BD Diesel Performance 1054745 User Manual

19 February 2007 Chevrolet/GMC Duramax BD X-Tuner # 1054745 1

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GMC/Chevy 6.6L Duramax Installation Instructions

1054745

*** READ THIS MANUAL & DISCLAIMER COMPLETELY BEFORE INSTALLING THIS PR ODUCT ***

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U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295

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GMC/Chevy Duramax 6.6L LLY / LBZ

Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9

Phone: [phone] Fax: [phone] Internet: www.bd-power.com

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(2500/3500/C4500/C5500 & Kodiak)

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Installation Manual P/N#: I1054745

BD Engine Brake Inc.

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2006-2007

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19 February 2007 Chevrolet/GMC Duramax BD X-Tuner # 1054745 2

TABLE OF CONTENTS

Power Settings Chart......................................................................................3

Package Contents...........................................................................................3

Pre-Installation................................................................................................4

Keypad Layout................................................................................................5

Installation.......................................................................................................6

Main Screen..............................................................................................................8

Download Function...................................................................................................8

Speed Limiter............................................................................................................9

Adjusting Tire Size..................................................................................................10

Returning To Stock.......................................................................................12

DTC Function (Diagnostic Trouble Code) ..................................................12

Recovery Mode .............................................................................................13

Updating Your X-Tuner.................................................................................14

Downloading the X-Tuner Update...........................................................................15

Running the Update Program.................................................................................17

Questions/Technical Support......................................................................18

LIMITED WARRANTY STATEMENT.............................................................19

DTC Trouble Code Listings..........................................................................20

U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295

Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9

Phone: [phone] Fax: [phone] Internet: www.bd-power.com

BD Engine Brake Inc.

19 February 2007 Chevrolet/GMC Duramax BD X-Tuner # 1054745 3

Power Settings Chart

Values were taken from a 2006 Duramax LBZ vehicle.

X-TUNER
SETTING

Tune 3 +140HP +295 lbs-ft Extreme

Tune 2 +70HP +210 lbs-ft Performance

Tune 1 +50HP +135 lbs-ft Economy

Est. HP

GAIN

Est. TORQUE

GAIN

DESCRIPTION

RECOMMENDED USE

Racing – must use pyrometer

and boost gauges. Will incur

damage to stock

transmissions.

Driving and light towing –

must use pyrometer and

boost gauges.

Every day driving and towing

– may increase fuel economy

under normal driving

conditions.

Factory N/A N/A Stock

Choose between any of the available power levels by scrolling and then pressing “Y”

Package Contents

Choose the stock setting to

return to stock.

U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295

Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9

Phone: [phone] Fax: [phone] Internet: www.bd-power.com

BD Engine Brake Inc.

19 February 2007 Chevrolet/GMC Duramax BD X-Tuner # 1054745 4

Pre-Installation

The BD X-Tuner for the GMC/Chevrolet Duramax (LBZ Engine) is a very simple
instrument to operate. All operations take place inside the cab with the downloader
hooked up to the OBD II diagnostic port. Operating this downloader does not require a
mechanical background. While operating this downloader we encourage you to simply
follow the instructions provided on the screen of the X-Tuner; the instructions on the
screen are easy to read and comprehensive.

The X-Tuner is meant for the 6.6L Duramax LBZ Engine (2006+), and cannot be used for
any vehicle other than this specific application.

This instruction booklet will provide you with a detailed description on how to perform
downloader operations and is split up into easy-to-read sections labeled with headings.

Once you have downloaded a power program into your vehicle, remember to always
keep the downloader with you, if possible as you may want to change the power program
that is loaded, or to check and erase Diagnostic Trouble Codes (DTC’s) on the road.

**** IMPORTANT ****

The power program must always be removed before taking the vehicle in for any kind of
service, as it may interfere with diagnostic tools used by your dealer. Sometimes, even if
your truck does not require a diagnostic service, the dealer may flash your trucks’
computer without your knowledge, so it is absolutely recommended to remove your
power program BEFORE bringing it to your dealer. In the event that your trucks computer
is flashed while your program is loaded, your X-Tuner may have to be sent back to BD to
be re-flashed.

IF STACKING PERFORMANCE PRODUCTS, IT IS NOT RECOMMENDED TO HAVE BOTH
PRODUCTS ON THE HIGHEST OUTPUT SETTI NG. FOR EXAMPLE A COMMON STACK IS
TO HAVE THE EDGE JUICE SET ON LEVEL 3 AND THE X-TUNER ON TUNE 1 OR TUNE 2.

U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295

Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9

Phone: [phone] Fax: [phone] Internet: www.bd-power.com

BD Engine Brake Inc.

19 February 2007 Chevrolet/GMC Duramax BD X-Tuner # 1054745 5

Keypad Layout

U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295

Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9

Phone: [phone] Fax: [phone] Internet: www.bd-power.com

BD Engine Brake Inc.

19 February 2007 Chevrolet/GMC Duramax BD X-Tuner # 1054745 6

Installation

Make sure that your vehicle is in the key off/engine off position, with all electronics (such
as the radio) turned off before you plug in the X-Tuner.

Locate the fuse box inside the engine compartment, on the driver’s side. Remove the

fuses marked in the picture above. There are four fuses that have to be removed in total:

TBC BATT / TBC IGN1 / RADIO / INFO

U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295

Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9

Phone: [phone] Fax: [phone] Internet: www.bd-power.com

BD Engine Brake Inc.

19 February 2007 Chevrolet/GMC Duramax BD X-Tuner # 1054745 7

Inside the cab, connect the communications
cable that came with the downloader into the top
of the X-Tuner and the other end into the OBD II
port (see picture on the right).

The OBD II port is the diagnostic port located
underneath the dash on the driver’s side of the
vehicle.

OBDII Port

The downloader will power up with a BD logo.
Press any key to continue to the next screen.
It will then ask you to confirm that you agree with

the warranty statement that can be found on page
19 of this instruction booklet.

At this point, the downloader will ask you to turn
your key to the ON position (but do not start the
engine).

BD Engine Brake Inc.

Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9

U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295

Phone: [phone] Fax: [phone] Internet: www.bd-power.com

19 February 2007 Chevrolet/GMC Duramax BD X-Tuner # 1054745 8

Main Screen

The main screen will give you two options to
choose from:

DOWNLOAD – Select this option to download a
power program, remove the vehicle’s speed
limiter, adjust tire size for the speedometer, or to
return the program to stock.

DTCs – Select this option to view and erase
diagnostic trouble codes.

Download Function

Highlight the downloader option from the main menu, and press the Y key.

If this is the first time you’ve used the tuner, then
the downloader will then read and save the
vehicle’s stock information. This procedure will
take 5-7 minutes.

If this is not the first time you’ve used the tuner,
then it will read and verify your trucks information,
and then proceed to the tuning menu.

Once the save/read is complete, the downloader
will display a list of available power settings. Use
the up/down arrows to move through and select a
power program.

Refer to the Power Settings chart on page 3 for
more information on available power levels. Using
the “Factory” power level returns the truck to
stock, or leaves the OEM settings intact if the
truck has never been programmed.

U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295

Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9

Phone: [phone] Fax: [phone] Internet: www.bd-power.com

BD Engine Brake Inc.

19 February 2007 Chevrolet/GMC Duramax BD X-Tuner # 1054745 9

Speed Limiter

The X-Tuner gives racing enthusiasts the option
to remove the OEM speed limiter/governor. This
allows the vehicle to reach speeds in excess of
where the OEM governor was set (most trucks
are set below 100mph/140kmh). By selecting
“Yes” to remove the speed limiter you agree that
your vehicle has the appropriate tires,
suspension and any other necessary
modifications rated for speeds in excess of
130mph.

The speed limiter removal function of the X-Tuner
is adjustable. Available options are:

50 - 135mph in 5mph increments.

THIS MODIFICATION IS INTENDED FOR RACE PURPOSES ONLY AND SHOULD
NEVER BE USED ON A PUBLIC ROAD OR HIGHWAY.

U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295

Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9

Phone: [phone] Fax: [phone] Internet: www.bd-power.com

BD Engine Brake Inc.

19 February 2007 Chevrolet/GMC Duramax BD X-Tuner # 1054745 10

Adjusting Tire Size

If your truck has aftermarket tires that are larger
than the truck’s stock size, then your speedometer
is most likely reading an erroneous speed value.
The X-Tuner has the ability to adjust the tire size
and correct the speedometer to read the correct
speed.

Measure your tires from the ground to the top of
the tire. Enter that number (in inches) using your
up/down arrows on the X-Tuner’s keypad.

Available options are:

25.00 – 45.00” with 0.25” increments.

Due to the programming in GMC computers,
selecting a tire diameter larger than 35.00” may
cause the ABS light to come on.

U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295

Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9

Phone: [phone] Fax: [phone] Internet: www.bd-power.com

BD Engine Brake Inc.

19 February 2007 Chevrolet/GMC Duramax BD X-Tuner # 1054745 11

The X-Tuner will now compile all the parameters
you specified and will upload the proper power
program into your truck’s computer. This process
will take roughly 3-5 minutes.

The X-Tuner will now complete the download with a simple test procedure. Follow the
instructions provided on the screen.

Once the verification is complete, the X-Tuner will
finish the flash and re-initialize the truck’s computer.
The X-Tuner will count down from 9. DO NOT
DISTURB THE TUNER.

You are now done! Congratulations! Have fun, but
be careful with your new-found power.

U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295

Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9

Phone: [phone] Fax: [phone] Internet: www.bd-power.com

BD Engine Brake Inc.

19 February 2007 Chevrolet/GMC Duramax BD X-Tuner # 1054745 12

Returning To Stock

This option is for when you are taking your
vehicle in for a diagnostic service, or just want
your settings to be back to the OEM
specifications.

Plug in the X-Tuner and select the Download
option from the main menu. Once you have
entered the power level selection screen, select
“Factory” and then press “Y”. Follow the
instructions set out on the downloader. When you
are finished, the X-Tuner will have returned the
vehicle to the stock power level.

DTC Function (Diagnostic Trouble Code)

The DTC function will display all diagnostic trouble
codes set on your vehicle. This function will also
allow you to read and erase trouble codes from
your vehicle’s ECU.

To erase DTC codes, simply press “Y” and all
DTC codes will be erased. If no DTC’s are
displayed, then simply unplug the X-Tuner and
cycle the key.

U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295

Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9

Phone: [phone] Fax: [phone] Internet: www.bd-power.com

BD Engine Brake Inc.

19 February 2007 Chevrolet/GMC Duramax BD X-Tuner # 1054745 13

Recovery Mode

In the event that a downloader goes into recovery mode, take the following steps to
recover:

1. Press “Y” to go into recovery mode.

2. If an error code is displayed, unplug the X-Tuner, wait ten seconds, then plug it
back in.

3. Once the downloader has been plugged back in, it will again display a prompt to
enter the recovery mode. Press “Y”.

4. The X-Tuner will recover the vehicle’s programming by returning it to stock.

5. Once the vehicle finishes restoring the stock program, the power programming
process can be safely restarted.

U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295

Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9

Phone: [phone] Fax: [phone] Internet: www.bd-power.com

BD Engine Brake Inc.

19 February 2007 Chevrolet/GMC Duramax BD X-Tuner # 1054745 14

Updating Your X-Tuner

Requirements:

¾ Microsoft .NET Framework v1.1
¾ Windows XP
¾ WinZIP, WinRAR or equivalent

The X-Tuner has the ability to update via a
USB connection. The port is located on the
top of the X-Tuner module, beside the serial
port that the OBDII port cable attaches to.

Updates can be downloaded via BD’s
website. If it is the first time you are updating
your module, you will have to register and
create a user profile.

The X-Tuner update program is a small and
easy to use application. This program can be used with Windows XP. It is mandatory to
download and install the Microsoft .NET Framework v1.1 or v2.0 package from the
Microsoft Downloads website (

http://www.microsoft.com/downloads/) or the program

will not run.

X-Tuner’s USB Port

A USB A-B cable (see photo to the right) will have to
be purchased separately in order to use this function.
This is a widely used cable in the computer market
(used mostly in newer style printers & scanners) and
can easily be picked up at any retail store that sells
computer parts. An example would be Best Buy,
Circuit City or Future Shop.

U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295

Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9

Phone: [phone] Fax: [phone] Internet: www.bd-power.com

BD Engine Brake Inc.

19 February 2007 Chevrolet/GMC Duramax BD X-Tuner # 1054745 15

Downloading the X-Tuner Update

Log into the X-Tuner update site by typing

http://xtuner.bd-power.com/ into your

preferred internet browser.

Click on the “Enter X-Tuner Upgrade Portal”
button to enter the website.

If this is your first time updating your X­Tuner, then click the respective link. You will
be asked to create a user profile. Don’t
forget to have your X-Tuner serial number
handy, as it is a required field.

Once you have logged in, navigate to the
“GM” link for your Duramax. Click on the
update link and select “Open” (In Internet
Explorer) or “Open as” (In Mozilla/Firefox).

Once the file has completed downloading, it
will spawn either WinRAR or WinZip
(whichever you have installed).

U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295

Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9

Phone: [phone] Fax: [phone] Internet: www.bd-power.com

BD Engine Brake Inc.

19 February 2007 Chevrolet/GMC Duramax BD X-Tuner # 1054745 16

A

There will be only one file inside the archive
you downloaded. Double click on this file
and it will spawn the installation program for
the Duramax updater. Follow the
instructions set out on the screen.

fter the installation program has
completed, you will notice that it created
entries in the Start Menu which you can use
to start the main program.

U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295

Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9

Phone: [phone] Fax: [phone] Internet: www.bd-power.com

BD Engine Brake Inc.

19 February 2007 Chevrolet/GMC Duramax BD X-Tuner # 1054745 17

Running the Update Program

** NOTE – When re-flashing your X-Tuner to the latest version, you MUST return the
stock program into your truck’s computer, otherwise the tuner will not update. This is a
security feature to ensure that you don’t overwrite the stock program in your tuner.

Open your Start Menu, browse to “Duramax
Downloader”, and execute the application
located inside.

This will open up the main X-Tuner update
program window. You may now plug your X-
Tuner into your computer.

The X-Tuner should light up and display the
BD Power logo on its screen. Do not push any
buttons on the X-Tuner at this time.

Press the Upgrade button in the update
program on your computer. It will begin the
reflash process.

While the update program is progressing on
the computer, you should see the display on
the X-Tuner running the flash upgrade
program at the same time, as shown on the
diagram to the right.

DO NOT DISTURB THE X-TUNER DURING
THIS PROCESS.

Once the flash is complete, the X-Tuner will run a short checksum test of the internal
software. After this is complete, it will then automatically close the X-Tuner update
program, and will re-load the BD logo screen on your X-Tuner module. You can now
unplug the X-Tuner. The update is now complete! Feel free to reload the new program
onto your truck’s computer.

U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295

Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9

Phone: [phone] Fax: [phone] Internet: www.bd-power.com

BD Engine Brake Inc.