SALES:1800-396-6614
TECH: 1-800-531-5484
SALES: 1-800-396-6614
THANK YOU
Thank you for choosing DiabloSport, the World's Greatest Automotive Performance Company.
We hope that you enjoy your new Extreme PowerPuck. Although we would love to tell you
that you are the rst one to touch this individual Extreme PowerPuck that is not the case.
The Extreme PowerPuck you are now holding has gone through many dierent hands to
individually inspect each component to ensure it meets DiabloSport's highest standards.
We take pride in each and every product we produce and hope you take the same pride
in the product you are now holding in your hands. Welcome to the DiabloSport family.
Happy Driving,
The DiabloSport Team
End User
License
Agreement,
Warranty
and
Disclaimer
1
www.DIABLOSPORT.COM
THIS END USER LICENSE AGREEMENT (the “Agreement”) is an
agreement between you, as the purchaser (the “Purchaser”)
of either the Diablo Module (the “Module”) or the hand-held
computer unit (the “Unit”), and as the manufacturer of the
Product DiabloSport (“DiabloSport”). The Product and the Unit
shall be referred to collectively herein as the “product” and
DiabloSport Inc. shall be referred to herein as “DiabloSport”.
1. Acknowledgment And Acceptance Of Agreement. If you do
not agree to the terms and conditions of this Agreement, do
not use the Product. Instead, promptly contact the distributor
from which you purchased the Product in writing, requesting
a refund of the purchase price. Any use of the Product by you
will constitute your agreement to the terms and conditions
contained herein.
2. Grant Of License. The parties hereto acknowledge that DiabloSport
is granting a non-transferable restricted license to Purchaser
to use the Product for the sole purpose of installation in
Purchaser’s vehicle. DiabloSport shall retain all title, ownership
rights and intellectual property rights in and to the Product.
Purchaser agrees that Purchaser shall not, directly or indirectly,
modify, translate, reverse engineer, decompile, disassemble, or
create derivative works based on the Product. Purchaser further
agrees not to permit any third parties to modify, translate,
reverse engineer, decompile, disassemble, or create derivative
works based on the Product.
www.DIABLOSPORT.COM
End User License Agreement, Warranty and
Disclaimer
3. Disclaimer. The Product is being sold with no warranties of
any kind, express or implied. The Product is not endorsed by
the manufacturer of your vehicle and there is no aliation
between DiabloSport and the manufacturer of your vehicle.
Installation of the Product in your vehicle or use of the Product
with your vehicle may limit or void your rights under any
warranty provided by the manufacturer of your vehicle, and
DiabloSport assumes no responsibility in such event. Any
warranty not provided herein, and any remedy which, but for
this provision, might arise by implication or operation of law,
is hereby excluded and disclaimed. The implied warranties of
merchantability and of tness for any particular purpose herein
are expressly disclaimed.
4. No Liability For Damages, Injuries Or Incidental, Special Or Consequential
Damages. Under no circumstances shall DiabloSport,
or any other party related to DiabloSport, be liable to Purchaser
or any other person for any damage to Purchaser’s vehicle, loss
of use of Purchaser’s vehicle, or for personal injuries suered by
any person, or for any incidental, special or consequential damages,
whether arising out of negligence, breach of warranty,
breach of contract, or otherwise. DiabloSport’s liability for any
damages, loss and/or claims associated with the Product shall be
limited to the price of the Product paid by purchaser. Purchaser
hereby releases DiabloSport from all liability, claims and damages
associated with the Products, with the sole exception of
DiabloSport’s liability for the refund of the purchase price of
the Product to Purchaser in the event that a court of competent
jurisdiction determines the Purchaser suered damages directly
resulting from the malfunction of the Product.
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End User License Agreement, Warranty and
Disclaimer
5.Warranty. Notwithstanding the provisions of the End User
License Agreement, DiabloSport warrants the Product to be
free from all defects in material and workmanship for 2 years
from the date of original purchase. This limited warranty applies
only to the original Purchaser of the Product. This limited
warranty does not cover damage caused by modication, alteration,
repair or service of the Product by anyone other than
DiabloSport, physical abuse, misuse, use in a manner contrary to
the instructions, which accompany the Product, or any damage
caused by acts of God. Contacting your Distributor or Dealer
may make claims for repair service or replacement of the Product
pursuant to this limited warranty. The Chip will either be
repaired or replaced, at the option of DiabloSport, at no cost
to Purchaser, if the defective Product is covered by this limited
warranty. DiabloSport’s liability pursuant to this limited warranty
and for any damages, loss and/or claims associated with
the Product shall be limited to the price of the Product paid by
Purchaser, or, at DiabloSport’s option, repair or replacement of
the Product.
a. DiabloSport oers a 30 day satisfaction guarantee on all
products.
b. DiabloSport products carry a 2 year warranty against defects
in materials or workmanship.
i. DiabloSports liability under this warranty shall be limited to
the correction or replacement of any defective part or product
in question which DiabloSport determines to be necessary.
ii. Warranty freight charges are the responsibility of the dealer
distributor and/or customer.
iii. This warranty is to the original purchaser and is non transferable.
iv. This warranty is void unless proof of purchase is submitted.
www.DIABLOSPORT.COM
Warranty Information
End User License Agreement, Warranty and
Disclaimer
Product must be purchased at an DiabloSport Authorized
Dealer in order to qualify for warranty.
v. Removal of serial numbers and/or alteration of product or
packaging will also void all warranties.
c. DiabloSport shall not be held responsible for direct or indirect
failures due to our product.
d. DiabloSport shall not credit or repair any units that are not
properly restored to the original backup upon time of return
or may be VIN locked.
i. VIN locked units, or improperly restored units, will be returned
to customer.
ii. It is the customers responsibility to check any and all DiabloSport
product to make sure the original backups have been
restored to vehicles before the product shall be returned.
e. Technical Support
i. DiabloSport customers should maintain adequate knowledge
of the DiabloSport product line to be able to properly
sell, and to service the needs of their customers.
ii. DiabloSport will provide technical assistance and advice
directly to the dealer/distributor to enable them to answer
and eld technical questions.
iii. It is the responsibility of the dealer distributor to handle
their own technical issues with customers, and not to direct
them to DiabloSport.
f. Product updates
i. DiabloSport shall inform all customers of the latest product
as soon as they are available. DiabloSport will inform customers
on our website at www.diablosport.com.
ii. DiabloSport cannot be held accountable for any or all damages
caused by using outdated product.
iii. Products that need updates will be handled in the following
fashion:
1. DiabloSport will charge a labor and handling fee for products
that are internet updateable or remotely updateable.
www.DIABLOSPORT.COM
End User License Agreement, Warranty and
Disclaimer
End User License Agreement, Warranty and
Disclaimer
2. DiabloSport will not charge a fee for products that are
not internet updateable or remotely updateable. Shipping
charges may apply.
iv. All products returned for update purposes must have a corresponding
DiabloSport RMA number for processing.
g. Returns and RMA/RGA policies and procedures
i. DiabloSport will not warranty, credit, or exchange any product
returned without a valid RMA number.
1. All RMA numbers are issued by DiabloSport RMA department.
2. Defective units shall be repaired and returned in like kind.
All units that must be re-furbished to like new condition
are subject to labor and parts charges to be determined by
DiabloSport.
ii. Customers are subject to a 20% restocking fee for all product
returned for credit.
iii. All units on RMA MUST have conditions for which they were
returned clearly labeled on the box, or given to a DiabloSport
RMA representative at the time the RMA is issued.
6. State Law. Some states do not allow limitations of
implied warranties, or the exclusion or limitation of incidental,
special or consequential damages, so the above
limitations may not apply to you. In such states, liability shall
be limited to the greatest extent permitted by applicable law.
7. Governing Law & Venue. This Agreement shall be governed
by and construed in accordance with the laws of the State of
Florida, and venue for any legal proceeding or action at law
arising out of or construing this Agreement shall lie in the state
or federal courts of Orange County, Florida, and the parties
specically waive any other venue.
DISCLAIMER Not legal for sale or use on any pollution controlled
motor vehicles. Legal in California only for racing vehicles which
may never be used upon a highway.
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INDEX
2
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LIGHT DUTY TRUCKS
Ford Powerstroke 6.0L 2004.5-2007.5 1-3
Dodge 24 Valve 5.9L 2003-2006 4-6
Dodge Cummins 5.9L C.R. 2004-2007 7-8
Dodge 6.7L 2007.5+ 9-14
GM LB7/LLY 6.6L 2001-2005 15-19
GM LBZ/LMM 6.6L 2006-2008 20-22
JEEP Liberty CRD 2005-2006 23-25
MEDIUM DUTY TRUCKS
Cummins 8.3L CAPS 1998-2005 26-28
Cummins 8.3L C.R. 2005-2007 29-30
LLY-Topkick 6.6L Duramax 2004-2007 31-33
7.8L Duramax 2004.5+ 34-36
CAT .C7/3126-C9 (1998-2005/2000-2007) 37-39
INT. DT444 1992-2002 40-41
INT. DT466/DT530/DT570 1997-2003.5 42-43
INT. DT466/DT530/DT570 2004-2006 44-45
INT. VT365 2003-2007 46
INSTALLATION INDEX
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Make/Model Year(s) Pages
INT. = International
CAT.= Caterpillar
CONTENT
3
www.DIABLOSPORT.COM
www.DIABLOSPORT.COM
1. One(1) DiabloSport Extreme PowerPuck
2. One(1) DiabloSport Extreme PowerPuck Wiring Harness
3. One(1) DiabloSport Extreme PowerPuck adjustable 3
position switch or One(1) DiabloSport Extreme PowerPuck
adjustable "Diablo Dial" switch.
4. Two(2) Zip Ties
5. One(1) strip of velcro
6. One(1) small tube Dielectric Grease
* Depending on your vehicle application, your
DiabloSport Extreme PowerPuck may/may not include
the following items:
Shim Kit
CONTENTS
INSIDE YOUR DIABLO BOX
CONTENTS
INSIDE YOUR DIABLO BOX
www.DIABLOSPORT.COM
Installation
of the
DIABLOSPORT
EXTREME
POWERPUCK
4
www.DIABLOSPORT.COM
Pre-Installation Instructions
www.DIABLOSPORT.COM
Please be sure to read all instructions and have
a complete understanding of them before you
attempt to install you new
DiabloSport Extreme PowerPuck.
Please make sure to disconnect the battery and
remove your keys from the ignition before beginning
the installation process
Before connecting any electrical components place
a sucient amount of Di-Electric grease
onto each connection.
NEVER UN-PLUG YOUR EXTREME POWERPUCK FROM
YOUR VEHICLE WHILE THE ENGINE IS RUNNING.
THIS MAY CAUSE UNEXPECTED ERRORS / ENGINE FAILURES.
To lessen the regeneration process frequency, turn Extreme Powerpuck back to stock in stop and
go trac. When going through regeneration process, turn the module to back to stock.
If there are any questions on the product or installation of the
EXTREME POWERPUCK give us a call at DIABLOSPORT
(1-800) 531-5484
1
2004.5-2007.5 Ford Powerstroke 6.0L
www.DIABLOSPORT.COM
1. Find a desired location under the hood of your vehicle
to mount the DiabloSport Extreme PowerPuck. Ensure
that the location you pick is free from extreme heat,
moisture, and has sucient room for mounting. We have
found a good place to mount the Puck is on the canister
directly behind the passenger’s side battery.
2. Route the adjustable switch through the rewall into the
cab of your vehicle. Route the wire away from any moving
devices and away from extreme heat that may burn the wire.
Avoid cutting any factory wiring.
INSTALLATION
Ford Powerstroke 6.0L
2004.5-2007.5
INSTALL ATION
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3. Locate your vehicle’s MAP sensor. This can be found on
your vehicle’s passenger side of the engine compartment.
It should be mounted to the heater box by a metal plate.
4. Unplug your vehicle’s factory harness from the MAP sensor
and plug in the harness from your new
DiabloSport Extreme PowerPuck.
5. Locate your vehicle’s injection control pressure sensor.
This can be found on the passenger’s side valve cover.
Disconnect the factory harness ensuring that the small key
connector is removed as well. If the key connector does not
come out with the harness simply use a small set of needle
nose pliers to remove the key and insert it onto the
factory connector.
2
2004.5-2007.5 Ford Powerstroke 6.0L
INSTALL ATION
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6. Unplug your vehicle’s ICP sensor and plug the
DiabloSport Extreme PowerPuck’s harness into it.
7. Mount the adjustable “Diablo Dial” in a convenient
location inside the cab of your vehicle.
3
2004.5-2007.5 Ford Powerstroke 6.0L
4
www.DIABLOSPORT.COM
1. Using your supplied velcro strips securley mount the
Extreme PowerPuck to a desired location. We recomend
mounting the Extreme PowerPuck on top of the fuse and
relay module. This module can be found on the drivers
side of the engine compartment just in front of the battery.
INSTALLATION
Dodge 5.9L 24 Valve
2003-2006
2003-2006 Dodge 5.9L 24 Valve
INSTALL ATION
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2. On the driver's side just next to the valve cover you will
nd your vehicle's MAP sensor. The sensor should have a blue
weather tight seal around it. Disconnect the harness currently
plugged into your MAP sensor and plug in the
Extreme PowerPuck's harness.
3. Just in front of the MAP sensor you will nd the Fuel
Pressure Sensor (FPS). As you did in step 2, disconnect the
current harness and plug in the Extreme PowerPuck's harness.
5
2003-2006 Dodge 5.9L 24 Valve
INSTALL ATION
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4. Run the "Diablo Dial" switch wire through your vehicle's
rewall to the DiabloSport Extreme PowerPuck
5. In a location of your choice, mount the "Diablo Dial" in
you vehicle's cab
6. Reconnect your vehicle's battery and enjoy your drive!
6
2003-2006 Dodge 5.9L 24 Valve
INSTALLATION
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Cummins 5.9L Common Rail
2004-2007
1. Inside you engine compartment you will see six steel
lines that run directly to the injectors. Next to this you will
nd your Fuel Injection rail.
2. Once the fuel injection rail is located, nd your vehicle's
fuel pressure sensor. this will be on the actual
fuel injection rail.
3. Unplug you vehicle's fuel pressure sensor and plug in
your new DiabloSport Extreme PowerPuck into the sensor.
4. Plug in your vehicle's factory harness into the other
side of the DiabloSport Extreme PowerPuck's harness.
7
2004-2007 Dodge Cummins 5.9L Common Rail
INSTALL ATION
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5. Using the included zip ties run the adjustable switch
from the DiabloSport Extreme PowerPuck
through the rewall into the cab of your vehicle
making sure to route the cables away from
any parts which may move and become entangled.
6. Mount the “DIABLO DIAL” in a convienent location.
Power increases as you turn the “DIABLO DIAL”
clockwise
8
2004-2007 Dodge Cummins 5.9L Common Rail
www.DIABLOSPORT.COM
1. Locate the plastic cover plate on top of the engine.
Carefully remove the dipstick and 4 bolts
holding the plastic cover plate.
2. After removing the plastic cover plate, locate
the Exhaust Gas Recirculation tube. Using a
11mm wrench carefully remove the two clamps,
which hold the EGR tube, in front of the valve cover
without removing the EGR tube.
9
2007.5+ Dodge 6.7L
INSTALLATION
Dodge 6.7L
2007.5+
INSTALL ATION
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3. Locate the single bolt which holds the dipstick
tube to the bracket and the 6 bolts which hold
the air horn to the manifold. Using a 10mm socket
and wrench remove all 7 bolts. Carefully slide the
air horn forward so the front of the fuel
rail is accessible. Please be careful not to
damage the gasket
4. Carefully remove the 18mm fuel
rail valve. This valve can be found on the
front of the fuel rail.
10
2007.5+ Dodge 6.7L
INSTALL ATION
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5. Carefully screw the supplied nut tool onto the valve.
Place the fuel rail valve into a vice. The vice should
clamp down on the sides of the valve cap.
6. In order to remove the valve cap, carefully unscrew the nut.
CAUTION: This piece is spring loaded. Be sure that you are
holding the end of the valve while unscrewing to prevent
a possible loss of parts. When removing the cap take note
of how the holes inside the cap lined up with the spring.
11
2007.5+ Dodge 6.7L
INSTALLATION
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7. By carefully removing the metal spring you can now
place the three supplied metal shims into the valve.
8. Place the spring back into the valve and replace the cap.
NOTE: The inside of the valve cap has three holes which
form the shape of a triangle. Do not remove this and ensure
that these holes face towards the spring as they did
when you removed it.
12
2007.5+ Dodge 6.7L
13
INSTALL ATION
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9. To prevent damage to the valve seal surface, place the
valve into the vice with a thick piece of cardboard
or wood facing the valve cap.
10. Using your small punch and hammer, carefully re-apply
the 3 factory indentations to the valve lip. These indentations
should be applied to the lip where
the valve casing covers the valve
cap. In order to rotate the valve
you may need to loosen the vice.
When doing this be sure not to
allow the spring to push the cap
out. After punching the three
indentations, remove the valve
and make sure the valve cap is held in place by your new
indentations. if not, repeat step 9 & 10.
2007.5+ Dodge 6.7L
11. Carefully re-install the fuel valve. Be sure to tighten
the valve to 50 ft/lbs.
12. Line up the 6 bolt holes on the air horn with the 6 holes
in the gasket and re-install the air horn. After the air horn is
installed, re-connect the dipstick tube to the bracket on the
air horn.
13. Carefully re-install the EGR tube. The easiest way to do this
is to line up one side at a time and gently install the clamp
leaving it loose enough for adjustment. Once both sides are
gently clamped in place, ensure the EGR tube is in it's proper
palcement and tighten both sides.
14. On the back of the fuel rail close to the re wall you should
see the fuel pressure sensor. After locating this sensor plug the
factory connector into the Extreme PowerPuck's harness. Plug
he other side of the Extreme PowerPuck's harness into the fuel
pressure sensor.
15. Connect the harness to your DiabloSport Extreme PowerPuck
and using the provided velcro strips mount the Extreme
PowerPuck in a convienent location.
16. Run the switch wire through the rewall and plug it into the
Extreme PowerPuck. Mount the switch in the cab where you would
have easy access while driving.
17. Drive and enjoy.
INSTALL ATION
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14
2007.5+ Dodge 6.7L
GM Duramax LB7 & LLY 6.6L
2001-2005
INSTALLATION
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1. Find a desired location under the hood of your vehicle to
mount the DiabloSport Extreme PowerPuck. Ensure that the
location you pick is free from extreme heat, moisture, and
has sucient room for mounting.
2. Route the adjustable switch through the rewall into the
cab of your vehicle. Route the wire away from any moving
devices and away from extreme heat that may burn the wire.
Avoid cutting any factory wiring.
15
2001-2005 GM Duramax LB7 & LLY 6.6L
INSTALL ATION
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3. Locate your vehicle’s MAP sensor.
4. For LB7 Applications the MAP sensor will be located under
your vehicle’s air intake module on top of the vehicle’s engine.
In order to access the MAP sensor you will need to remove the
intake box and tube.
5. For LLY Applications the MAP sensor will be located directly
behind your vehicle’s AC compressor. In order to access the
MAP sensor you might need to remove the belt and the bolts
(15mm) holding the compressor in place. CAUTION: Do not
remove any of the lines leading into the compressor. After the
bolts have been removed just move the compressor
slightly to the side.
16
2001-2005 GM Duramax LB7 & LLY 6.6L
INSTALL ATION
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6. Unplug your vehicle’s factory harness from the MAP
sensor and plug in the harness from your new
DiabloSport Extreme PowerPuck. If you
removed your AC-compressor re-attach your AC
compressor with the bolts you removed and put the
belt back on.
7. Locate your vehicle’s fuel pressure sensor.
17
2001-2005 GM Duramax LB7 & LLY 6.6L
INSTALL ATION
www.
DIABLOSPORT
.COM
9. For LLY applications the Fuel
Pressure Sensor is located just below the
air intake tube on the passenger’s side of the
engine (see picture).
18
2001-2005 GM Duramax LB7 & LLY 6.6L
8. For LB7 applications the Fuel Pressure Sensor is located
just below the intercooler tube. You will need to remove
the intercooler tube itself to expose the sensor.
after plugging in the harness be sure to reconnect the tube)
10. Unplug your vehicle’s factory harness from
the fuel pressure sensor and plug in the harness
from your new DiabloSport Extreme PowerPuck.
*Please See Graphic references on next page
INSTALL ATION
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19
2001-2005 GM Duramax LB7 & LLY 6.6L
www.DIABLOSPORT.COM
1. Find a desired location under the hood of your vehicle to
mount the DiabloSport Extreme PowerPuck. Ensure that the
location you pick is free from extreme heat, moisture, and has
sucient room for mounting.
2. Route the adjustable switch through the rewall into the
cab of your vehicle. Route the wire away from any moving
devices and away from extreme heat that may burn the wire.
Avoid cutting any factory wiring.
20
2006-2008 GM Duramax LBZ & LMM 6.6L
GM Duramax LBZ & LMM 6.6L
2006-2008
INSTALLATION
3. Locate your vehicle’s MAP sensor. The sensor should be
located just in front of the air intake manifold tube which is
located in front of the vehicle’s engine.(see picture)
4. Unplug your vehicle’s factory harness from the MAP sensor
and plug in the harness from your new
DiabloSport Extreme PowerPuck.
INSTALL ATION
www.DIABLOSPORT.COM
21
2006-2008 GM Duramax LBZ & LMM 6.6L
5. Locate your vehicle’s fuel pressure sensor. If sensor is
found on the back of the fuel rail on the passenger side
of the engine. See attached diagram for location
of this sensor.
INSTALL ATION
www.DIABLOSPORT.COM
6. Unplug your vehicle’s factory harness from the fuel
pressure sensor and plug in the harness from your new
DiabloSport Extreme PowerPuck.
7. Mount the adjustable “Diablo Dial” in a convenient location
inside the cab of your vehicle.
22
2006-2008 GM Duramax LBZ & LMM 6.6L
www.DIABLOSPORT.COM
1. Find a desired location under the hood of your vehicle
to mount the DiabloSport Extreme PowerPuck. Ensure
that the location you pick is free from extreme heat, moisture,
and has sucient room for mounting. We have found a good
place to mount the Puck is on the fuse box located on the
driver’s side of the engine compartment directly in front
of the battery.
2. Route the adjustable switch through the rewall into the
cab of your vehicle. Route the wire away from any moving
devices and away from extreme heat that may burn the wire
Avoid cutting any factory wiring.
23
2005-2006 Jeep Liberty CRD
INSTALLATION
JEEP Liberty CRD
2005-2006
INSTALL ATION
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3. Locate and remove your vehicle’s oil llet cap and
plastic engine cover. This will expose the sensors which
you will need access to.(be sure to re-install the cap and
cover after step 4 is completed)
4. Look for a connector with a blue weather seal.
This is the MAP sensor. It can be found toward the back
of the engine compartment atop the rewall just under
the wipers on the driver’s side.
5. Unplug your vehicle’s factory harness from the MAP sensor
and plug in the harness from your new
DiabloSport Extreme PowerPuck.
24
2005-2006 Jeep Liberty CRD
INSTALL ATION
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6. Locate your vehicle’s fuel pressure sensor. This can
be found just in front of the MAP sensor connector.
It should have a orange indicator when disconnected
7. Unplug your vehicle’s factory harness from the fuel
pressure sensor and plug in the harness from your
new DiabloSport Extreme PowerPuck
8. Mount the adjustable “Diablo Dial” in a convenient
location inside the cab of your vehicle.
25
2005-2006 Jeep Liberty CRD
26
Cummins 8.3L Caps
www.DIABLOSPORT.COM
1. Locate you vehicle’s fuel pump. It can be found by
locating the six large steel lines that run to your
vehicle’s injectors.
2. On the back side of the fuel pump you will nd you
Vehicle’s fuel pressure sensor. The connection should
Look identical to the connector on the DiabloSport
PowerPuck Extreme’s harness.
3. Unplug you vehicle’s fuel pressure sensor and plug in
the DiabloSport Extreme’s PowerPuck harness
4. Now plug your vehicle’s harness into the other side of
The DiabloSport Extreme PowerPuck’s harness.
INSTALLATION
Cummins 8.3L CAPS
1998-2005
INSTALL ATION
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5. Using the picture below as a reference, locate your vehicle’s
MAP sensor
6. Unplug your vehicle’s factory map sensor and plug in the
harness From you new DiabloSport Extreme PowerPuck into the
MAP sensor.
7. Taking the leftover connector plug it into the factory harness
8. Mount the DiabloSport Extreme PowerPuck in a safe location
Using the supplied Zip Ties/Velcro
9. Route the adjustable switch through the rewall into the
cab of your vehicle. Plug the connector into the
DiabloSport Extreme PowerPuck.
27
Cummins 8.3L Caps
INSTALL ATION
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10. Mount the adjustable “Diablo Dial” in a convenient
location inside the cab of your vehicle.
28
Cummins 8.3L Caps
www.DIABLOSPORT.COM
1. Inside you engine compartment you will see six steel
lines that run directly to the injectors. Next to this you
will nd your Fuel Injection rail.
29
2005-2007 Cummins 8.3L Common Rail
INSTALLATION
Dodge Cummins 8.3L Common Rail
2005-2007
2. Once the fuel injection rail is located, nd your vehicle's
fuel pressure sensor. This will be on the actual fuel injection rail.
3. Unplug you vehicle's fuel pressure sensor and plug in your
new DiabloSport Extreme PowerPuck into the sensor.
4. Plug in your vehicle's factory harness into the other side
of the DiabloSport Extreme PowerPuck's harness
5. Using the included zip ties route the cables away from
any parts which may move and become entangled.
INSTALL ATION
www.DIABLOSPORT.COM
6. Run the adjustable switch from the DiabloSport
Extreme PowerPuck through the rewall into the
cab of your vehicle.
7. Mount the switch in a convienent location.
Power increases as you turn the “DIABLO DIAL” clockwise
30
2005-2007 Cummins 8.3L Common Rail
INSTALLATION
www.DIABLOSPORT.COM
GM Duramax LLY Topkick 6.6L
2004-2007
1. Find a desired location under the hood of your vehicle
to mount the DiabloSport Extreme PowerPuck. Ensure that
the location you pick is on the driver’s side and is free from
extreme heat, moisture, and has sucient room for mounting.
2. Locate your vehicle’s MAP sensor. See diagram for location
of this sensor.
3. Unplug your vehicle’s factory harness from the MAP sensor
and plug in the harness from your new
DiabloSport Extreme PowerPuck.
31
2004-2007 Duramax LLY Topkick 6.6L
INSTALL ATION
www.DIABLOSPORT.COM
4. Locate your vehicle’s fuel pressure sensor. The fuel
pressure sensor should be located on the back of the
fuel rail, on the passenger side.
32
2004-2007 Duramax LLY Topkick 6.6L
INSTALL ATION
www.DIABLOSPORT.COM
5. Unplug your vehicle’s fuel pressure sensor and plug the
DiabloSport Extreme PowerPuck’s harness into it.
6. Route the adjustable switch through the rewall into the
cab of your vehicle. Plug the connector into the
DiabloSport Extreme PowerPuck.
7. Mount the adjustable “Diablo Dial” in a convenient location
inside the cab of your vehicle.
33
2004-2007 Duramax LLY Topkick 6.6L
34
www.DIABLOSPORT.COM
1.Find a desired location under the hood of your vehicle
to mount the DiabloSport Extreme PowerPuck. Ensure
that the location you pick is on the driver’s side and is
free from extreme heat, moisture, and has sucient
room for mounting.
2. Locate your vehicle’s MAP sensor. This can be found
by locating your vehicle’s intercooler and following it to
the manifold. The MAP sensor is located on the manifold.
See Picture Below.
2004.5-2007.5 DURAMAX 7.8L
INSTALLATION
DURAMAX 7.8L
2004.5-2007.5
INSTALL ATION
www.DIABLOSPORT.COM
3. Unplug your vehicle’s factory harness from the
MAP sensor and plug in the harness from your new
DiabloSport Extreme PowerPuck.
4. Locate your vehicle’s fuel rail. Once your fuel rail
is located you should be able to nd the fuel pressure
sensor (see picture)
35
2004.5-2007.5 DURAMAX 7.8L
INSTALL ATION
www.DIABLOSPORT.COM
5. Unplug your vehicle’s injection control pressure sensor
and plug the DiabloSport Extreme PowerPuck’s harness into it
6. Route the adjustable switch through the rewall into the
cab of your vehicle. Plug the connector into the
DiabloSport Extreme PowerPuck.
7. Mount the adjustable “Diablo Dial” in a convenient
location inside the cab of your vehicle.
36
2004.5-2007.5 DURAMAX 7.8L
INSTALLATION
Caterpillar C7/3126-C9
1998-2005/2000-2007
1. Find a desired location under the hood of your vehicle to
mount the DiabloSport Extreme PowerPuck. Ensure that the
location you pick is free from extreme heat, moisture, and has
sucient room for mounting. We have found a good place to
mount the Puck is on the driver’s side.
2. Route the adjustable switch through the rewall into the cab
of your vehicle. Route the wire away from any moving devices
and away from extreme heat that may burn the wire. Avoid
cutting any factory wiring.
www.DIABLOSPORT.COM
37
1998-2005 / 2000-2007 CAT. C7/3126 - C9
INSTALL ATION
www.DIABLOSPORT.COM
3. Locate your vehicle’s fuel
pressure sensor(ICP). This
sensor can be found on the
driver’s side of the engine
block on the front side of the
engine. The sensor can be
identied by white, brown,
and green wires.
4. Unplug your vehicle’s
factory harness from the
fuel pressure sensor and
plug in the harness from
your new DiabloSport
Extreme PowerPuck.
38
1998-2005 / 2000-2007 CAT. C7/3126 - C9
INSTALL ATION
www.DIABLOSPORT.COM
5. To locate your vehicle’s MAP sensor, simply locate the intake
manifold. This should be located on the rear of the engine closer
to the driver’s side next to the valve cover. The MAP sensor can
usually be identied by nding the sensor with green, white,
and pink wires.
6. Unplug your vehicle’s factory harness from the MAP sensor
and plug in the harness from your new DiabloSport
Extreme PowerPuck.
7. Mount the adjustable “Diablo Dial” in a convenient location
inside the cab of your vehicle.
39
1998-2005 / 2000-2007 CAT. C7/3126 - C9
www.DIABLOSPORT.COM
1. Find a desired location under the hood of your vehicle
to mount the DiabloSport Extreme PowerPuck. Ensure that
the location you pick is free from extreme heat, moisture,
and has sucient room for mounting. We have found a good
place to mount the Puck is on the driver’s side.
2. Route the adjustable switch through the rewall into the
cab of your vehicle. Route the wire away from any moving
devices and away from extreme heat that may burn the wire.
Avoid cutting any factory wiring.
INSTALLATION
International DT444
1992-2002
40
1992-2002 International DT444
INSTALL ATION
www.DIABLOSPORT.COM
3. Locate your vehicle’s fuel pressure sensor(ICP).
This sensor can be found on the driver’s side of the engine
block on the front side of the engine. You will see a tube
running from the intercooler to the engine. The fuel pressure
sensor is located under this tube.
4. Unplug your vehicle’s factory harness from the fuel
pressure sensor and plug in the harness from your new
DiabloSport Extreme PowerPuck.
41
1992-2002 International DT444
5. Mount the adjustable “Diablo Dial” in a convenient location
inside the cab of your vehicle.
www.DIABLOSPORT.COM
1. Find a desired location under the hood of your vehicle to
mount the DiabloSport Extreme PowerPuck. Ensure that the
location you pick is free from extreme heat, moisture, and has
sucient room for mounting. We have found a good place to
mount the Puck is on the fuse box located on the driver’s side.
2.a Route the adjustable switch through the rewall into the
cab of your vehicle. Route the wire away from any moving
devices and away from extreme heat that may burn the wire.
Avoid cutting any factory wiring.
INSTALLATION
International DT466/DT530/DT570
1997-2003.5
42
1997-2003.5 INT. DT466/DT530/DT570
INSTALL ATION
www.DIABLOSPORT.COM
2.b Locate your vehicle’s fuel pressure sensor. This sensor
can be found on the driver’s side of the engine block.
If your vehicle is the DT466E the sensor can be found
behind a computer next to the engine block.
3. Unplug your vehicle’s factory harness from the fuel
pressure sensor and plug in the harness from your new
DiabloSport Extreme PowerPuck.
43
1997-2003.5 INT. DT466/DT530/DT570
INSTALLATION
www.DIABLOSPORT.COM
1. Find a desired location under the hood of your vehicle
to mount the DiabloSport Extreme PowerPuck.
Ensure that the location you pick is free from extreme heat,
moisture, and has sucient room for mounting. We have
found a good place to mount the Puck is on the driver’s side.
2. Route the adjustable switch through the rewall into the
cab of your vehicle. Route the wire away from any moving
devices and away from extreme heat that may burn the wire.
Avoid cutting any factory wiring.
3. Locate your vehicle’s fuel pressure sensor(ICP).
This sensor can be found on the driver’s side of the engine
block on the rear side of the engine.
International DT466, DT530, DT570
2004-2006
4. Unplug your vehicle’s factory harness from the fuel
pressure sensor and plug in the harness from your new
DiabloSport Extreme PowerPuck.
44
2004-2006 INT. DT466 - DT530 - DT570
45
2004-2006 INT. DT466 - DT530 - DT570
INSTALL ATION
www.DIABLOSPORT.COM
5. Locate your vehicle’s MAP sensor(see diagram). The MAP
sensor should be located on the same side as the ICP sensor
slightly toward the front of the engine.
6. Unplug your vehicle’s factory harness from the MAP sensor
and plug in the harness from your new
DiabloSport Extreme PowerPuck.
7. Mount the adjustable “Diablo Dial” in a convenient location
inside the cab of your vehicle.
46
2003-2007 INT. VT 365
INSTALLATION
www.DIABLOSPORT.COM
International VT 365
2003-2007
1. Find a desired location under the hood of your vehicle
to mount the DiabloSport Extreme PowerPuck. Ensure that
the location you pick is free from extreme heat, moisture,
and has sucient room for mounting. We have found a good
place to mount the Puck is on the driver’s side.
2. Route the adjustable switch through the rewall into the
cab of your vehicle. Route the wire away from any moving
devices and away from extreme heat that may burn the wire.
Avoid cutting any factory wiring.
3. Locate your vehicle’s fuel pressure sensor. This sensor can
be found on the driver’s side of the engine block directly
behind the turbo for 2003-2004.5 trucks. You will need to
remove the Fuel Pressure Sensor inspection plate rst. If your
vehicle is newer then 2004.5 the sensor can be found on the
passenger side cylinder head.
4. Unplug your vehicle’s factory harness from the fuel pressure
sensor and plug in the harness from your new
DiabloSport Extreme PowerPuck.
5. Mount the adjustable “Diablo Dial” in a convenient location
inside the cab of your vehicle.
SALES: 1-800-396-6614
TECH: 1-800-531-5484
www.DIABLOSPORT.com
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