The following are copies of our instruction manuals.
DuraMax Diagnostic Manual
Diesel Tools . Net
HEUI Injector Control Module
User Manual
1999 –2004
Duramax Edition
Getting Started
Tools and supplies
To assure a complete diagnostic and a timely repair, the following Is a minimum recommendation list of tools and supplies:
1. Engine shop manual.
2. A 0-100 PSI gauge with a 90* Shrader attachment.
3. A compression tester rated to 750 PSI with a glow plug adapter.
4. Spare injector O-ring seals and copper injector seals.
5. Scan Tool capable of performing a KOEO injector Electrical Self-Test (“Buzz” Test).
Injector Control Module
Control Module
The Control Module (CM) is a rugged, shop-quality device. It houses a series of control switches, wired through the case for attachment of the engine adapter harness.
Engine Adapter
The engine Interface Adapter (EA) allows the CM to be used on multiple engines from various manufactures. See your distributor for a list of available adapters.
Preparing To Test
Install the ICM as described on page 3. Route the harness away from the fan, pulleys, and hot exhaust. Secure the CM in an area where it is protected from falling and attach the EA.
Safety Precautions
· Always wear protection eyewear.
· Be sure the ignition switch is off unless required by the diagnostic procedure.
· Set the park brake and chock the wheels.
· Operate the vehicle in a well-ventilated area.
· Keep yourself, clothes, jewelry, and hair away from moving parts when operating this engine.
· Avoid contact with the engine related parts such as exhaust system, cooling system, and radiator.
· Use extreme caution around and about the engine fan, drive belts, and pulleys.
· Use extreme caution around the wiring harness. Voltages as high as 115VDC are present.
Pretest Inspections
As always, first verify the concern. Once verified, certain base engine items should be checked before using the Injector Control Module to test cylinder contribution. This procedure assumes there are no other active sensor faults and the ML lamp is not on.
1. Inspect vehicle for sufficient, clean diesel fuel. Obtain a sample from the fuel filter while cranking the engine.
2. Inspect the engine oil level. Check for contaminants (fuel, coolant). Verify last oil change is current and oil type is correct. Check oil level in reservoir as per instructions in the shop manual.
3. Inspect the air filter restriction indicator (if equipped) and make sure engine air inlet system is free of obstructions.
4. Inspect for fuel supply aeration. Install a clear fuel hose between fuel filter and fuel return line as per the engine shop manual. View clear line for steady air bubbles during low idle speeds.
5. Perform a visual inspection of the engine wiring paying close attention to abrasion, routing issues and insulation damage.
Service or correct any discrepancies before performing a cylinder test.
Engine Harness Connector Locations for All Models Built With Duramax Diesel
1999 - 2004 : Connector is above engine, left of longitudinal center of vehicle, center of engine just below the connector in the circle. (See picture)
Installation
1. Verify the ignition key is off and the park brake is set.
Locate the engine harness connector.
2. Disengage the connector from the retaining clip and separate the connector hard shell halves.
3. Attach the appropriate ends of the engine Adapter (EA) to the engine harness connector halves and secure.
4. Connect the EA to the control module.
Performing The Cylinder Contributing Test With A Scan Tool
If desired, a Scan Tool (Snap-On MT2500 with a VCI and MT2500-1098 OBD2 Interface) can be used to monitor Fuel Rate (mm3) parameter. The “Fuel Rate mm3” is the amount of total fuel the ECM is requesting. Fuel Rate will increase momentarily when a contributing injector is shut off. A low or non-contributing injector will cause little or no increases in Fuel Rate when shut off.
1. Start the engine and note the baseline Fuel Rate. (Range 0 to 80 mm3) The numbers on the screen will fluctuate so the average should be used for comparisons. The ICU will perform the Cylinder Contribution Test at any engine temperature and can be used during the test drive once the concern is verified.
2. Press the hold injector #1 button on the control module and note the momentary change Fuel Rate. This is the contribution Cylinder #1. Release the button.
3. Repeat step 2 on Cylinders #2 through 8.
4. The cylinder (s) with the least momentary change observed when switched off should be considered weak or defective.
5. This test may set a diagnostic Trouble Code (DTC). You must clear the DTCs at the completion of the repair.
Interpreting The Results
Prior to replacing an injector, check base engine.
Perform a compression test on all faulty cylinders and compare to a strong cylinder. If the compression tests within 75% of the strong cylinder, replace the suspect injector. If the compression tests below 75% of the strong cylinder, service or repair the condition per the shop manual.
Performing The Cylinder Contribution Test Without A Scan Tool
1. Start the engine and note the baseline idle speed. The IPA will perform the Cylinder Contribution Test at any engine temperature and can be used during test drive once the concern is verified.
2. Press and hold injector #1 button on the Control Module and immediately note the idle speed drop. This is the contribution of Cylinder #1. Release the button.
3. Repeat step 2 on the Cylinders #2 through #8. Cylinders having the largest RPM drop are presumed to be contributing the most power. A healthy engine should produce a fairly consistent RPM drop on all cylinders. A cylinder with minimal or no RPM drop is faulty.
This test may set a Diagnostic Trouble Code (DTC). You must clear the DTCs at the completion of the repair.
WARRANTY STATEMENT
This product is warranted free from manufacture’s defects for a period of one (1) year for the date of purchase.
For warranty consideration, contact:
Mission Valley Truck Equipment
780 East Brokaw Rd.
San Jose , CA. 95112
(408)933.2300
service@missionvalleyford.com
We reserve the right to repair or replace a defective unit. This warranty excludes damage caused by improper use and/or uses not intended. Warranty is void if case seal is broken.
Ford PowerStroke 7.3 Service Tip
The tool referanced in the following article, 164-R25535 is the same product available at on this site. dieseltools.net, a division of Mission Valley Ford Truck Sales Inc. is the patent owner and is now selling direct to end users.
PowerStroke Diagnostic Manual
HEUI PowerStroke User Manual
Safety Precautions
· Always wear protection eyewear.
· Be sure the ignition switch is off unless required by the diagnostic procedure.
· Set the park brake and chock the wheels
· Operate the vehicle in a well-ventilated area.
· Keep yourself, clothes, jewelry, and hair away from moving parts when operating this engine.
· Avoid contact with the engine related parts such as exhaust system, cooling system, and radiator.
· Use extreme caution around and about the engine fan, drive belts, and pulleys.
· Use extreme caution around the wiring harness. Voltages as high as 115VDC are present.
Getting Started
Tools and supplies
To assure a complete diagnostic and a timely repair, the following is a minimum recommendation list of tools and supplies:
1. Engine shop manual.
2. A 0-100 PSI gauge with a 90* Shrader attachment.
3. A compression tester rated to 750 PSI with a glow plug adapter.
4. Spare injector O-ring seals and copper injector seals.
5. Scan Tool capable of performing a KOEO injector Electrical Self-Test (“Buzz” Test).
Injector Control Module
Control Module
The Control Module (CM) is rugged, shop-quality device. It houses a series of control switches, wired through the case for attachment of the engine adapter harness.
Engine Adapter
The engine Interface Adapter (EA) allows the CM to be used on a multiple engines from various manufacturers. See your distributor for a list of available adapters.
Preparing to Test
Install the ICM as described on page 3. Route the harness away from the fan, pulleys, and hot exhaust. Secure the CM in an area where it is protected from falling and attach the EA.
Pretest Inspections
As always, first verify the concern. Once verified, certain base engine items should be checked before using the injector Control Module to test cylinder contribution. This procedure assumes there are no other active sensor faults and the ML lamp is not on.
1. Inspect vehicle for sufficient, clean diesel fuel. Obtain a sample from the fuel filter while cranking the engine.
2. Inspect the engine oil level. Check for contaminants (fuel, coolant). Verify last oil change is current and oil type is correct. Check oil level in reservoir as per instructions in the shop manual.
3. Inspect the air filter restriction indicator (if equipped) and make sure engine air inlet system is free of obstructions.
4. Inspect for fuel supply aeration. Install a clear fuel hose between fuel filter and fuel return line as per the engine shop manual. View clear line for steady air bubbles during the low idle speeds.
5. Inspect the fuel pressure regulator for debris as per the engine shop manual. Measure fuel pressure at regular block. Compare results to shop manual specifications.
6. Verify that all injector solenoids are operational by performing a KOEO injector Electrical Self-Test (“Buzz” Test) using an NGS, SBDS, WDS or generic scan tool.
7. Inspect for a defective Dual Mass Flywheel, if so equipped.
Service or correct any discrepancies before performing a cylinder.
Installation
1. Verify the ignition key is off and park brake is set. Locate the engine harness connector.
2. Disengage the connector from the retaining clip and separate the connector hard shell halves.
3. Attach the appropriate ends of the engine Adapter (EA) to the engine harness connector halves and secure.
4. Connect the EA to the control module.
Engine Harness Connector Locations for Ford 7.3 DIT (Power Stroke)
· ’94-’98 F-Series: Connector is on the left fender well, aft of the air inlet ducting.
· ’99-Present F-Series: Connector is on the left-hand valve cover under the air inlet ducting. Remove the duct to gain access to the connector.
· ’94-present E-Series: Connector is under the center of the cowl behind the engine inlet ducting.
Performing the Cylinder Contribution Test Without a Scan Tool
1. Start the engine and note the baseline idle speed. The IPA will perform the Cylinder Contribution Test at any engine temperature and can be used during test drive once the concern is verified.
2. Press and hold injector #1 button on the Control Module and immediately note the idle speed drop. This is the contribution of Cylinder #1. Release the button.
3. Repeat step 2 on the Cylinders #2 through #8. Cylinders having the largest RPM drop are presumed to be contributing the most power. A healthy engine should produce a fairly consistent RPM drop on all cylinders. A cylinder with minimal or no RPM drop is faulty.
4. This test will set a Diagnostic Trouble Code (DTC). You must clear the DTCs at the completion of the repair.
Performing the Cylinder Contributing Test with a Scan Tool
If desired, a Scan Tool (NGS, SBDS, WDS, or Generic) can be used to monitor the Mass Fuel Desired (MFDES) parameter. MFDES values increase when a contributing injector is shut off. A low or non-contributing injector will cause little or no increases in MFDES when shut off.
1. Start the engine and note baseline MFDES. Then numbers on the screen will fluctuate so the average should be used for comparisons. The ICM will perform the Cylinder Contributions Test at any engine temperature and can be used during the test drive once the concern is verified.
2. Press the hold injector #1 button on the control Module and note the average MFDES. This is the contribution Cylinder #1. Release the button.
3. Repeat step 2 on Cylinders#2 through 8.
4. The cylinder(s) with the least change observed when switches should be considered weak or defective.
5. This test will set a diagnostic Trouble Code (DTC). You must clear the DTCs at the completion of the repair.
Interpreting the Results
Prior to replacing an injector, check base engine.
Perform a compression test on all faulty cylinders and compare to a strong cylinder. If the compression tests within 75% of the strong cylinder, replace the suspect injector. If the compression tests below 75% of the strong cylinder, service or repair the condition per the shop manual.
Warranty Statement
This product is warranted free from manufacture’s defects for a period of one (1) year from the date of purchase.
For warranty considerations, contact:
Mission Valley Truck Equipment
780 East Brokaw Rd.
San Jose, CA 95112
(408)933.2300
info@dieseltools.net