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Holley 526-24 Manual
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Holley 526-24 Manual

Holley 526-24 Manual

G-body return style fuel plumbing kit
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G-Body Return Style Fuel Plumbing Kit
Holley's GM G-Body Return Style Fuel Plumbing Kit has the majority of parts and accessories
for a complete plug and play fuel system kit. It includes everything to take the guesswork out
and not only replaces but upgrades the original fuel system. Giving you all the flexibility while
still maintaining a clean and easy OEM-like install.
Features:
Comes with everything needed to go from the fuel tank to the engine bay
Prepares your 1978-1988 GM G-Body for EFI
Simplifies your fuel system as a direct replacement
Pump gas and E85 compatible
Utilizes as many of the factory existing holes with minimal to no drilling required
Includes enough nylon braided hose to go from the tank to the fuel rails for both feed and return
Contains: AN fittings, 350 LPH EFI Fuel Pump Module, Billet Filter, Fuel Pressure Regulator & Gauge
New hardware and clamps
Pre-calibrated fuel level sending unit works with factory fuel gauge
Most complete solution for your G-Body
Part Number: 526-24
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Summary of Contents for Holley 526-24

  • Page 1 G-Body Return Style Fuel Plumbing Kit Part Number: 526-24 Holley’s GM G-Body Return Style Fuel Plumbing Kit has the majority of parts and accessories for a complete plug and play fuel system kit. It includes everything to take the guesswork out and not only replaces but upgrades the original fuel system.
  • Page 2 Overview/Parts List: General Layout for G-Body Return Style Fuel System Feed to rails/Sniper Return from rails/Sniper PICTURE QTY. DESCRIPTION HOLLEY REPLACEMENT P/N Return-Style Fuel Pump Module 350 LPH 12-329 Fuel Pump Module Pigtail 3/8 Clamp 750006ERL 3/8 Hose 750066ERL 3/8 to AN Adapter...
  • Page 3 NPT to AN Adapter 481666-BL NPT Plug 493204-BL Fuel Filter 162-550 1 1/2” P-Clamp 171024ERL Fuel Pressure Regulator 12-886 Gauge 26-507 Nylon Braided Hose 842006 5/8” P-Clamp 171010ERL Self-Tapping Frame Bolts 1 1/2" Flame Guard 570014ERL G Body Fuel Pressure Regulator Bracket, Pan Head Screw (2), Nylon-Insert Locknut (2) Fuel Pump Relay Kit 40205G...

  • Page 4: Installation Instructions

    Holley Performance Products cannot and will not be responsible for any alleged or actual engine or other damage, or other conditions resulting from misapplication of the fuel pumps and fuel pressure regulators described herein.
  • Page 5 NOTE: Due to manufacturers’ discrepancies, use these instructions as a general guide as some things may differ from your certain application. 1. Prepping the Car a.) Fuel tank will need to be removed, so have little to no gas in the tank. b.) If engine has been run in the past couple hours, let it cool down.
  • Page 6 c.) Remove fuel line clamp bolt with 1/2” socket and disconnect all (x3) hoses by relieving clamps with pliers. NOTE: Place fuel container underneath to prevent leakage onto floors. Remove bolt Remove all 3 hoses d.) Support fuel tank with a jack and use a 9” extension with 15mm socket to remove (x2) fuel tank strap bolts. Remove bolts NOTE: Fuel Tank not shown for visual purposes.
  • Page 7 5. Fuel Pump Module Install a.) Lift up and remove the Fuel Sender as it will be replaced with an in-tank Fuel Pump Module. b.) OE Style Fuel Pump Module has Hose Barb inlets, so we will convert the 3/8” Feed and 1/4” Return to AN. Using the clamps, hose and the hose barb to AN adapter, tighten clamps with a 7mm socket 3/8 Clamp 3/8 Hose...
  • Page 8 NOTE: For non-baffled fuel tanks, we recommend Part #: 16-150, 19mm Outlet Offset HydraMat, to greatly reduce the potential of air entering the fuel system and limit fuel starvation during hard cornering, braking acceleration, inclines, and low fuel conditions. c. If upgrading with the new 16-150 HydraMat, install HydraMat by aligning the “V” shape of the rubber grommet to arrow on the mat, press firmly to seat.
  • Page 9 e. Slide long end of the HydraMat first along with tucking in the fuel sender float arm into the hole entrance. NOTE: Be cautious to not tear the HydraMat while inserting into tank. Lubricate the lock ring’s O-ring with Earl’s Assembly Lube. Lube it g.
  • Page 10 6. Factory Fuel Lines Removal This kit replaces the factory fuel lines with Black Nylon Braided Hose. The factory fuel lines will need to be removed and new hardware and clamps are provided. a. Remove all bolts on passenger side frame rail that attach the fuel lines with a 1/2” socket. Remove bolts b.
  • Page 11 7. Assembling Billet Fuel Filter a. Apply Thread Sealant with PTFE (not supplied) around the entire diameter of the leading threads onto two NPT to AN Adapters. Force the sealant onto the threads to thoroughly fill voids. Skip the first thread when applying sealant Apply to 3-4 threads b.
  • Page 12 8. Assembling Fuel Pressure Regulator a. Apply Thread Sealant with PTFE (not supplied) around the entire diameter of the leading threads onto one NPT Plug. Force the sealant into the threads to thoroughly fill voids. Skip the first thread when applying sealant Apply to 3-4 threads b.
  • Page 13 Apply to 3-4 threads c. Install Gauge by hand first, then use a 7/16” open-end wrench - turn clockwise to tighten. TECH TIP: Align Holley logo to be horizontal for that professional install while tightening - don’t loosen.
  • Page 14 10. Mounting Fuel Pressure Regulator Brackets This G-Body specific kit comes with a direct mount fuel pressure regulator bracket that mounts on the firewall using existing hardware. We noticed that on some models, the left hole labeled “L” below is dimpled and not tapped, if this is the case, use a self-tapping screw (not supplied).
  • Page 15 a. Using the polished bracket supplied with the regulator, mount it onto the Black firewall bracket using the supplied pan head screws and nylon-insert locknuts. With a Flat Head screwdriver and 3/8” wrench, do not fully tighten until the final position is determined once mounted on firewall. Front Back Pan head screws...
  • Page 16 11. Adjusting Fuel Pressure The regulator pressure comes preset to 60 PSI with a range from 15-60 PSI. However, for individual requirements, it may be readjusted: a. Loosen locknut with 5/8” open-end wrench and turn adjustment screw with 5.5mm Hex key. Loosen 5/8”...
  • Page 17 12. Assembling AN Hose AN fittings and hose will replace the factory fuel lines, here we’ll show a general way to assemble them: a. Cut the hose square to the required length with Hose cutting shears or equivalent. TECH TIP: Before cutting, wrap hose tightly with masking or electrical tape and cut through the tape. This helps prevent the braid from fraying and trim any frayed ends with cutting pliers.
  • Page 18 TECH TIP: Wrap tape around hose right against bottom of socket, this will be your visual aid to detect any tendency of the hose to be pushed out as you complete the assembly. c. Lubricate inside of the hose and the fitting’s threads with Earl’s Assembly Lube. Lube it d.
  • Page 19 TECH TIP: Line up the flats on the hose end for that professional install while tightening, don’t loosen Tighten until socket must be within 0.060” or less of bottoming on the hose end. 0.060” or less Check the tape to see if the hose end has pulled away from the hose, if it did back out more than ~1/16” out of the socket, try again by returning back to Step 12c.
  • Page 20 13. Routing Fuel Hoses With factory fuel lines removed, route the new Feed and Return Black nylon braided hoses in the same location as the original lines. New 5/8” P-Clamps and Frame Bolts will be mounted using the same existing threaded hole locations. Thus, these will be a direct replacement and will keep the fuel hoses in the OE location.
  • Page 21 b. Reference the following photos to aid installation: Frame bolts Frame bolts (5) Frame bolts (5)
  • Page 22 Feed Return 90° Hose End (x2) Vent NOTE: The 5/16” vent hose can be replaced with 3 feet of 750055ERL and clamps: 750005ERL (not supplied). Vent Return Frame bolt Feed Fuel tank 45° Hose End Fuel Filter with 1.5” P-Clamp Straight Hose End Fuel hoses tucked on passenger frame rail...
  • Page 23 Flame Guard starts here Flame Guard ends here Comes with enough hose from tank to fuel rails NOTE: Again, some extra fittings are provided but depending on what type of engine is being used and how fuel is being delivered, additional fittings may be necessary to adapt to the fuel injection system. Thus, we stopped at the engine bay to give as much flexibility to plumb the last connections onto the fuel rails or sniper.
  • Page 24 Always crimp or solder connections and ensure surface is clean/grind where ground is connected. Cover it all up with the provided split wiring loom for that factory-look install and you’re ready to go! a. Follow the wiring instructions supplied with Holley® P/N 40205G and make the following modifications: 20 A...