DIESEL EGT GUGE INSTLLTION INSTRUCTIONS P4D4-9235- Revision: - Dated 3/9/4 Replaces: None
DIESEL EGT GUGE INSTLLTION HRDWRE CONTENTS P4D4-44- - DIESEL EGT GUGE KIT COMPONENT - DIESEL EGT GUGE SSY (PRT # P4D4-4800-) B - RELY (PRT # 43000) C - RELY SOCKET (PRT # 450003) D - TERMINL - RELY SOCKET (PI TO PRT # 450003) E - -MP FUSE (PRT # 420004) F - FUSE HOLDER W/WIRE LED (PRT # 4000) G- 5-MP FUSE (PRT # 420003) H - FUSE HOLDER (PRT # 40000) J - /4" RING TERMINL (PRT # 480000) K - #0 RING TERMINL (PRT # 48000) L - SELF TP SCREW (PRT # 950000) M - 8" TIE STRP (PRT # 50000) N - 8 G. RED WIRE (L=5') (PRT # 49002) P - /4" SPLIT CORRUGTE (L=20') (PRT # 350047) QTY 5 2 2 3 5 B E G C D F H J M N P K L
CRITICL PROCESS OPERTION 0 MKE SURE THE ENGINE IS COOL BEFORE STRTING THIS PROCEDURE 0) BEGIN BY INSTLLING THE THERMOCOUPLE INTO THE EXHUST, THEN WORK BCK TO THE GUGE. INSTLLING THE PROBE IN THE PROPER LOCTION WILL INSURE OPTIML TEMPERTURE REDINGS. 20) FOR NON-TURBO ENGINES INSTLL THE PROBE -2 INCHES FROM THE CYLINDER HED 30 20) FOR TURBO ENGINES REMOVE THE EXHUST MNIFOLD ND INSTLL THE PROBE -2 INCHES FROM THE CYLINDER HED; IF THE EXHUST MNIFOLD CNNOT BE REMOVED, INSTLL THE PROBE -2 INCHES FTER THE TURBO EXHUST OUTLET (EXHUST GS TEMPS COULD DROP OVER 200 WHEN INSTLLING FTER THE TURBO); CLEN LL METL FILINGS OUT OF THE EXHUST MNIFOLD. METL FILINGS WILL DMGE THE TURBO IMPELLOR IF THEY GO THROUGH THE TURBO. THE PROBE CN BE MOUNTED IN TWO DIFFERENT WYS, SO PLESE USE THE METHOD BEST SUITED FOR YOUR NEEDS 30) PRE-EXISTING /8" NPT THREDED HOLE SIMPLY SCREW THE THREDED INTO THE HOLE, INSERT THE PROBE ND TIGHTEN THE SET SCREW SNUGLY ONTO THE PROBE CUTION: DO NOT OVERTIGHTEN THE SET SCREW OR DMGE TO THE PROBE MY OCCUR MKE SURE THE PROBE IS ORIENTED SO THE WIRES DO NOT COME IN CONTCT WITH, OR BECOME TOO CLOSE TO THE MNIFOLD OR OTHER HOT ENGINE PRTS. PRT NUMBER QTY P4D4-4800- DESCRIPTION DIESEL EGT GUGE SSY TOOLS PROCESS NME DIESEL EGT GUGE INSTLLTION P4D4-9235- PGE OF 8
CRITICL PROCESS OPERTION STINLESS CLMP METHOD 30) THIS METHOD IS FOR PPLICTIONS THT REQUIRE FREQUENT REMOVL OF THE MNIFOLD OR HEDER FOR SERVICE, OR JUST FSTER ND ESIER INSTLLTION. 30 DRILL 7/6" DIMETER HOLE BOUNT 6" DOWN FROM THE JUNCTION OF THE EXHUST PIPE TO MNIFOLD JUNCTION. UNDO THE CLMP ND SLIDE THE PROBE INTO THE HOLE IN THE CLMP. SLIDE THE SET SCREW COLLR ONTO THE PROBE. BEFORE TIGHTENING THE COLLR IN POSITION, MKE SURE THT WHEN INSERTED, THE PROBE WILL HVE ITS TIP IN THE MIDDLE TWO-THIRDS OF THE EXHUST STREM. TIGHTEN SCREW COLLR IN POSITION. CUTION: DO NOT OVERTIGHTEN SET SCREW OR DMGE TO PROBE MY OCCUR HOLD THE CLMP OPEN WHEN INSERTING THE PROBE INTO THE 3/32" HOLE. RE-JOIN THE CLMP ENDS ND TIGHTEN IN POSITION. MKE SURE THE PROBE IS ORIENTED SO THE WIRES DO NOT COME IN CONTCT WITH, OR BECOME TOO CLOSE TO THE MNIFOLD OR OTHER HOT ENGINE PRTS. 40) WITH THE PROBE INSTLLED, ROUTE THE WIRE HRNESS TOWRD THE DSH PNEL OF THE VEHICLE 50) DISCONNECT THE NEGTIVE (-) BTTERY CBLE PRT NUMBER QTY DESCRIPTION TOOLS P4D4-4800- DIESEL EGT GUGE SSY 7/6" DRILL BIT DRILL PROCESS NME DIESEL EGT GUGE INSTLLTION P4D4-9235- PGE 2 OF 8
CRITICL PROCESS OPERTION 60) LOCTE EXISTING HOLE IN THE DSH PNEL, OR DRILL " DIMETER HOLE. P 70) 80) OBTIN THE /4" CORRUGTE (P) FROM THE KIT; STRTING FROM CONNECTOR END OF THE WIRE HRNESS, INSTLL PRROXIMTELY -2 FT. OF CORRUGTE ONTO THE WIRE HRNESS. OBTIN THE RUBBER GROMMET; CUT SLIT INTO THE GROMMET ND INSTLL THE GROMMET ONTO THE WIRE HRNESS WITH THE CORRUGTE INSTLLED; INSERT THE CONNECTOR END OF THE WIRE HRNESS INTO DSH PNEL HOLE; LIGN ND SET GROMMET INTO HOLE 90) FROM INSIDE THE VEHICLE, DETERMINE SUITBLE LOCTION FOR THE GUGE IN CLOSE PROXIMITY TO THE WIRE HRNESS (THE GUGE MOUNTS IN 2-/6" DIMETER HOLE - DRILL IS NECESSRY) NOTE - THE WIRE HRNESS IS N INTEGRL PRT OF THE GUGE CLIBRTION ND CN NOT BE SHORTENED OR LENGTHENED WITHOUT FFECTING THE GUGE CLIBRTION. 00) USING THE SUPPLIED BRCKETS ND NUTS, SECURE THE GUGE TO THE DSH PNEL 60 70 80 90 00 PRT NUMBER QTY DESCRIPTION TOOLS P 350047 /4" SPLIT CORRUGTE (L=20') 2-/6" HOLE SW " HOLE SW DRILL PROCESS NME DIESEL EGT GUGE INSTLLTION P4D4-9235- PGE 3 OF 8
CRITICL PROCESS OPERTION 0 20 30 0) FROM UNDERNETH THE INSTRUMENT PNEL, LOCTE ND GRSP THE DIESEL EGT GUGE WIRE HRNESS ND CONNECTOR; LIGN ND SET THE WIRE HRNESS ND CONNECTOR INTO THE BCKSIDE OF THE GUGE (PUSH/PULL CONNECTOR TO VERIFY FULLY SETED) 20) CONNECT THE WHITE WIRE ON THE DIESEL EGT GUGE WIRE HRNESS TO THE DSH LIGHTING OR SWITCHBLE 2V LIGHT SOURCE 40 30) LOCTE THE RED WIRE ON THE DIESEL EGT GUGE WIRE HRNESS; OBTIN THE FUSE HOLDER W/WIRE LED (F) ND MP FUSE (E); TTCH THE RED WIRE TO THE WIRE ON THE FUSE HOLDER 45 40) LOCTE THE 'KEY-ON' FUSE INSIDE THE FUSE BOX; REMOVE THE FUSE ND INSTLL INTO THE FUSE HOLDER S SHOWN 45) INSERT THE FUSE HOLDER INTO THE 'KEY-ON' FUSE LOCTION S SHOWN PRT NUMBER QTY DESCRIPTION TOOLS E 420004 -MP FUSE WIRE CRIMPERS F 4000 FUSE HOLDER W/WIRE LED PROCESS NME DIESEL EGT GUGE INSTLLTION P4D4-9235- PGE 4 OF 8
CRITICL PROCESS OPERTION 70 50 J K 50) CONNECT BOTH BLCK WIRES ON THE DIESEL EGT GUGE WIRE HRNESS TO GOOD ENGINE GROUND (USE PROVIDED RING TERMINLS IF NEEDED) B 60) OBTIN THE RELY (B), RELY SOCKET (C), RELY SOCKET TERMINLS (D), ND 8 G. RED WIRE (N), FUSE HOLDER (H) ND 5-MP FUSE (G) FROM THE KIT C D N 70) INSTLL () RELY SOCKET TERMINL (D) ONTO THE END OF THE BLUE WIRE ON THE DIESEL EGT GUGE WIRE HRNESS G 80) INSTLL () RELY SOCKET TERMINL (D) ONTO ONE END OF THE 8 G. RED WIRE (N) H 90 90) INSTLL THE FUSE HOLDER W/5 MP FUSE ONTO THE 8 G. RED WIRE PER ICOM INSTRUCTION PX-9208- PRT NUMBER QTY DESCRIPTION TOOLS B 43000 RELY WIRE STRIPPERS C 450003 RELY SOCKET WIRE CRIMPERS D PI 5 TERMINL - RELY SOCKET G 420003 5-MP FUSE H 40000 FUSE HOLDER J 480000 2 /4" RING TERMINL PROCESS NME K 48000 2 #0 RING TERMINL N 49002 8 G. RED WIRE (L=5') DIESEL EGT GUGE INSTLLTION P4D4-9235- PGE 5 OF 8
CRITICL PROCESS OPERTION 200) LOCTE THE PGS WIRE COMING FROM PIN #26 ON THE ICOM DIESEL ECU MODULE (WIRE GOES TO PIN #7 ON THE 8-PIN CONNECTOR) 200 20) USING PIR OF WIRE CUTTERS, CUT THE PGS WIRE T THE DESIRED LOCTION 20 220) INSTLL () RELY SOCKET TERMINL (D) ONTO ECH END OF THE CUT PGS WIRE 220 D D PRT NUMBER QTY DESCRIPTION TOOLS PI TERMINL - RELY SOCKET WIRE CUTTERS WIRE CRIMPERS PROCESS NME DIESEL EGT GUGE INSTLLTION P4D4-9235- PGE 6 OF 8
CRITICL PROCESS OPERTION B 230) SSEMBLE THE RELY CONNECTOR (C) S SHOWN BELOW C 240) INSTLL RELY (B) INTO SSEMBLED RELY CONNECTOR (C); SECURE RELY SSEMBLY TO DSH PNEL USING PROVIDED SELF TP SCREW (L) 250) CONNECT THE NEGTIVE (-) BTTERY CBLE L PIN #26 WIRE ON ICOM JTG-D ECU MODULE CONNECTOR 230 BLUE WIRE ON DIESEL EGT GUGE WIRE HRNESS 87 87 8 G. RED WIRE (W/5 MP FUSE) TO BTTERY 2V POSITIVE 86 30 85 PIN #26 WIRE TO PIN #7 ON 8-PIN CONNECTOR PRT NUMBER QTY DESCRIPTION TOOLS B 43000 RELY C 450003 RELY SOCKET L 480000 SELF TP SCREW PROCESS NME DIESEL EGT GUGE INSTLLTION P4D4-9235- PGE 7 OF 8
CRITICL PROCESS OPERTION 260 260) OBTIN THE /4" SPLIT CORRUGTE (P) FROM THE KIT; INSTLL CORRUGTE ONTO EXPOSED WIRES P 270) CREFULLY COIL EXCESS WIRE ND LOOSELY TIE WITH PROVIDED 8" ZIP TIE (M) (LOOSELY TYING THE EXCESS COIL PENTS EMBRITLEMENT CSUED BY VIBRTION) M 270 POWER UP 280) THE POINTER WILL MOVE COUNTER CLOCKWISE TO THE STOP ND THEN MOVES TO THE CURRENT GUGE REDING. THIS PROCEDURE IS N UTO-CLIBRTION FUNCTION ND IS PERFORMED ON EVERY POWER-UP. WHILE THIS TEST IS BEING PERFORMED, THE GUGE MY MKE 'CLICKING' SOUND (THIS IS NORML). PRT NUMBER QTY DESCRIPTION TOOLS M 50000 5 8" TIE STRP P 350047 /4" SPLIT CORRUGTE (L=20') PROCESS NME DIESEL EGT GUGE INSTLLTION P4D4-9235- PGE 8 OF 8
Title: DIESEL EGT GUGE INSTLLTION Document I.D.: P4D4-9235 Page Rev ISIONS OPERTION NUMBER ISION LEVEL DESCRIPTION OF CHNGE DTE PPROVED BY INITIL RELESE 8/5/203 M. STEPPEY uthor: Marc Steppey pproval: Date: 3/25/204 Title: Technical Manager Title: Initials