, from unpacking your components to firing up your engine. We've designed the Powerjection III to be as user-friendly as possible, and with this guide, you'll be able to achieve a professional installation. If at any point you encounter questions or require assistance, our dedicated Technical Support Line is available at 323-779-2020. Our knowledgeable staff is ready to help you through the entire process.

Understanding Your Powerjection III System

The Powerjection III EFI system is available in several configurations to suit your needs. You'll find versions that include essential fuel system components and others that allow you to supply your own. It's crucial to identify which version you have to ensure you have all the necessary parts.

System Versions:

• 70020 (Satin Finish) & 70021 (Polished Finish): These kits include the throttle body assembly but do not come with fuel system components. You will need to source an EFI-rated fuel pump, a 10-micron fuel filter, a fuel pressure regulator, and a fuel pressure gauge.
• 70026 (Satin Finish) & 70027 (Polish Finish): These are 'all-inclusive' packages, providing the throttle body assembly along with the fuel pump, filter, regulator, and gauge.

Important Note: All Powerjection III systems require a return fuel line, which allows unused fuel to flow back to the tank. Professional Products offers a return fuel line kit (part number 70107). Alternatively, you can convert to a returnless setup using the 70035 FuelOnDemand Kit, which also offers benefits like extended pump life and reduced noise.

Before You Begin: Component Check and Preparation

Before diving into the installation, it's essential to verify that you have all the components listed in your kit. This proactive step will prevent delays and ensure a smooth installation process.

Component Checklist:

1. Throttle body with EMS and dual feed inlet
2. Throttle body mounting gasket
3. Air cleaner mounting gasket
4. Coolant temperature sensor
5. Wide-band O² sensor
6. Sub-harness
7. O² sensor bung
8. Bung gasket
9. (2) Worm gear clamps for O² sensor bung
10. Stage III Dashboard Software CD
11. Installation / User manual
12. USB to Serial Cable Adapter
13. Fuel Pressure Regulator (70026/70027 Only)
14. Fuel Pressure Gauge (70026/70027 Only)
15. Fuel Pump (70026/70027 Only)
16. Fuel Filter (70026/70027 Only)

Essential Considerations:

• Fuel Tank Venting: Your fuel tank must be vented. A vented fuel cap is not sufficient. A minimum vent size of 1/4-inch is required.
• Fuel Lines: All fuel lines on the pressure side, from the pump to the throttle body, must be EFI pressure-rated. We recommend using factory steel lines or AN-style fittings and hose. Professional Products offers a full line of fuel line components.
• Intake Manifold Compatibility: The Powerjection III throttle body is designed to fit a square-bore intake manifold (like a Holley 4150). If you have a spread-bore manifold, you'll need a Professional Products #52111 Manifold Adapter Plate Kit.
• Pre-Filter Recommendation: To protect your fuel pump from debris, a pre-filter is recommended. However, ensure it's compatible with EFI systems to avoid fuel cavitation. Professional Products recommends their #10210 or #10211 Inline Filters.

Tools and Additional Parts

Most of the tools required for this installation are standard hand tools. However, you may need specific items for fuel system modifications, such as installing a fuel vent or return port in your fuel tank. Ensure you have wire strippers, crimpers, and a selection of wire terminals.

Recommended Fittings:

• Professional Products #10244: 1/4-NPT x 3/8" barbed fitting for fuel pump and filter if using slip-on hose.
• Professional Products #15239 (blue) or #16239 (black): 1/4-NPT x -06AN fitting for using slip-on -06AN hose.
• Professional Products #17239 (polished): 1/4-NPT x -06AN fitting if you are using AN hose.

Always use blue Loctite #246 on fuel system fittings. Never use Teflon tape in the fuel system, as it can break down and clog components.

Installing Your Powerjection III System

Follow these steps carefully for a successful physical installation of the throttle body and related components.

Step-by-Step Installation:

1. Disconnect Battery: For safety, disconnect the negative battery cable.
2. Remove Carburetor: Disconnect fuel lines and linkage from your stock carburetor and then remove it according to your vehicle manufacturer's guidelines.
3. Install Throttle Body Gasket: Fit the insulating mounting gasket onto the intake manifold. This gasket is crucial for heat insulation and prevents over-tightening.
4. Mount Powerjection III: Place the Powerjection III throttle body assembly onto the manifold. You may need longer carburetor studs (Professional Products #20151). Connect your throttle linkage and return spring. Tighten securely. The EMS grounds through the throttle body mounting.
5. Install Coolant Temperature Sensor: Screw the 3/8-NPT coolant temperature sensor into a manifold water port. A reducer bushing might be necessary. Connect the harness from the throttle body to the sensor.
6. Connect Vacuum Lines:
   • Connect your power brake vacuum line to the rear base vacuum port of the throttle body.
   • If your transmission requires vacuum, connect its modulator line to the same rear port. Use a vacuum "T" fitting if both are needed.
   • If you have a vacuum advance distributor, connect its vacuum line to the upper port on the front base of the throttle body.
   • Cap any unused vacuum nipples.

Oxygen Sensor Installation

Proper O2 sensor placement is vital for the system's adaptive learning capabilities.

O2 Sensor Placement:

• Location: Install the O2 sensor bung approximately 4-6 inches past the exhaust manifold collector, on a horizontal exhaust pipe.
• Angle: Ensure the sensor mounting is between the 9 o'clock and 3 o'clock positions to prevent condensation and debris buildup.
• Drilling: Drill a 5/8-inch hole for the bung.
• Securing the Bung: Use the supplied gasket and worm gear clamps to secure the bung. Alternatively, you can weld the bung in place.
• Connecting the Harness: Plug the harness cable from the throttle body into the O2 sensor cable. Secure the harness away from hot or moving parts using cable ties.

Note: If you previously had an O2 sensor, you may be able to reuse the existing bung, provided it's in the correct location.

Fuel Delivery System Installation

This section details the plumbing for your fuel system. Pay close attention to line sizing and fitting types.

Fuel System Plumbing:

• Fuel Pump Mounting: Mount the fuel pump below the fuel tank level and within 2 feet of the tank for proper gravity feed and priming. Ensure all fuel components are shielded from heat sources to prevent vapor lock.
• Connecting Lines:
  • Install a fuel line from the fuel tank supply outlet to the fuel pump inlet.
  • Connect a fuel line from the pump outlet to the EFI inline fuel filter.
  • Connect a fuel line from the EFI filter to the fuel inlet on the Powerjection III throttle body.
  • Install a return fuel line from the fuel tank to the bottom of the fuel pressure regulator.
• Fittings: Use appropriate 3/8-inch or -06AN size fittings. Install fittings into the fuel pump and filter using blue Loctite #246.
• Grounding: Connect a ground wire from the negative side of the fuel pump to the chassis.

Wiring Harness Installation

Correct wiring is crucial for the system's operation. Match wire colors and ensure secure connections.

Wiring Connections:

• Red Wire (12V Fused): Connect directly to the battery's positive terminal.
• Orange Wire (Pump): Connect to the positive side of your electric fuel pump.
• Yellow Wire (Key): Connect to a source that provides battery voltage when the ignition key is in the "On" or "Crank" position. Ensure voltage doesn't drop below 9 volts during cranking. Avoid connecting to the positive side of the ignition coil if using an MSD ignition with an amplifier box or if a ballast resistor is present.
• Tach Input:
  • Ready-to-Run Distributor: Connect the Black "SP" wire to the negative side of the ignition coil.
  • MSD Ignition (Amplifier Box): Connect the Green "CP" wire to the tachometer output of the amplifier box.

Crucial Warning: Do not connect both the Green "CP" wire and the Black "SP" wire simultaneously. Tape off the unused wire to prevent it from grounding, which can cause severe damage to the computer. The brown wire is not used and does not require taping.

Final Mechanical Checks and Initial Power-Up

Before starting the engine, perform these final checks.

Pre-Start Checks:

1. Grounding: Ensure a quality ground connection exists between the engine block and the chassis/body.
2. Battery Charge: Verify the vehicle's battery is fully charged.
3. Throttle Body Security: Confirm the throttle body is properly tightened and secured with lock washers.
4. Reconnect Battery: Reconnect the negative battery cable.
5. Check for Leaks: Turn the ignition key to the "On" position and carefully inspect all fuel connections for leaks. Correct any leaks before proceeding.
6. Adjust Fuel Pressure: Adjust the fuel pressure regulator to 42-45 PSI, as indicated on the fuel gauge. If the initial reading is high, turn the key off, bleed off pressure by loosening the fuel supply line, and re-adjust.
7. Do Not Start Yet: Avoid starting the engine at this stage.

Installing the Dashboard Software

The Stage III Dashboard software is your interface for tuning and monitoring the Powerjection III system.

Software Installation:

1. Insert CD: Place the supplied Dashboard CD into your laptop's CD drive. The Install Wizard should launch automatically. If not, navigate to "My Computer" and double-click the CD drive.
2. Follow Prompts: The wizard will guide you through the installation process.
3. Connect Laptop: Once the software is installed, connect your laptop to the Powerjection III throttle body harness using the supplied USB to Serial Cable Adapter. Ensure the ignition key is in the "Off" position during connection.

Opening and Connecting the Dashboard

Establishing a connection between your laptop and the Powerjection III ECU is essential for configuration.

Connecting to the ECU:

1. Launch Software: Click the Dashboard icon on your laptop's desktop.
2. ECU Search: The software will begin searching for the Stage III ECU across available Comm Ports.
3. Connection Status: When the ECU is found, the status will change from "Connecting" (yellow) to "ECU Connected" (green).
4. Initial Profile: Your Powerjection III ECU comes with a pre-installed base profile, typically for a 300 HP small-block Chevy. If your engine is similar, you can proceed to the "Starting Your Vehicle" section. However, it's recommended to familiarize yourself with the software's capabilities by reviewing the subsequent sections.

Creating Your Base "Profile"

The Fuel Wizard and Main Setup sections allow you to tailor the system to your specific engine.

Main Setup:

• MAP & RPM Boundaries: Default values are suitable for naturally aspirated engines. Adjustments may be needed for boosted applications.
• Cylinder Selection: Choose the correct number of cylinders for your engine (4, 6, or 8).
• Tuning Strategy: Select "Automatic" for the system to calculate the fuel curve.
• Closed Loop & Adaptive Learning: These should typically be set to "On" for optimal performance and learning.
• Tach Input: Match this setting to how you wired the tachometer signal (e.g., "Coil (-)" or "6A Tach").
• Idle Cell Setup: Fine-tune idle parameters if necessary.

Fuel Wizard:

This wizard helps generate a base fuel map based on your engine's specifications.

• Torque: Enter your engine's maximum rear-wheel torque. If using flywheel torque, reduce it by approximately 20%.
• Number of Injectors: Typically 4.
• Boost: Enter the maximum boost pressure if applicable.
• Injector Flow Rate: Use the default (62 lbs/hr) unless you have different injectors.
• Intake Manifold Type & Camshaft Type: Select the appropriate options based on your engine's components and vacuum readings.
• Calculate & Lock: After entering all parameters, click "Calculate" to generate the profile, then "Lock" the slider to prevent accidental changes.

Calibrating the Throttle Position Sensor (TPS)

Accurate TPS calibration ensures the system correctly interprets throttle inputs.

TPS Calibration Steps:

1. Navigate to "Setup" and select "Calibrate TPS."
2. With the throttle closed, click "Calibrate TPS Min."
3. With the throttle fully open (pedal to the floor), click "Calibrate TPS Max."
4. Close the calibration window.

Starting Your Vehicle for the First Time

With the installation and initial setup complete, it's time to start your engine.

First Start Procedure:

1. Turn Key On: Listen for the fuel pump to prime.
2. Check for Leaks: Re-inspect all fuel connections.
3. Start Engine: Allow the engine to reach approximately 150 degrees Fahrenheit.
4. Adjust Fuel Pressure: Ensure fuel pressure is at 45 PSI.
5. Idle RPM: Aim for 900-1000 RPM when warm. Adjust throttle stop screws if necessary.
6. Air Cleaner: Install the air cleaner and gasket.

Important Idle Adjustment Note: If adjusting idle RPM, place tape over the IAC hole on the throttle body. Ensure primary and secondary throttle blades open equally. Adjust idle screws incrementally.

Navigating the Dashboard Software

The Dashboard software provides real-time data and tuning capabilities.

Key Dashboard Features:

• Real-Time ECU Data: Monitor vital engine parameters like RPM, MAP, coolant temperature, air/fuel ratio, and more.
• Status Lights: Indicate active functions such as "Idle," "Closed Loop," and "Adaptive Learning."
• Data Logging: Record engine data while driving for later analysis. Toggle the data logging button to "ON" (red) to start.

Advanced Tuning: Edit Menu Options

The "Edit" menu allows for fine-tuning of various engine parameters. These adjustments are typically for advanced users or highly modified engines.

Edit Menu Options:

• Target Air/Fuel Ratio: Adjust the desired air/fuel ratio across different RPM and MAP ranges.
• Adaptive Learn Fuel: Fine-tune the learned fuel adjustments. Cells can be protected to prevent automatic updates.
• Accel/Decel: Modify acceleration enrichment and deceleration fuel cut-off.
• Cranking/Cold Engine: Adjust fuel delivery during cranking and cold operation, similar to a choke.
• Idle Air Control (IAC): Configure the IAC motor for stable idle speeds under various conditions.

Boosted Applications

For supercharged or turbocharged engines, specific setup adjustments are necessary.

Boosted Setup:

• MAP Sensor: The Powerjection III features a 2.5 Bar MAP sensor capable of reading up to 21 PSI of boost.
• Vacuum Line Relocation: For draw-through boosted systems, relocate the vacuum line from the throttle body to the intake/plenum. Cap the throttle body nipple.
• Blow-Through Systems: No vacuum line relocation is needed for blow-through systems.
• Fuel Pressure Regulator: Route a vacuum line from the fuel pressure regulator vent nipple to the intake/plenum.

Data Logging and Analysis

Data logging is a powerful tool for diagnosing performance issues and optimizing your tune.

Using Data Logging:

• Enable Logging: Connect your laptop and toggle the data logging switch to "ON" (red).
• Stop Logging: Toggle the switch to "OFF" once you've finished.
• Access Log Files: Use the "Log Charter" shortcut on your desktop to open and view recorded data.
• Parameter Selection: Choose the parameters you wish to analyze (e.g., RPM, MAP, A/F ratio).
• Analysis: Use the crosshairs to examine specific points in the data log.

Frequently Asked Questions

Q1: What if I have questions during installation?

A: Please call our Technical Support Line at 323-779-2020. Our team is fully equipped to assist you.

Q2: Can I use a different fuel pump than the one supplied?

A: Yes, but it must be EFI-rated. Ensure it meets the system's flow and pressure requirements.

Q3: Do I need a return fuel line?

A: Yes, all Powerjection III systems require a return fuel line unless you are using the 70035 FuelOnDemand Kit.

Q4: What is "Adaptive Learning"?

A: This feature uses the O2 sensor to make real-time adjustments to the air/fuel ratio, optimizing performance under various driving conditions. It requires "Closed Loop" to be enabled.

Q5: How do I adjust idle speed?

A: Idle speed can be adjusted via the throttle stop screws on the throttle body and by configuring the Idle Air Control (IAC) settings within the Dashboard software.

By following these instructions, you can confidently install and configure your Powerjection III EFI system. Enjoy the enhanced performance and drivability!