Read 1202007E.qxd text version

Instructions For

PowerMaxTM Performance

Part Number 1202-007

Power TunerTM

2001-2004 GM Full Size PU and Suburban w/6.6L Duramax Diesel Part No. 1202-007 Extensive dynamometer and "on the road testing" has enabled us to develop a tuner which will maximize torque, power and fuel economy without compromising the reliability and dependability of your vehicle's drivetrain. Some competing tuners offer diesel owners up to three levels of power to select. If you select the highest power level, you can easily compromise the weakest link in the drivetrain if the tires break loose and then "hook-up" unexpectedly. If you select the lowest level of performance, you might not be getting all that you could out of your vehicle. At Crane Cams, we decided to give you the maximum useable power short of compromising the integrity of your vehicle's drivetrain. You don't have to worry about how to drive the vehicle; or in some cases, "who is driving the vehicle". Simply, read these instructions thoroughly and install our custom tuning. You can then enjoy the power and economy your vehicle is capable of delivering while having the "peace of mind" that you aren't inflicting damage on your truck; and you can return it to stock tuning in only a couple of minutes (this can be done as many times as you desire). In addition, you can take pride and comfort that your Crane Cams Powermax Performance Tuner has been developed and manufactured here in the USA!

INTRODUCTION TO YOUR CRANE CAMS POWERMAX PERFORMANCE POWER TUNER

LCD DISPLAY will guide you through your selections. BUTTON to scroll UP to a menu choice or selection. BUTTON to scroll Down to a menu choice or selection.

BUTTON means YES when choosing a menu item. BUTTON means NO when choosing a menu item.

CAUTION: Unless these directions are followed step-by-step, the vehicle and/or the computer may be rendered inoperable!

Thank you for purchasing your Crane Cams Powermax Performance Power Tuner. It is the finest, most flexible hand-held, engine/transmission tuner on the market today. Most people initially buy a tuner to enhance the full throttle performance of their vehicle. You will definitely see a full throttle power improvement; however, most of the operation of any vehicle occurs under "part throttle" conditions, and improvements in throttle response and fuel economy at part throttle will truly be appreciated as much or more than the full throttle gains.

What You Can Do with the Powermax Power Tuner:

to · Change yourofvehicle speed limiter carematch the speed rating your tires (Note: take to assure that the speed rating of your tires matches the highest intended operating speed of your vehicle).

· Adjust your speedometer/odometer to compensate for oversize/undersize tires within ¼" OD (25" to 44"

on most trucks). man· Adjust your speedometer/odometer/engine(3.08 agement system for changes in gear ratios 5.13 for most applications). from · Adjust the engine tuningin juststock to performance or performance to stock minutes.

· Add 70hp and 180 lb/ft of torque gain over stock

1 1202-007E

CRANE CAMS, INC. 530 Fentress Blvd., Daytona Beach, FL 32114 www.cranecams.com Tech Line: (386) 258-6174 Fax: (386) 258-6167

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DTC reader · Use thecontrol errors. function to cipher and clear engine

LET'S BEGIN: Before operating your Crane Cams Powermax Performance Power Tuner:

Remove the fuse panel cover. Three 10 amp fuses must be removed from this panel prior to programming your vehicle. Remember to reinstall the fuses in their proper receptacles before restarting your vehicle.

booklet The · Read this entire instructionwill makecarefully. your step-by-step instructions using Powermax Power Tuner much easier. The Powermax Power Tuner will perform many steps automatically. battery is fully · Be sure the vehicle'sPower Tuner. Docharged before using the Powermax not attempt to reprogram your computer with a low charged battery or while connected to a battery charger. electrical systems: Lights, radio, air con· Turn off allfan, CD, DVD players, power-amplifiers, ditioning, cellular phones, etc. parking brake. the Daytime · Set the Lights (DRL) off. This turnsthis may interRunning If left on, fere with programming.

Figure 1. Figure 2.

Fuse Name SEO IGN RDO 1 RAP 2

Fuse Description Special Equipment Option Audio System Radio and Power Options

· Disable the OnStar feature if equipped. equipment by removing · Disable all necessarydescribed in Figures 3 and the appropriate fuses as 4.

your starting · Pre-determinesessionchoices before diameter your programming (measure tire and determine gear ratio if changing from stock).

Figure 3.

CAUTION: Unless these directions are followed step-by-step, the vehicle and/or the computer may be rendered inoperable! Step 1: Fuse Removal Whether your vehicle is equipped with these options or not, you must pull these fuses.

2001-2002 Models Fuses must be removed from a panel inside the passenger compartment and from a panel under the hood. (See figures 1 and 2) Locate the fuse panel just inside the driver's side door.

2003-2004 Models Locate the fuse panel under the hood along the driver's side inner fender. Remove the cover. Remove the following 15-amp fuse: Fuse Name INFO Fuse Description Information Center

Figure 4.

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After all the appropriate fuses have been removed, you are just about ready to start the programming process. Before you begin there are a couple of important rules to follow. Do not attempt to stop download or programming process at any time by removing the cable, turning the ignition key off, or disconnecting the battery power! Wait for the Powermax Power Tuner prompt "Remove the Tuner from your car" before disconnecting the tuner cable from the OBD II link connector.

VIN will be locked into the tuner memory for use with this vehicle only. 7. The tuner will download the vehicles stock settings into memory. This information will be saved for future use. DO NOT DISTURB, UNPLUG, OR PUSH ANY TUNER BUTTONS DURING THIS FUNCTION. If the cable is accidentally disconnected or programming is interrupted, turn ignition key to the "OFF" position. Unplug the tuner cable from the OBDII link connector and start the process from the beginning. Call 1-386-2586174 for further assistance.

Unlocking PCM, Do Not Disturb Or Start the Engine Do Not Disturb Or Start Engine, Saving Stock Information

PROGRAMMING YOUR VEHICLE

1. To begin programming process, plug the small end of the cable (supplied in box) into the bottom of the PowerMax hand held tuner. 2. Turn the key to the ignition "ON" (engine off) position. (DO NOT START VEHICLE) 3. Plug the large end of the cable into the OBDII link connector under the lower edge of the dash, near the parking brake. 4. The first prompt will appear in the tuner display window after the cable has been plugged into the OBDII link connector.

PowerMax by Crane Cams, Inc CraneCams.com For Help Call 1-386-258-6174

8. Move the cursor to "Tune Car" and press "Y".

Please Choose _Tune Car _Get DTC Codes _Y to Select

9. The tuner will now ask if you want to customize your vehicle's programming or return it back to stock settings.

Please Choose _Custom Tune Car _Return to Stock _Y to Select

Please turn your key to the On Position, Do Not Start your car.

10. To customize the vehicle, move the cursor to "Custom Tune Car", then press "Y". To return your vehicle to stock, move the cursor to "Return to Stock", press the "Y" button, and proceed to step 18. 11. Your first customizing choice is the speed limiter. To leave the speed limiter stock, place the cursor at "Stock" and press "Y". Proceed to step 12. To change to 130 MPH, place the cursor in front of "130 MPH" and press "Y". To change to unlimited, place the cursor in front of "Unlimited" and press "Y". Make sure your tires have the appropriate speed rating before increasing the speed limiter.

Select MPH Limiter _Stock 98 MPH _Y to Select _130 MPH _Unlimited

5. Within a few seconds another prompt will automatically appear. DO NOT START ENGINE. 6. The tuner will read in the Vehicle Identification Number (VIN). The

Leave Key in On Position. Do not Disturb or Start Engine.

Checking Stored VIN# against Car VIN#, Please Wait.

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12. To adjust your speedometer for a change in tire diameter or rear axle ratio press "Y", if not, press "N" and skip to step 15.

Correct Your Speedometer for Tire / Axle Ratio Select Y or N

13. If the vehicle gear ratio has been changed from stock, scroll the cursor to the correct value and press "Y". If the axle ratio has not been changed, press "N". Changing the tuner axle ratio does not automatically change the gears in the vehicle axle. If you Change Rear Axle Gear have 3.08 gears, Ratio to telling the tuner it _2.73 has 3.73 does not Y to Select make the gears 3.73. 14. To correct the speedometer for under or oversized tires, measure the height of the tire (from the pavement to the top of the tire) and round this value to the nearest .25". Scroll the cursor through the tire size choices and select the size by pressing "Y". Make sure your tires have the appropriate speed rating before increasing the speed limiter. If the tire size has not changed from stock, press "N". 15. To select performance engine tuning, press "Y". To leave the tuning stock, press "N".

Select your Engine Tune Need _Orig. Stock _Y to Select

prompt window Please Wait for scrolling as the tuner XX seconds updates the PCM. Once the tuner has finished updating your PCM, you will hear the fuel pump cycle Tuning Installed Turn and the message to key off and Remove wait several seconds the Tuner From Your and remove the tuner Car will appear. Turn the key to OFF, and remove the cable from the OBDII link connector. 17. Replace any disconnected or removed fuses. Your vehicle is now ready to be started with the new enhanced tuning. 18. If you are returning the vehicle back to stock from step 10, stock data is now restored to the vehicle. DO NOT DISTURB the tuner or the cable.

Returning Car Back to Stock Restoring to Stock Data Back to Stock Turn key off and Remove the Tuner From Your Car

DTC Code Reader Once you have programmed your vehicle, you now have the capabilities to read your vehicles DTC trouble codes. Plug the PowerMax cable into the DLC and move the cursor down to "Get DTC codes". Press "Y" and the PowerMax Tuner will retrieve the trouble codes. Compare the codes (if any) to the included list of GM DTC codes. The output of codes is just a diagnostic aid and not a conclusive problem solver. If you have a code, research the error first before replacing parts. Once the codes have been recorded, clear the codes by pressing "Y" on the keypad.

Please Choose Tune Car Get DTC codes _Y to Select DTC Code - _____

16. This is the final step Install Your Selected before the PowerMax Tuning? tuner session is finSelect Y or N ished. To agree with all of your choices, press the "Y" button. If you are unsure, Installing Selected press the "N" button Tuning to restart the selecDO NOT Disturb_ tion process. After pressing "Y", the tuner will start to upload the new data. When the PowerMax tuner is transferring data, DO NOT DISTURB the tuner or the cable. You will see the

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_Y = Clear DTC

DTC's Cleared Turn key off and Remove Tuner From Your Car

No DTC Codes Set Turn key off and Remove Tuner From Your Car

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Note: After programming, many vehicles with "drive by wire" throttle control will have the DTC indicator lit on the dashboard and an associated trouble code will be set in the computer. This is not uncommon, nor is it a problem. Simply plug the tuner into the OBDII port (no fuses need to be removed at this time). Scroll to the screen that displays "Choose, Tune car, Get DTC codes" and select "DTC Codes". The next screen will display the code number and "Clear DTC". Select "Clear DTC" and press "Y". Once the code has been cleared, the vehicle is ready to drive. Diagnostic trouble codes (DTC) are listed at the end of these instructions. Complete information on DTC's can be found in the factory service manual.

P0103

Mass air flow (MAF) sensor voltage signal is high. Intake air temperature (IAT) sensor is excessively low signal voltage. Intake air temperature (IAT) sensor is excessively high signal voltage. Engine coolant temperature (ECT) sensor failure. Engine coolant temperature (ECT) sensor too high. Engine coolant temperature (ECT) sensor too low. Engine coolant temperature (ECT) sensor low/high temperature. Fuel temperature circuit failure. Fuel temperature too high. Fuel temperature too low. High fuel temperature sensor voltage. Fuel rail pressure (FRP) sensor low signal. Fuel injection control module (FICM) circuit failure. Cylinders 1, 4, 6, or 7, DTCs P0201, P0204, P0206, P0207 will set, along with DTC P2146. Cylinders 2, 3, 5, or 8, DTCs P0202, P0203, P0205, P0208 will set, along with DTC P2149. Boost sensor signal is above the predicted range. Boost sensor signal is below the predicted range. Boost sensor signal voltage that is excessively low. Boost sensor signal voltage that is excessively high.

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P0112

P0113

P0116

P0117

What to do BEFORE you take your vehicle in for service.

At some point, you may have to take your vehicle to a mechanic or a dealership for service. You must remove the Powermax Power Tuner programming and restore your vehicle to its stock settings. Failure to program the vehicle back to stock can result in unnecessary and costly repairs not covered by Crane Cams, Inc. Before you have any work done on the vehicle make sure the Powermax Performance Power Tuner custom tuning is removed from your vehicle's computer. If you have failed to return the vehicle back to its stock condition and the vehicle computer is reflashed, due to updates, your PowerMax Power Tuner may not work correctly, which is not covered by the Crane Cams, Inc. warranty.

P0118

P0128

P0168 P0181 P0182 P0183 P0193

P0016

Crankshaft position (CKP) and the camshaft position (CMP) signals failure. Fuel rail pressure (FRP) too low. Fuel rail pressure (FRP) too high. Fuel rail pressure (FRP) sensor indicates a pressure more than 20 MPa greater than desired. Fuel rail pressure (FRP) circuit failure.

P0087 P0088 P0089

P0201 thru P0208

P0234

P0090 P0101

P0236 Mass air flow (MAF) sensor signal is too low or too high. P0237 P0102 Mass air flow (MAF) sensor voltage signal is low. P0238

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P0300 P0301 thru P0308 P0335

Fuel delivery excessive. Fuel delivery per cylinder X excessive.

P0462 P0463 P0489

Fuel level sensor low. Fuel level sensor high. The exhaust gas recirculation (EGR) valve low voltage condition. The exhaust gas recirculation (EGR) valve high voltage condition. Vehicle speed sensor (VSS) assembly no signal. Engine oil pressure (EOP) sensor low. Engine oil pressure (EOP) sensor high. A/C refrigerant pressure sensor pressure is too high. Intake air heater (IAH) incorrect voltage. Intake air heater (IAH) incorrect voltage. Power train Control Module (PCM) excessively low voltage. Power train Control Module (PCM) excessively high voltage. Voltage is present on the cruise control resume/accel switch signal circuit more than 90 seconds. Voltage is present on the cruise control set/coast switch signal circuit more than 90 seconds. Torque converter clutch (TCC) low signal. Engine control module (ECM) is not programmed. Engine control module (ECM) is not programmed. Engine control module (ECM) is not programmed.

Crankshaft position (CKP) sensor signal out of range. Crankshaft position (CKP) sensor signal out of range more than 2 seconds. Camshaft position (CMP) out of range.

P0490

P0336

P0500

P0340 P0341

P0522 Camshaft position (CMP) out of range for more than 2 seconds Ignition Coil 4 Control Circuit Fuel injection control module (FICM) signal failure. P0523 P0530

P0354 P0370 thru P0374 P0380

P0540 P0543

Federal RPO FE9, NG1 The glow plug system performance. California RPO YF5, NE1 The glow plug system feedback voltage is not within range. The fault detection circuit senses a voltage other than what is expected on ignition voltage circuit. Exhaust gas recirculation (EGR) valve vacuum sensor performance. Exhaust gas recirculation (EGR) valve vacuum sensor signal is lower than expected. Exhaust gas recirculation (EGR) vacuum sensor signal voltage is pulled below a calibrated value. Exhaust gas recirculation (EGR) vacuum sensor signal voltage is pulled above a calibrated value. The fuel level sensor lack of signal.

P0562

P0563

P0381

P0567

P0401

P0568

P0404

P0571 P0601

P0405

P0602 P0406

P0603

P0461

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P0604

Engine control module (ECM) is not programmed. Fuel injection control module (FICM) problem in the circuits. Ignition relay control circuit excessive voltage on circuit. Accelerator pedal position (APP) sensor 3, fuel rail pressure (FRP) sensor, engine oil pressure (EOP) sensor out of range. Malfunction indicator lamp (MIL) has improper voltage on the MIL control circuit.

P1232

Fuel injection control module (FICM) cylinder 4. Fuel injection control module (FICM) cylinder 5. Fuel injection control module (FICM) cylinder 6. Fuel injection control module (FICM) cylinder 7. Fuel injection control module (FICM) cylinder 8. Accelerator pedal position (APP) low sensor function. Exhaust gas recirculation (EGR) is not closing. Fuel injector control module (FICM) low voltage condition. Engine control module (ECM) is not programmed. Pass-Lock enable failure. Pass-Lock enable failure. Pass-Lock enable failure. Fuel injection control module (FICM) internal circuit fault. Secondary fuel level sender signal is stuck . Primary fuel level sender signal is stuck . Secondary fuel level sender signal is higher than normal . Accelerator pedal position (APP) sensor out of range condition. ECM determines an out of range condition with the APP sensor.

P0611

P1235

P0612

P1238

P0641

P1241

P1244 P0650

P1270 P0651 Boost sensor, accelerator pedal position (APP) sensor 2, and exhaust gas recirculation (EGR) vacuum sensor, voltage is out of range. Transmission control module (TCM) is requesting MIL. Transmission control module (TCM) is requesting MIL. Clutch switch transition failure. Fuel rail pressure (FRP) sensor circuit malfunction. Fuel rail pressure (FRP) sensor low circuit voltage. Accelerator pedal position (APP) circuit voltage out of range. Fuel transfer pumps voltage/cycle out of range. Fuel injection control module (FICM) cylinder 1. P2122 P1226 Fuel injection control module (FICM) cylinder 2. P2123 P1229 Fuel injection control module (FICM) cylinder 3.

P1404

P0700

P1550

P0802

P1621

P0833 P1093

P1626 P1631 P1637

P1094

P1658

P1125

P2066 P2067 P2068

P1172

P1223

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P2127

ECM determines an out of range condition with the APP sensor. ECM determines an out of range condition with the APP sensor. ECM determines an out of range condition with the APP sensor. ECM determines an out of range condition with the APP sensor. ECM determines an out of range condition with the APP sensor. ECM determines an out of range condition with the APP sensor. ECM determines an out of range condition with the APP sensor. EGR throttle valve vacuum solenoid control circuit low voltage. EGR throttle valve vacuum solenoid control circuit high voltage. EGR vacuum vent solenoid control circuit low voltage.

P2145

EGR vacuum vent solenoid control circuit high voltage. Fuel injection control module (FICM) circuit fault.Cylinders 1, 4, 6, or 7, DTCs P0201, P0204, P0206, P0207. Cylinders 2, 3, 5, or 8, DTCs P0202, P0203, P0205, P0208. Fuel injection control module (FICM) circuit fault. Barometric pressure (BARO) sensor low reference circuit. Barometric pressure (BARO) sensor out of range. Barometric pressure (BARO) high voltage circuit. Mass airflow (MAF) sensor detects an air intake leak. Engine control module (ECM) is not programmed.

P2128

P2146

P2132

P2133

P2149

P2138

P2227

P2139

P2228

P2140

P2229

P2141

P2279

P2142

P2610

P2144

Crane Cams, Inc. Limited Warranty

Crane Cams, Incorporated warrants that all of its products are free from defects in material and workmanship. All Crane Cams performance products are subject to the conditions established in this policy. Crane Cams, Incorporated warrants that when our products are properly installed in their correct application, they will be free from defect and will function as specified. Due to the variety of modifications made on performance applications, Crane Cams' obligation under this warranty is limited to the repair or replacement, only of Crane products, when the consumer returns these products to: Crane Cams, Incorporated, Attention: Warranty Dept., 530 Fentress Boulevard, Daytona Beach, Florida 32114. This Limited Warranty begins on the date of purchase and is good for a period of one year from validated date of purchase unless otherwise specified to the original purchaser. This warranty will be void on all products that show evidence of misapplication, improper installation, abuse, lack of proper maintenance, negligence, abnormal use, or alteration from their original design. Crane Cams, Incorporated reserves the right to make necessary changes in the products it manufactures and markets at any time to improve product performance. These changes in products will be made without obligation to change or improve products that were previously manufactured. This warranty limits any implied warranty to one year, and no person, company or organization is authorized to assume for Crane Cams, Incorporated, any other liability in connection with the sale of Crane Cams products. Some states do not allow limitations on how long an implied warranty lasts. This Limited Warranty gives you specific legal rights, and you may also have other rights which vary from state to state. Crane Cams, Inc., 530 Fentress Boulevard, Daytona Beach, FL 32114 386/258-6174 FAX: 386/258-6167 Made In U.S.A.

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