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INSTALLATION MANUAL
Mercedes Rapid Power Module
Applications Rapid Power Module Number
Mercedes 2.7L & 3.2L diesel ‘01-’06 44631
Mercedes 3.0L V6 diesel ‘07-’09 44632
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TABLE OF CONTENTS
TROUBLESHOOTING:
If you have questions during the installation of this product,
please visit www.bullydog.com/Product_Updates.php.
The latest version of these instructions can be found at the same
location. Technical support is available by calling 866-bullydog (866-285-5936).
TABLE OF CONTENTS
INTRODUCTION ..........................................................................................................PG. 1
PARTS DESCRIPTIONS ............................................................................................ PGS. 23
INSTALLATION .......................................................................................................PGS. 49
Installation of 44631, 2.7L and 3.2L ............................................................... PGS. 46
Installation of 44632, 3.0L ............................................................................. PGS. 79
INTERNET UPDATES, UPDATE AGENT .......................................................................... PG. 10
INTRODUCTION
You have just purchased the most technologically advanced power module available for the Mercedes
CDI engine. The Rapid Power module is the safest and longest lasting module on the market. The Rapid
Power module also comes with free technical support, just call: 1-866-285-5936.
This instruction set outlines how to install and operate the Rapid Power module on Mercedes
Benz diesel engines 2.7L, 3.2L and 3.0L. Always remember to remove the module from the vehicle
before taking it in for any kind of service as the module may interfere.
Bully Dog recommends installing a pyrometer gauge to monitor exhaust gas temperature when using
any product to increase horsepower.
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Product Description
Product Description:
This section displays the parts included in the package and describes the main parts of the module.
Packaging Contents:
1. Rapid Power Module
with Wiring Harness
2. Zip Ties
3. Velcro
THE MODULE BOX: The module box contains the electronics
that will allow your vehicle to produce more horsepower. It is very
important that this module is mounted away from all moving or
hot parts. The box should be placed in an area protected from dirt
and moisture.
USB PORT: The USB port which is used to update the module when new updates come available through the
Bully Dog Update Agent. The USB port can be accessed by simply unscrewing the four screws on the top of the
module enclosure.
USB Port
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Product Description
THE WIRING HARNESS: The wiring harness is made up of the cable coming from the box and a cable with two
plugs. The wiring harness allows the Rapid Power Module to connect to your vehicles engine. At the end of the
wiring harness are two plugs, one male and one female plug. These plugs will connect directly to the vehicles
engine and wiring harness requiring no modication of the vehicle.
FUEL RAIL PRESSURE SENSOR PLUGS
Female Plug
MOUNTING GEAR: The zip ties and velcro are included to secure the module and harness.
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Male Plug
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Installation sec. 1
Installation:
Installation is split into two sections: 1. Installation of the module 44631, 2. Installation of the module 44632.
SECTION 1, Installing the 44631: Follow the instructions in this section to install the 44631 Rapid Power
Module on a 2.7L Sprinter or a 3.2L Mercedes Sedan.
Engine Overview 2.7L, 3.2L ‘01-’06
Fuel Rail Pressure Sensor
The engine overview seen above is an example of a 2.7L
Mercedes engine on a Sprinter Van. The 3.2L Mercedes
engine is nearly the same, the dierence is that the
2.7L is a strait ve cylinder and the 3.2L is a strait six
cylinder. The Fuel Rail sensor plug is located in the same
place on both engines.
Warning: Do not attempt to perform
installation of any type on the vehicle while the engine is running.
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RL
F
B
Installation sec. 1
1.Make sure vehicle’s engine is o.
2.Locate the common rail plug sensor on the
engine. The common rail is located on the
driver’s side of the engine by the radiator.
Engine Orientation and Location of Fuel
Rail Pressure Sensor for 2.7L and 3.2L.
3. Disconnect the stock female sensor plug from the common rail.
Common Fuel Rail
Sensor Plug
Common Fuel Rail
4. Connect the male module sensor plug to the stock female fuel pressure sensor plug.
Stock Female Plug
Stock Female Plug
Module male Plug
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Installation sec. 1
5. Connect female module plug to the rail pressure sensor male end. This will complete the
installation of the plug set. See the picture below for an example of a completed plug set
install.
Female module Plug connected to rail sensor male plug
6. Secure module and the wiring
harness as far away from heat and
moving parts as possible using the
velcro and zip ties that are included
in the package.
7. With the module secured, quickly
recheck all of the plugs to make sure
that they are fully snapped together.
Then start the engine to make sure
that everything is working and take
the vehicle for test drive. the module
has been secured start engine and
enjoy.
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Installation sec. 2
SECTION 2, Installing the 44632: Follow the instructions in this section to install the 44632 Rapid Power
Module on a 3.0L V6 Mercedes engine on the Sprinter Vans and Mercedes SUVs and Sedans.
The engine overview seen above is an example of a 3.0L V6 Mercedes engine on a Sprinter Van, Mercedes SUV
and Mercedes Sedan.
Engine Overview 3.0L, V6 ‘07-’09
Fuel Rail Pressure Sensor
Do not plug this module into the wrong fuel
rail. The correct rail is on the passenger side
of the engine the fuel rail pressure sensor is in
the back of the engine.
Warning: Do not attempt to perform
installation of any type on the vehicle while the engine is running.
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RL
F
B
Installation sec. 2
1.Make sure vehicle’s engine is o.
2.Locate the common rail fuel sensor on the
engine. There are two common rails, the
common rail that the module plugs into is
on the passenger’s side of the vehicle.
Engine Orientation and Location of Fuel Rail
Pressure Sensor for the 3.0L.
3. Disconnect the rail sensor plug from the common rail, this plug will be at the back of the
common rail.
4. Connect the female module sensor plug onto the male fuel pressure sensor plug.
5. Connect male module plug into
female fuel pressure sensor
plug.
Fuel Rail Pressure Sensor
Module Male Fuel Pressure Plug
Fuel Rail Pressure Female Plug
Fuel Rail Pressure Sensor
Do not plug this module into the wrong fuel rail. The correct rail is on the passenger
side of the engine the fuel rail pressure sensor is in the back of the engine.
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Installation Sec. 2
6. Secure module and the wiring harness as far away from heat and moving parts as possible using the velcro and zip ties that are included in the package.
7. With the module secured, quickly recheck all of the plugs to make sure that they are fully
snapped together. Then start the engine to make sure that everything is working and take
the vehicle for test drive. the module has been secured start engine and enjoy.
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Update Agent
UPDATE AGENT
IMPORTANT: The information on this page is applicable to all electronic products made by Bully Dog.
If new udpates come available for the Rapid Power Module, those updates will only be available
through the Update Agent. The Update Agent is an internet update program designed by Bully Dog
Technologies to update Bully Dog products. The Update Agent is free of charge and all updates available through the Update Agent are free of charge as well.
How to Get the Update Agent:
• Update Agent CD: included in your Rapid Power package
is the Update Agent CD. This CD contains the Update Agent
and all other necessary components to make the Update
Agent work on your PC.
• Online Download Center: To acquire the Update Agent
online simply visit Bully Dog’s web site www.bullydog.
com/download_center.php to access the Download Center
and download it for free.
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Bully Dog Technologies, LLC is a team built on integrity that is dedicated to leading the vehicle performance
industry with an uncompromising code of ethics demonstrated in the soundness of its employees, excellent
customer service and superior products.
UNLEASH THE POWER
WITH BULLY DOG PERFORMANCE PRODUCTS
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For a full listing of Diagnostic Trouble Codes go to: www.bullydog.com/DTC.php
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Doc.# BD44631-99 v1
®
For Free Technical Support
Call: 866-bullydog (866-285-5936)
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