2501 Ludelle Street Fort Worth, Texas 76105 817-244-6212 Phone • 817-244-4024 Fax 888-350-6588 Sales • 800-423-9696 Tech E-mail: [email protected] Web: www.painlessperformance.com Installation Instructions #63000 Striker Diesel MD Power Module 2001-2004 Chevrolet Duramax 6.6L Diesel 1st Edition July 2008 Copyright © 2008 by Perfect Performance Products, LLC 1 TABLE OF CONTENTS Section Page Introduction………….....................................................................................................................3 Engine Harness Installation……………………………………………………………………………………………………….4 FPS Sensor Location and Connection……………………..………………………………………………………………….4 Boost Sensor Location and Connection……………………………………………………………………………………….5 Firewall Penetration………………………………………………………………………………………………………………….6 Diesel MD Mounting………………………………………………………………………………………………………………….7 Thermocouple Connection…………………………………………………………………………………………………………8 12 Volt Power Connection………….…………………………..…………………………………………………………………9 Ignition Switch Connection………………………………………………………………………………………………………10 Ground Connection…………………………………………………………………………………………………………………11 Finalizing Installation………………………………………………………………………………………………………………11 Initial Start-up………………………………………………………………………………………………………………………..12 Idle Calibration……………………………………………………………………………………………………………………….13 EGT Warning LED Set-up…………………………………………………………………………………………………………14 LCD Brightness Set-up…………………………………………………………………………………………………………….14 LCD Contrast Set-up……………………………………………………………………………………………………………….14 LCD Display Selection……………………………………………………………………………………………………………..15 Profile Selection………………………………………………………………………………………………………………………16 Storing User Configuration……………………………………………………………………………………………………….17 What are Profile Scale Factors…………………………………………………………………………………….……………18 Fuel Pressure Scale Factors…………………………….……………………………………………………………………….19 Boost Pressure Scale Factors……………………………………………………………………………………………………20 Modifying Scale Factors………………………………………………………………………………………………………21-22 Factory Refresh……………………………………………………………………………………………………………………..23 Trouble Shooting…………………………………………………………………………………………………………………….24 Warranty……………………………………………………………………………………………………………………………….25 2 Please read these entire instructions before beginning the installation. Make sure the ignition key has been off for two or more minutes before any connections are made. After a few simple connections the tune-ability that you have always wanted from your Duramax diesel will be available at a touch of a button. Welcome to the new era of plug in play diesel power modules. Parts List: 1- Striker Diesel MD Power Module 1- Engine Wire Harness 10- 7” tie wraps 1- Instruction Sheet 4- Inches Velcro 1- Parts Bag Kit Tool List: Phillips and flat head screwdrivers Wire strippers Terminal crimpers Drill and Drill bits 3/8 Ratchet and Metric sockets NOTE: The 63000 Striker Diesel MD kit does not include a thermocouple. The Diesel MD module has capabilities of reading a K-type thermocouple if you so choose to purchase and install one separately. If a thermocouple is already installed in your vehicle, you may double up the Diesel MD thermocouple wires with the mechanical gauge wires. If this doubling is done, you may experience a slight misreading of both the EGT gauges. 3 Harness Installation: The Striker Diesel MD Power Module is shipped with a harness to match your vehicles configuration. Harness altercations are not needed. If difficulties during installation are experienced please contact us via phone at 800-423-9696 or email to [email protected]. Three connections will be made in the engine compartment and two under the dash. Make sure to route all wires and connectors away from potential hot spots on the engine. Securely attach the wires using the supplied tie wraps. Intake Resonator To gain access to the Fuel Pressure Sensor and MAP sensor the intake resonator must be removed. It is attached to the engine with a hose clamp and Torx head bolt. Fuel Pressure Sensor Connector: The Fuel Pressure Sensor (FPS) is mounted on the driver side of the engine just in front of the turbo discharge tube. Disconnect the factory FPS sensor connector. Plug this male connector into the female FPS connector on the Diesel MD engine harness. See note on next page for specific instructions on how these connectors mate. Plug the male FPS connector on the Diesel MD engine harness into the FPS sensor mounted into the common fuel rail. 4 The illustration below shows the correct orientation for the mating of the factory Duramax male FPS connector to the female FPS connector on the Striker Diesel MD harness. Because of the tight seals built into this connector series, slight force may be needed in order for the CPA TAB to click up over the CPA RAMP. NOTE: Take care to plug these connectors in correctly. If you force them in backwards, you may burn up the FPS sensor and put the truck in limp mode. Boost Pressure Sensor (MAP) Connection: Locate the MAP sensor. On 2001- 2004 6.6L Duramax trucks the MAP sensor is located on the boost tubing directly in front of the waste gate actuator. Disconnect the factory male boost sensor connector from the sensor and plug it into the female MAP sensor connector on the Diesel MD engine harness that is labeled ECM. Plug the male MAP sensor connector labeled MAP on the Diesel MD engine harness into the MAP sensor. 5 Firewall Penetration On the driver side of the firewall there is a large rubber grommet. Using a sharp knife cut a slit into this grommet large enough for the ENGINE B connector on the Diesel MD engine harness and the thermocouple wire to pass through. Now go inside the cab and look up and left of the brake pedal. You will see the same grommet as you did from the engine compartment. This grommet is double walled. The second wall is about ½” thick and can be very hard to cut through. If you gently push a long, wide flat screwdriver from the engine compartment through the slit you cut, you can usually dislodge the inner part of this grommet from its outer ring. You only need to move this inner part out of the way enough to push through the ENGINE B connector and the thermocouple wire (if you are using it). 6 Mounting the Diesel MD: Since the Diesel MD module harness comes attached to the Diesel MD module, we suggest that you route the harness inside the cab and loosely tie wrap it in place. Keep in mind the ENGINE A connector must reach and plug into the ENGINE B connector on the engine harness. Below you see how we usually mount the Diesel MD with a suction cup window mount. Many electronic retailers offer suction cup window mounts that should allow you to mount the Diesel MD onto the windshield. If you choose this mounting solution, remove the fuse panel on the left side of the dash as shown to the right. Remove the two Phillips head screws that hold the dash skin in place. Gently pull the dash skin away from the dash brace enough to push the ENGINE A connector behind it. 7 One other potential place to keep the Diesel MD is the cubby hole just below the AC/Heat controls. Make sure when you route the Diesel MD module harness over to the hole in the firewall that you stay away from any moving parts of the steering column, brake, accelerator and gear shifter. In parts the kit is some Velcro. You can also use this Velcro to attach the Diesel MD module on the dash. Once you have decided where to mount the Diesel MD route the module harness over to the grommet in the firewall. Plug the ENGINE A and ENGINE B connectors together. Thermocouple: If you are not using a pyrometer then roll up the wire and store it inside the cab. If you are using a pyrometer, route the wire to the thermocouple and attach it using the two #6 ring terminals supplied from the parts kit. Wires connect red to red and yellow to yellow. Use the heat shrink provided from your thermocouple kit to protect the terminals from grounding. 8 Power and Ground: In the parts kit is a fuse holder, two brass terminals for the fuse holder, a 5 amp fuse, one blue Posi- tap, one yellow Posi-tap, one insulated ring terminal, two un-insulated ring terminals and two self tapping black sheet metal screws. On the Diesel MD module harness there is an orange wire labeled RUN/START 12VOLT and a black wire labeled GROUND. The orange power wire can be either connected to the fuse block behind the left side dash panel or directly to an ignition switch wire. Power: If you plan to wire the orange power wire for the Diesel MD into an ignition switch wire on the bottom of the steering column, please fuse the circuit. All of the parts you need to fuse this power circuit can be found in the parts kit. Find a good place to mount the fuse holder. Figure out what length the orange wire labeled RUN/START 12VOLT needs to be to reach the fuse holder. Cut it to length, strip 3/8” of the insulation from the copper and terminate one of the brass terminals to the wire. Take the extra orange wire from the parts kit and terminate the other brass terminal to one side of it in the same fashion. Push both terminated wires into the fuse holder. The terminals insert with the flat side to the outside of the fuse holder. Push the barbed steel mounting clip into the slot on the back side of the fuse holder. Use one of the black self tapping screws to mount the fuse holder. 9 IGNITION SWITCH WIRE: Remove the plastic cover from the front of the dash just under the steering column. Two screws hold this panel from the bottom. Two clips hold this panel to the dash. Remove the two screws and carefully pull the plastic cover towards the driver seat and away from the dash. You will most likely have to pop the dash bezel loose in order to remove this cover. Use a ratchet and 10mm socket to remove the fours nuts that attach the metal cover below the steering column. Locate the large pink wire coming from the ignition switch wires. This is the wire used to supply the Diesel MD 12 Volts with the ignition key in the run or start positions. Route the open ended orange wire from the fuse holder up to the pink ignition switch wire.