SALES: 1-800-396-6614 SALES:1800-396-6614 TECH: 1-800-531-5484
THANK YOU Thank you for choosing DiabloSport, the World's Greatest Automotive Performance Company. We hope that you enjoy your new Extreme PowerPuck. Although we would love to tell you that you are the first one to touch this individual Extreme PowerPuck that is not the case. The Extreme PowerPuck you are now holding has gone through many different hands to individually inspect each component to ensure it meets DiabloSport's highest standards.
End User License Agreement, Warranty and Disclaimer 1 w w w.D I A B L O S P O R T .
End User License Agreement, Warranty and Disclaimer THIS END USER LICENSE AGREEMENT (the “Agreement”) is an agreement between you, as the purchaser (the “Purchaser”) of either the Diablo Module (the “Module”) or the hand-held computer unit (the “Unit”), and as the manufacturer of the Product DiabloSport (“DiabloSport”). The Product and the Unit shall be referred to collectively herein as the “product” and DiabloSport Inc. shall be referred to herein as “DiabloSport”. 1.
End User License Agreement, Warranty and Disclaimer 3. Disclaimer. The Product is being sold with no warranties of any kind, express or implied. The Product is not endorsed by the manufacturer of your vehicle and there is no affiliation between DiabloSport and the manufacturer of your vehicle.
End User License Agreement, Warranty and Disclaimer 5.Warranty. Notwithstanding the provisions of the End User License Agreement, DiabloSport warrants the Product to be free from all defects in material and workmanship for 2 years from the date of original purchase. This limited warranty applies only to the original Purchaser of the Product.
End User License Agreement, Warranty and Disclaimer Product must be purchased at an DiabloSport Authorized Dealer in order to qualify for warranty. v. Removal of serial numbers and/or alteration of product or packaging will also void all warranties. c. DiabloSport shall not be held responsible for direct or indirect failures due to our product. d. DiabloSport shall not credit or repair any units that are not properly restored to the original backup upon time of return or may be VIN locked. i.
End User License Agreement, Warranty and Disclaimer 2. DiabloSport will not charge a fee for products that are not internet updateable or remotely updateable. Shipping charges may apply. iv. All products returned for update purposes must have a corresponding DiabloSport RMA number for processing. g. Returns and RMA/RGA policies and procedures i. DiabloSport will not warranty, credit, or exchange any product returned without a valid RMA number. 1. All RMA numbers are issued by DiabloSport RMA department. 2.
INDEX 2 w w w.D I A B L O S P O R T .
INSTALLATION INDEX Make/Model Year(s) Pages LIGHT DUTY TRUCKS Ford Powerstroke 6.0L Dodge 24 Valve 5.9L Dodge Cummins 5.9L C.R. Dodge 6.7L GM LB7/LLY 6.6L GM LBZ/LMM 6.6L JEEP Liberty CRD 2004.5-2007.5 2003-2006 2004-2007 2007.5+ 2001-2005 2006-2008 2005-2006 1-3 4-6 7-8 9-14 15-19 20-22 23-25 Cummins 8.3L CAPS 1998-2005 Cummins 8.3L C.R. 2005-2007 LLY-Topkick 6.6L Duramax 2004-2007 7.8L Duramax 2004.5+ CAT .C7/3126-C9 (1998-2005/2000-2007) INT. DT444 1992-2002 INT. DT466/DT530/DT570 1997-2003.5 INT.
CONTENT 3 w w w.D I A B L O S P O R T .
CONTENTS INSIDE YOUR DIABLO BOX 1. One(1) DiabloSport Extreme PowerPuck 2. One(1) DiabloSport Extreme PowerPuck Wiring Harness 3. One(1) DiabloSport Extreme PowerPuck adjustable 3 position switch or One(1) DiabloSport Extreme PowerPuck adjustable "Diablo Dial" switch. 4. Two(2) Zip Ties 5. One(1) strip of velcro 6. One(1) small tube Dielectric Grease * Depending on your vehicle application, your DiabloSport Extreme PowerPuck may/may not include the following items: Shim Kit w w w.D I A B L O S P O R T .
CONTENTS INSIDE YOUR DIABLO BOX w w w.D I A B L O S P O R T .
Installation of the DIABLOSPORT EXTREME POWERPUCK 4 w w w.D I A B L O S P O R T .
Pre-Installation Instructions Please be sure to read all instructions and have a complete understanding of them before you attempt to install you new DiabloSport Extreme PowerPuck. Please make sure to disconnect the battery and remove your keys from the ignition before beginning the installation process Before connecting any electrical components place a sufficient amount of Di-Electric grease onto each connection. NEVER UN-PLUG YOUR EXTREME POWERPUCK FROM YOUR VEHICLE WHILE THE ENGINE IS RUNNING.
1 INSTALLATION Ford Powerstroke 6.0L 2004.5-2007.5 1. Find a desired location under the hood of your vehicle to mount the DiabloSport Extreme PowerPuck. Ensure that the location you pick is free from extreme heat, moisture, and has sufficient room for mounting. We have found a good place to mount the Puck is on the canister directly behind the passenger’s side battery. 2004.5-2007.5 2. Route the adjustable switch through the firewall into the cab of your vehicle.
2 INSTALLATION 3. Locate your vehicle’s MAP sensor. This can be found on your vehicle’s passenger side of the engine compartment. It should be mounted to the heater box by a metal plate. 4. Unplug your vehicle’s factory harness from the MAP sensor and plug in the harness from your new DiabloSport Extreme PowerPuck. T .COM Ford Powerstroke 6.0L w w w.D I A B L O S P O R 2004.5-2007.5 5. Locate your vehicle’s injection control pressure sensor. This can be found on the passenger’s side valve cover.
3 INSTALLATION 6. Unplug your vehicle’s ICP sensor and plug the DiabloSport Extreme PowerPuck’s harness into it. 7. Mount the adjustable “Diablo Dial” in a convenient location inside the cab of your vehicle. 2004.5-2007.5 Ford Powerstroke 6.0L w w w.D I A B L O S P O R T .
4 INSTALLATION Dodge 5.9L 24 Valve 2003-2006 1. Using your supplied velcro strips securley mount the Extreme PowerPuck to a desired location. We recomend mounting the Extreme PowerPuck on top of the fuse and relay module. This module can be found on the drivers side of the engine compartment just in front of the battery. 2003-2006 Dodge 5.9L 24 Valve w w w.D I A B L O S P O R T .
5 INSTALLATION 2. On the driver's side just next to the valve cover you will find your vehicle's MAP sensor. The sensor should have a blue weather tight seal around it. Disconnect the harness currently plugged into your MAP sensor and plug in the Extreme PowerPuck's harness. 3. Just in front of the MAP sensor you will find the Fuel Pressure Sensor (FPS). As you did in step 2, disconnect the current harness and plug in the Extreme PowerPuck's harness. 2003-2006 Dodge 5.9L 24 Valve w w w.
6 INSTALLATION 4. Run the "Diablo Dial" switch wire through your vehicle's firewall to the DiabloSport Extreme PowerPuck 5. In a location of your choice, mount the "Diablo Dial" in you vehicle's cab 6. Reconnect your vehicle's battery and enjoy your drive! 2003-2006 T .COM Dodge 5.9L 24 Valve w w w.
7 INSTALLATION Cummins 5.9L Common Rail 2004-2007 2004-2007 1. Inside you engine compartment you will see six steel lines that run directly to the injectors. Next to this you will find your Fuel Injection rail. 2. Once the fuel injection rail is located, find your vehicle's fuel pressure sensor. this will be on the actual fuel injection rail. Dodge Cummins 5.9L Common Rail 3. Unplug you vehicle's fuel pressure sensor and plug in your new DiabloSport Extreme PowerPuck into the sensor. 4.
8 INSTALLATION 5. Using the included zip ties run the adjustable switch from the DiabloSport Extreme PowerPuck through the firewall into the cab of your vehicle making sure to route the cables away from any parts which may move and become entangled. w w w.D I A B L O S P O R T .COM Dodge Cummins 5.9L Common Rail Power increases as you turn the “DIABLO DIAL” clockwise 2004-2007 6. Mount the “DIABLO DIAL” in a convienent location.
9 INSTALLATION Dodge 6.7L 2007.5+ 1. Locate the plastic cover plate on top of the engine. Carefully remove the dipstick and 4 bolts holding the plastic cover plate. 2. After removing the plastic cover plate, locate the Exhaust Gas Recirculation tube. Using a 11mm wrench carefully remove the two clamps, which hold the EGR tube, in front of the valve cover without removing the EGR tube. 2007.5+ Dodge 6.7L w w w.D I A B L O S P O R T .
10 INSTALLATION 3. Locate the single bolt which holds the dipstick tube to the bracket and the 6 bolts which hold the air horn to the manifold. Using a 10mm socket and wrench remove all 7 bolts. Carefully slide the air horn forward so the front of the fuel rail is accessible. Please be careful not to damage the gasket 4. Carefully remove the 18mm fuel rail valve. This valve can be found on the front of the fuel rail. 2007.5+ Dodge 6.7L w w w.D I A B L O S P O R T .
11 INSTALLATION 5. Carefully screw the supplied nut tool onto the valve. Place the fuel rail valve into a vice. The vice should clamp down on the sides of the valve cap. 6. In order to remove the valve cap, carefully unscrew the nut. CAUTION: This piece is spring loaded. Be sure that you are holding the end of the valve while unscrewing to prevent a possible loss of parts. When removing the cap take note of how the holes inside the cap lined up with the spring. 2007.5+ Dodge 6.7L w w w.
12 INSTALLATION 7. By carefully removing the metal spring you can now place the three supplied metal shims into the valve. 8. Place the spring back into the valve and replace the cap. NOTE: The inside of the valve cap has three holes which form the shape of a triangle. Do not remove this and ensure that these holes face towards the spring as they did when you removed it. 2007.5+ T .COM Dodge 6.7L w w w.
13 INSTALLATION 9. To prevent damage to the valve seal surface, place the valve into the vice with a thick piece of cardboard or wood facing the valve cap. 2007.5+ Dodge 6.7L 10. Using your small punch and hammer, carefully re-apply the 3 factory indentations to the valve lip. These indentations should be applied to the lip where the valve casing covers the valve cap. In order to rotate the valve you may need to loosen the vice. When doing this be sure not to allow the spring to push the cap out.
14 INSTALLATION 11. Carefully re-install the fuel valve. Be sure to tighten the valve to 50 ft/lbs. 12. Line up the 6 bolt holes on the air horn with the 6 holes in the gasket and re-install the air horn. After the air horn is installed, re-connect the dipstick tube to the bracket on the air horn. 13. Carefully re-install the EGR tube. The easiest way to do this is to line up one side at a time and gently install the clamp leaving it loose enough for adjustment.
15 INSTALLATION GM Duramax LB7 & LLY 6.6L 2001-2005 1. Find a desired location under the hood of your vehicle to mount the DiabloSport Extreme PowerPuck. Ensure that the location you pick is free from extreme heat, moisture, and has sufficient room for mounting. 2001-2005 2. Route the adjustable switch through the firewall into the cab of your vehicle. Route the wire away from any moving devices and away from extreme heat that may burn the wire. Avoid cutting any factory wiring. GM Duramax LB7 & LLY 6.
16 INSTALLATION 3. Locate your vehicle’s MAP sensor. 4. For LB7 Applications the MAP sensor will be located under your vehicle’s air intake module on top of the vehicle’s engine. In order to access the MAP sensor you will need to remove the intake box and tube. T .COM GM Duramax LB7 & LLY 6.6L w w w.D I A B L O S P O R 2001-2005 5. For LLY Applications the MAP sensor will be located directly behind your vehicle’s AC compressor.
17 INSTALLATION 6. Unplug your vehicle’s factory harness from the MAP sensor and plug in the harness from your new DiabloSport Extreme PowerPuck. If you removed your AC-compressor re-attach your AC compressor with the bolts you removed and put the belt back on. 7. Locate your vehicle’s fuel pressure sensor. 2001-2005 GM Duramax LB7 & LLY 6.6L w w w.D I A B L O S P O R T .
INSTALLATION 18 8. For LB7 applications the Fuel Pressure Sensor is located just below the intercooler tube. You will need to remove the intercooler tube itself to expose the sensor. after plugging in the harness be sure to reconnect the tube) 9. For LLY applications the Fuel Pressure Sensor is located just below the air intake tube on the passenger’s side of the engine (see picture). w w w.D I A B L O S P O R T .COM GM Duramax LB7 & LLY 6.6L *Please See Graphic references on next page 2001-2005 10.
19 INSTALLATION 2001-2005 GM Duramax LB7 & LLY 6.6L w w w.D I A B L O S P O R T .
20 INSTALLATION GM Duramax LBZ & LMM 6.6L 2006-2008 1. Find a desired location under the hood of your vehicle to mount the DiabloSport Extreme PowerPuck. Ensure that the location you pick is free from extreme heat, moisture, and has sufficient room for mounting. 2. Route the adjustable switch through the firewall into the cab of your vehicle. Route the wire away from any moving devices and away from extreme heat that may burn the wire. Avoid cutting any factory wiring. w w w.D I A B L O S P O R T .
21 INSTALLATION 2006-2008 5. Locate your vehicle’s fuel pressure sensor. If sensor is found on the back of the fuel rail on the passenger side of the engine. See attached diagram for location of this sensor. GM Duramax LBZ & LMM 6.6L w w w.D I A B L O S P O R T .
22 INSTALLATION 6. Unplug your vehicle’s factory harness from the fuel pressure sensor and plug in the harness from your new DiabloSport Extreme PowerPuck. 7. Mount the adjustable “Diablo Dial” in a convenient location inside the cab of your vehicle. 2006-2008 T .COM GM Duramax LBZ & LMM 6.6L w w w.
23 INSTALLATION JEEP Liberty CRD 2005-2006 1. Find a desired location under the hood of your vehicle to mount the DiabloSport Extreme PowerPuck. Ensure that the location you pick is free from extreme heat, moisture, and has sufficient room for mounting. We have found a good place to mount the Puck is on the fuse box located on the driver’s side of the engine compartment directly in front of the battery. 2. Route the adjustable switch through the firewall into the cab of your vehicle.
24 INSTALLATION 3. Locate and remove your vehicle’s oil fillet cap and plastic engine cover. This will expose the sensors which you will need access to.(be sure to re-install the cap and cover after step 4 is completed) 4. Look for a connector with a blue weather seal. This is the MAP sensor. It can be found toward the back of the engine compartment atop the firewall just under the wipers on the driver’s side. 5.
25 INSTALLATION 6. Locate your vehicle’s fuel pressure sensor. This can be found just in front of the MAP sensor connector. It should have a orange indicator when disconnected 7. Unplug your vehicle’s factory harness from the fuel pressure sensor and plug in the harness from your new DiabloSport Extreme PowerPuck 8. Mount the adjustable “Diablo Dial” in a convenient location inside the cab of your vehicle. 2005-2006 Jeep Liberty CRD w w w.D I A B L O S P O R T .
26 INSTALLATION Cummins 8.3L CAPS 1998-2005 1. Locate you vehicle’s fuel pump. It can be found by locating the six large steel lines that run to your vehicle’s injectors. 2. On the back side of the fuel pump you will find you Vehicle’s fuel pressure sensor. The connection should Look identical to the connector on the DiabloSport PowerPuck Extreme’s harness. 3. Unplug you vehicle’s fuel pressure sensor and plug in the DiabloSport Extreme’s PowerPuck harness 4.
27 INSTALLATION 5. Using the picture below as a reference, locate your vehicle’s MAP sensor 6. Unplug your vehicle’s factory map sensor and plug in the harness From you new DiabloSport Extreme PowerPuck into the MAP sensor. 7. Taking the leftover connector plug it into the factory harness 8. Mount the DiabloSport Extreme PowerPuck in a safe location Using the supplied Zip Ties/Velcro 9. Route the adjustable switch through the firewall into the cab of your vehicle.
28 INSTALLATION 10. Mount the adjustable “Diablo Dial” in a convenient location inside the cab of your vehicle. T .COM Cummins 8.3L Caps w w w.
29 INSTALLATION Dodge Cummins 8.3L Common Rail 2005-2007 2005-2007 1. Inside you engine compartment you will see six steel lines that run directly to the injectors. Next to this you will find your Fuel Injection rail. 2. Once the fuel injection rail is located, find your vehicle's fuel pressure sensor. This will be on the actual fuel injection rail. 3. Unplug you vehicle's fuel pressure sensor and plug in your new DiabloSport Extreme PowerPuck into the sensor. Cummins 8.3L Common Rail 4.
30 INSTALLATION 6. Run the adjustable switch from the DiabloSport Extreme PowerPuck through the firewall into the cab of your vehicle. 7. Mount the switch in a convienent location. 2005-2007 Power increases as you turn the “DIABLO DIAL” clockwise Cummins 8.3L Common Rail w w w.D I A B L O S P O R T .
31 INSTALLATION GM Duramax LLY Topkick 6.6L 2004-2007 2004-2007 1. Find a desired location under the hood of your vehicle to mount the DiabloSport Extreme PowerPuck. Ensure that the location you pick is on the driver’s side and is free from extreme heat, moisture, and has sufficient room for mounting. 2. Locate your vehicle’s MAP sensor. See diagram for location of this sensor. 3.
32 INSTALLATION 2004-2007 w w w.D I A B L O S P O R T .COM Duramax LLY Topkick 6.6L 4. Locate your vehicle’s fuel pressure sensor. The fuel pressure sensor should be located on the back of the fuel rail, on the passenger side.
33 INSTALLATION 5. Unplug your vehicle’s fuel pressure sensor and plug the DiabloSport Extreme PowerPuck’s harness into it. 6. Route the adjustable switch through the firewall into the cab of your vehicle. Plug the connector into the DiabloSport Extreme PowerPuck. 7. Mount the adjustable “Diablo Dial” in a convenient location inside the cab of your vehicle. 2004-2007 Duramax LLY Topkick 6.6L w w w.D I A B L O S P O R T .
34 INSTALLATION DURAMAX 7.8L 2004.5-2007.5 1.Find a desired location under the hood of your vehicle to mount the DiabloSport Extreme PowerPuck. Ensure that the location you pick is on the driver’s side and is free from extreme heat, moisture, and has sufficient room for mounting. T .COM DURAMAX 7.8L w w w.D I A B L O S P O R 2004.5-2007.5 2. Locate your vehicle’s MAP sensor. This can be found by locating your vehicle’s intercooler and following it to the manifold.
35 INSTALLATION 3. Unplug your vehicle’s factory harness from the MAP sensor and plug in the harness from your new DiabloSport Extreme PowerPuck. 4. Locate your vehicle’s fuel rail. Once your fuel rail is located you should be able to find the fuel pressure sensor (see picture) 2004.5-2007.5 DURAMAX 7.8L w w w.D I A B L O S P O R T .
36 INSTALLATION 5. Unplug your vehicle’s injection control pressure sensor and plug the DiabloSport Extreme PowerPuck’s harness into it 6. Route the adjustable switch through the firewall into the cab of your vehicle. Plug the connector into the DiabloSport Extreme PowerPuck. 7. Mount the adjustable “Diablo Dial” in a convenient location inside the cab of your vehicle. 2004.5-2007.5 T .COM DURAMAX 7.8L w w w.
37 INSTALLATION Caterpillar C7/3126-C9 1998-2005/2000-2007 1. Find a desired location under the hood of your vehicle to mount the DiabloSport Extreme PowerPuck. Ensure that the location you pick is free from extreme heat, moisture, and has sufficient room for mounting. We have found a good place to mount the Puck is on the driver’s side. 1998-2005 / 2000-2007 CAT. C7/3126 - C9 2. Route the adjustable switch through the firewall into the cab of your vehicle.
38 INSTALLATION 3. Locate your vehicle’s fuel pressure sensor(ICP). This sensor can be found on the driver’s side of the engine block on the front side of the engine. The sensor can be identified by white, brown, and green wires. w w w.D I A B L O S P O R T .COM 1998-2005 / 2000-2007 CAT. C7/3126 - C9 4. Unplug your vehicle’s factory harness from the fuel pressure sensor and plug in the harness from your new DiabloSport Extreme PowerPuck.
39 INSTALLATION 5. To locate your vehicle’s MAP sensor, simply locate the intake manifold. This should be located on the rear of the engine closer to the driver’s side next to the valve cover. The MAP sensor can usually be identified by finding the sensor with green, white, and pink wires. 6. Unplug your vehicle’s factory harness from the MAP sensor and plug in the harness from your new DiabloSport Extreme PowerPuck. 1998-2005 / 2000-2007 CAT. C7/3126 - C9 7.
40 INSTALLATION International DT444 1992-2002 1. Find a desired location under the hood of your vehicle to mount the DiabloSport Extreme PowerPuck. Ensure that the location you pick is free from extreme heat, moisture, and has sufficient room for mounting. We have found a good place to mount the Puck is on the driver’s side. T .COM International DT444 w w w.D I A B L O S P O R 1992-2002 2. Route the adjustable switch through the firewall into the cab of your vehicle.
41 INSTALLATION 3. Locate your vehicle’s fuel pressure sensor(ICP). This sensor can be found on the driver’s side of the engine block on the front side of the engine. You will see a tube running from the intercooler to the engine. The fuel pressure sensor is located under this tube. 4. Unplug your vehicle’s factory harness from the fuel pressure sensor and plug in the harness from your new DiabloSport Extreme PowerPuck. 1992-2002 International DT444 5.
42 INSTALLATION International DT466/DT530/DT570 1997-2003.5 1. Find a desired location under the hood of your vehicle to mount the DiabloSport Extreme PowerPuck. Ensure that the location you pick is free from extreme heat, moisture, and has sufficient room for mounting. We have found a good place to mount the Puck is on the fuse box located on the driver’s side. T .COM INT. DT466/DT530/DT570 w w w.D I A B L O S P O R 1997-2003.5 2.
43 INSTALLATION 2.b Locate your vehicle’s fuel pressure sensor. This sensor can be found on the driver’s side of the engine block. If your vehicle is the DT466E the sensor can be found behind a computer next to the engine block. 3. Unplug your vehicle’s factory harness from the fuel pressure sensor and plug in the harness from your new DiabloSport Extreme PowerPuck. 1997-2003.5 INT. DT466/DT530/DT570 w w w.D I A B L O S P O R T .
44 INSTALLATION International DT466, DT530, DT570 2004-2006 1. Find a desired location under the hood of your vehicle to mount the DiabloSport Extreme PowerPuck. Ensure that the location you pick is free from extreme heat, moisture, and has sufficient room for mounting. We have found a good place to mount the Puck is on the driver’s side. 4. Unplug your vehicle’s factory harness from the fuel pressure sensor and plug in the harness from your new DiabloSport Extreme PowerPuck. w w w.
45 INSTALLATION 5. Locate your vehicle’s MAP sensor(see diagram). The MAP sensor should be located on the same side as the ICP sensor slightly toward the front of the engine. 6. Unplug your vehicle’s factory harness from the MAP sensor and plug in the harness from your new DiabloSport Extreme PowerPuck. 7. Mount the adjustable “Diablo Dial” in a convenient location inside the cab of your vehicle. 2004-2006 INT. DT466 - DT530 - DT570 w w w.D I A B L O S P O R T .
46 INSTALLATION International VT 365 2003-2007 1. Find a desired location under the hood of your vehicle to mount the DiabloSport Extreme PowerPuck. Ensure that the location you pick is free from extreme heat, moisture, and has sufficient room for mounting. We have found a good place to mount the Puck is on the driver’s side. 2. Route the adjustable switch through the firewall into the cab of your vehicle. Route the wire away from any moving devices and away from extreme heat that may burn the wire.
SALES: 1-800-396-6614 TECH: 1-800-531-5484 www.DIABLOSPORT.
