INSTALLATION INSTRUCTIONS - · PDF fileINSTALLATION INSTRUCTIONS 6 Position Chip Installation Instructions for 1995-2003 7.3L Ford Powerstroke® Diesel DieselManor, Inc. 61 Peppermint

INSTALLATION INSTRUCTIONS

6 Position Chip Installation Instructions for 1995-2003 7.3L Ford Powerstroke® Diesel

DieselManor, Inc. 61 Peppermint Street Goffstown, NH 03045 www.dieselmanor.com [email protected] Phone 603-497-2281

DIESELMANOR PRODUCTS FOR FORD POWERSTROKE®

6 Position Chip Installation

PROFILE CHIP Customer Name: Pos 1:

Chip SN: Pos 2:

Burn Date: Pos 3:

Truck Year/Model: Pos 4:

Cab/Chassis: Pos 5:

Transmission: Pos 6:

P-Type:

Box Code:

Default Code:

Other:

DieselManor, Inc. 61 Peppermint Street

Goffstown, NH 03045 © 2009 – All Rights Reserved

No unauthorized duplication permitted without written permission from the publisher. Documentation number: DM-TS73LMPC-1.5

Printed in the U.S.A.


DM-TS73LMPC -1.5 Page 3 Copyright © 2009 DieselManor, Inc.

Distribution or duplication without permission is prohibited.

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Dear Customer, Thank you for purchasing your 6 Position Chip from DieselManor. We know that you have many choices regarding where you purchase your diesel performance products from. We appreciate your business and your 100% satisfaction is what we strive for. Please take a moment to read over this installation guide to familiarize yourself with the procedure, all of the enclosed components, and the tools required to install your new chip. This document is intended to guide you through the installation process of a 6 Position Chip. Throughout this guide you will find small pictures corresponding to the task being performed. A larger picture of the same image can be found toward the end of this document. While most of our customers have no difficulty installing their chip themselves, if you feel that it is beyond your capability we suggest that you take your vehicle to a qualified mechanic for the installation. The typical installation time for the average home mechanic is about 45 minutes.

WORK SAFELY ! Your safe work habits will make the installation of this product go smoothly

and be more enjoyable. Think SAFETY at all times. Please be sure to read and pay attention to all safety notes in this guide.

INSTALLATION:

Disconnect both of the negative battery terminals before starting any of the installation. Failure to do so can result in damage of the vehicles PCM (computer).

1. In the engine compartment below the brake master cylinder you will find

the PCM connector. There are 3 different connectors in this area. The PCM connector is the one that is closest to the drivers side fender and has a single 10mm. bolt holding it in place. Remove the bolt and pull the connector off (see Figure 1).

2. From inside the cab, locate the PCM. It is just forward of the parking brake pedal and to the far left of the under dash area. First remove the two 7mm. bolts holding the black plastic PCM housing to the metal PCM mounting bracket . These bolts are located at the rear of the computer. Next, remove the two 10mm. fasteners holding the metal PCM mounting bracket in place. One of the 10mm. fasters is a bolt that is located above the top of the PCM and through the metal bracket, and threads into the left side (drivers side) of the under dash kick panel area. The other 10mm. fastener is a nut and is located at the bottom of the computer on the firewall (see Figure 2). NOTE: 1995-1997 Powerstoke owners will have to remove the emergency pedal assembly by removing three 13mm mounting bolts to gain access to the PCM.

3. Remove the PCM from the firewall and away from the metal bracket. Remove the black plastic sleeve from the computer by sliding it outward.

4. With the PCM removed, place it on a clean workbench. Before proceeding any further, you must verify that the PCM Code on the computer sticker is the same as what was entered on page 2 of this instruction sheet. In this example the computer PCM code is DPC-422 (see Figure 3) and the P-Type entered on page 2 of this customer’s installation instructions should be the same.

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Figure 7

You will now be preparing it for the chip. Remove the black plastic access port cover on the end of the computer opposite of the wiring block connector. The cover may be fastened with a screw, but most are just snapped into place.

5. With the cover removed, the printed circuit board edge connector will be visible. Both sides of the

connector MUST BE CLEANED COMPLETELY! Failure to do so could result in the chip not working correctly, damage to the chip and/or PCM, and failure in starting the truck. NOTE: Damage to chip due to improper installation is not covered by the warranty. Both sides (top and bottom) of the edge connector must be cleaned for a proper connection of the chip module. The edge connector is encapsulated with a clear lacquer and/or silicone grease covering. Remove the silicone coating with a clean soft cloth dampened with lacquer thinner, alcohol, or acetone (nail polish remover). NOTE: The printed circuit board of the PCM is delicate. Avoid using excessive force on it during the cleaning process. After the silicone grease has been removed, use the supplied scotch-brite pad to remove the lacquer coating. It is permissible to apply a small amount of lacquer thinner or acetone to the scotch-brite pad to aid in removal of the coating. NOTE - DO NOT erode any of the silver material on the edge connectors while cleaning the contacts of silicone or lacquer coatings. DO NOT spray any cleaning chemicals into the computer! Finally wipe the edge connector dry with another clean soft cloth and check for any debris you find. Refer to Figure 4 for what the edge connector should look like after proper cleaning. NOTE: Most installation problems are due to incomplete edge connector cleaning. Once again, BOTH SIDES of the edge connector need to be cleaned for proper communication between the chip module and the PCM. After you are satisfied that the edge connector is properly cleaned, place the PCM aside. You will be installing it shortly.

6. Before installing the chip module you should decide where you want to mount the selector knob. Mount the knob anywhere that is convenient for the driver. It can be exposed or hidden. In Figure 5 the knob is mounted on the bottom of the steering column. If the chip has been programmed with the Anti-Theft feature you may want it in an inconspicuous location such as the metal brace behind the fuse panel cover with the knob mounted downward. The knob is held in place with a 2mm. set screw. A 3/8” hole is required for the shaft of the knob to protrude through. You will also notice that there is a small round index pin between the number 2 and 3 position of the switch (see figure 6 green arrow). This is to keep the entire selector switch from turning when the knob is operated. You should drill a 1/8” hole for this pin, 1/4" on-center from the edge of the shaft hole you just drilled. The distance from hole to hole O.C. is 0.475”. There is also an index washer (Figure 6 blue arrow) that is used for limiting the number of positions of the switch. If you have purchased a 6 position switch, the small detent in this washer should be set to the #6 hole. After you have mounted the switch, route the cable toward the ECM.

7. Next you will be installing the chip module. Before you can do that you need to route the selector switch cable through the black PCM sleeve. You will need to make an elliptical hole for the cable connector to pass through (see Figure 7). Pass the cable through the hole and connect the cable connector to the chip module with the notched side of the connector facing away from the chip module. Next, gently insert the chip module into place on the edge connector until the connector bottoms out on the PCM’s circuit board. There will be a small portion of the chip module that is not flush with the computer case (see Figure 8). This is by design to ensure that the chip module will be held in place by the black plastic sleeve housing. Next apply a piece of cloth backed tape to the chip module to prevent any movement (see Figure 9).




Figure 9

Figure 8

8. With the PCM fully seated in the black sleeve, insert it back in the metal mounting bracket and so that the large connector passes through the firewall grommet. Note: The side of the PCM that has the “X” stamped on it should be toward the far left of the vehicle (see figure 8). Also note that there is a small metal clip that needs to be inserted into the black plastic sleeve prior to installing the PCM. Insert this clip so that it’s hole protrudes through the slit in the plastic sleeve. Fasten the metal bracket with the 10mm. bolt and nut you removed earlier. Reinstall the two 7mm. screws that hold the plastic sleeve to the metal bracket. Make sure that the selector switch cable will not interfere with the operation of the vehicle. Any excess should be secured with cable ties.

9. From under the hood, reinsert the PCM wiring block and secure it with its

10mm. bolt. Reconnect the negative battery cables. Check the position of the selector switch ensuring that the chip is in a suitable setting. Position 1 is fully counter clockwise. Start the engine and let it idle. If the Check Engine Light fails to shut off normally after the truck is started then the PCM has gone into Limp Mode. This is due to improper cleaning of the edge connector.

We would like to thank you again for purchasing your 6 Position Chip from DieselManor. If you experience any problems with this product please give us a call so that we can resolve the problem immediately. Your complete satisfaction is what we strive for. For service and support: 603-497-2281 or Email: [email protected]

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DISCLAIMER OF LIABILITY

NOTICE – THIS IS A PERFORMANCE PRODUCT AND IS INTENDED FOR OFF ROAD USE ONLY – USE AT YOUR OWN RISK

Do not use this product until you have carefully read the following agreement.

This product may affect the ability of your dealer to diagnose any problem on your vehicle, so it must be removed before taking it to your dealer.

This agreement sets forth the terms and conditions for the use of this product. The installation of this product indicates that the buyer has read and understands this agreement and accepts the terms and

conditions. DieselManor, Inc., its distributors, jobbers, and authorized dealers (hereafter “Seller”) shall be in no way responsible for the product’s proper use and service. THE BUYER HERBY WAIVES ALL LIABILITY CLAIMS. The Buyer acknowledges that he or she is not relying on the Sellers skill or judgment to select or furnish goods suitable for any particular purpose and that there are no liabilities which extend beyond the description on the face hereof, and the Buyer hereby waives all remedies or liabilities expressed or implied, arising by law or otherwise, (including without any obligations of the Seller with respect to fitness, merchantability and consequential damages) or whether or not occasioned by the Seller’s negligence. The Seller disclaims any warranty and expressly disclaims any liability for personal injury or damages. The buyer acknowledges and agrees that the disclaimer of any liability for personal injury is a material term for this agreement and the Buyer agrees to indemnify the Seller and to hold the Seller harmless from any claim related to the item of the equipment purchased. Under no circumstances will the Seller be liable for any damages or expenses by reason of use or sale of any such equipment or product. The Seller assumes no liability regarding the improper installation or misapplication of its products. It is the installer’s responsibility to check for proper installation and if in doubt contact the manufacturer. The Buyer is solely responsible for all warranty issues from the merchandise.

LIMITATIONS OF WARRANTY DieselManor, Inc., (hereafter “Seller”) gives Limited Warranty as to description, quality, merchantability, and fitness for any particular purpose, productiveness, or any other matter of Seller’s product sold herewith. The Seller shall be in no way responsible for the products proper use and service and the Buyer hereby waives all rights other than those expressly written herein. This warranty shall not be extended, altered or varied except by a written instrument signed by the Seller and Buyer. The Warranty is Limited to one (1) year from the date of sale and limited solely to the parts contained within the products kit. All products that are in question of Warranty must be returned prepaid to the Seller and must be accompanied by a dated proof of purchase receipt. All Warranty claims are subject to approval by DieselManor, Inc. Under no circumstances will the Seller be liable for any labor charged or travel time incurred in diagnosis for defects, removal, or reinstallation of this product or any other contingent expenses. Under no circumstances will the Seller be liable for any damage or expenses incurred by reason of the use or sale of any such equipment. IN THE EVENT THAT THE BUYER DOES NOT AGREE WITH THIS AGREEMENT: THE BUYER MAY PROMPTLY RETURN THIS PRODUCT, IN A NEW AND UNUSED CONDITION, WITH A DATED PROOF OF PURCHASE TO THE PLACE OF PURCHASE WITHIN FIFTEEN (15) DAYS FROM DATE OF PURCHASE FOR A FULL REFUND. THE INSTALLATION OF THIS PRODUCT INDICATES THAT THE BUYER HAS READ AND UNDERSTANDS THIS AGREEMENT AND ACCEPTS ITS TERMS AND CONDITIONS.

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INSTALLATION INSTRUCTIONS - · PDF fileINSTALLATION INSTRUCTIONS 6 Position Chip Installation Instructions for 1995-2003 7.3L Ford Powerstroke® Diesel DieselManor, Inc. 61 Peppermint