DiabloSport Extreme PowerPuck Shim Kit Instalation Guide - Manual

Shim Kit
Instalation Guide
Dodge 6.7L 2007.5+
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.
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.
Locating your Fuel Rail Valve:
Locating your Fuel Rail Valve:
GM 6.6L Duramax, 2004.5-2006 Models LLY & LBZ
1. Located on the driver’s side firewall you should see the glow plug controller.
Find the controller’’s two bolts and remove them.
2. You will now see 5 bolts, one located on the metal tubing and 4 on the case.
Remove them all exposing the fuel pressure valve.
3. Unscrew the fuel pressure valve and carefully remove it from the fuel rail.
Installing the Shim Kit: Dodge 6.7L 2007.5+
GM 6.6L Duramax, 2004.5-2006 Models LLY & LBZ
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.
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.
9. To prevent damage to the valve seal surface, place the valve into the vice with a thick
piece of cardboard valve into the vice with a thick
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
is held in place by your new indentations. if not, repeat step 9 & 10.
11. Carefully re-install the fuel valve. Be sure to tighten the valve to 100 ft/lbs.
1. 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.
2. 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.
Dodge 6.7L 2007.5+
(Re-Assebly)
GM 6.6L Duramax, 2004.5-2006 Models LLY & LBZ
(Re-Assebly)
1. Carefully place the plastic case back onn insuring that all bolts are lined up. Thighten
all 5 bolts
2. Line up the two bolts you removed on the glow plug controller, and re-install the bolts
insuring that the case is on tight.
www.diablosport.com
Tech Support: 1-800-531-5484
In order for your truck to run properly the
following part numbers MUST install the
DIABLOSPORT Shim Kit: P1040 / P2010 /
P2020 / P2030 / P2040 / M4000