INSTALLATION GUIDE 95-98 CHEVY/GMC C/K 6.5L TURBO DIESEL 1995-1998
1995-1998 INSTALLATION GUIDE GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved 6.5L TURBO DIESEL • Safety Glasses & Gloves • Assorted Wrenches • Socket Set • Flat Head Screwdriver • Phillips Screwdriver • Center Punch • Marker • Drill & Drill Bits • Tap Handle • Multi-Meter/Test Light • Wire Strippers & Crimper • Shop Vacuum • Pen Magnet • 6.5L Boost Bolt • 3 Gauge Wiring Kit • 6.5L Fuel Pressure Adapter • Mini Expandable Circuits • 1/8-27 NPT Drill and Tap set TABLE OF CONTENTS SECTION 1 Preparing The Installation 1 SECTION 2 Boost Gauge Installation 2 SECTION 3 Fuel Pressure Gauge Installation 4 SECTION 4 Transmission Temp Gauge Installation 5 SECTION 5 Pyrometer EGT Gauge Installation 6 SECTION 6 Preparing The Pillar Pod 7 SECTION 7 Mounting The Pillar Pod 8 SECTION 8 Connecting to Power 9 • Panel Pop Tool • Cutting Oil • Pick Tool • Zip Ties • Grommet • Drain Pan • Teflon Tape • Wire Connectors • Anti-Seize • Transmission Fluid • Intake Manifold Gasket TOOLS & ACCESSORIES NOT INCLUDED OPTIONAL ADD-ONS AND ADAPTERS SOLD SEPARATELY AT GLOWSHIFT.COM GlowShift Installation Guides are designed so that you don’t need to be a professional mechanic to install our products. Whether you’re a beginner or a seasoned pro, we’ll walk any Do-It-Yourselfer through every step of the process for installing our gauges, gauge pods and accessories. The custom gauge package featured in this guide is a popular combination gauge and pod set for the 1995-1998 Chevrolet C/K or GMC Sierra with a 6.5L Turbo Diesel. Before getting started, confirm you have the tools and accessories below and let’s get to work. For MaxTow® Gauges, the wire colors on the gauge power harnesses are different than what appears in this installation guide. Additionally, for the Boost Gauge, please follow the same steps but instead of installing the brass compression fittings and boost line, thread the 1/8-27 NPT boost sensor into your desired location and tighten with a 22mm Wrench. Please note that in some applications additional adapters may also be required. CHECK OUT THE FULL INSTALL VIDEO FOR THIS DETROIT DIESEL: GLOWSHIFT.COM/9598CK
1995-1998 INSTALLATION GUIDE 1 GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved 6.5L TURBO DIESEL Preparing The Installation SECTION 1 This Diesel Gauge Set Installation Guide will feature the installation of the GlowShift 7 Color Series Diesel Gauge Set into your ‘95- ’98 Chevy/GMC 2500 or 3500 with a 6.5L Turbo Diesel. For the purpose of the installation, a three-gauge Triple Pillar Pod will be featured, and you will have the choice between GlowShift’s Boost, Pyrometer EGT, Transmission Temperature and Fuel Pressure Gauges. 1. Open the hood and locate the truck’s two batteries. Using an 8mm Wrench, disconnect the negative terminal of each battery to ensure there is no power running through the truck during the installation. When it comes time to wire and connect the gauges to their power source, you will be able to reconnect power to the negative terminals of the batteries. 2. Remove the driver’s side factory A-pillar trim by releasing the spring clips. The triple pillar gauge pod you will be installing is an overlay. 3. Now that you have the power disconnected from your truck and your factory A-pillar has been removed, proceed with the installation. 1. 2. 3.
1995-1998 INSTALLATION GUIDE GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved 6.5L TURBO DIESEL 2 Boost Gauge Installation SECTION 2 The Boost Gauge can be installed one of two ways: The first is using a 6.5L Boost Bolt Adapter that threads into the Intake Manifold and replaces the Rear Middle Intake Manifold Bolt. The second option applies if you did not purchase an adapter and would like to install the Boost Line directly to the manifold by drilling and tapping the Intake Manifold to 1/8-27 NPT. Option 1: BOOST BOLT INSTALLATION 1. Locate and remove the Rear Intake Manifold Bolt using a 10mm Socket. 2. Apply Teflon Tape to the Ferrule Fitting Adapter. Wrap the tape clockwise on the male threads. 3. Thread the Ferrule Fitting Adapter into the Boost Bolt, and tighten using an 11mm Wrench. 4. Thread the Boost Bolt Adapter into the Intake Manifold and tighten with the 16mm torque Wrench to 17 ft lbs. Note: The Boost Bolt Adapter allows you to replace the existing bolt in the factory location. 5. Slide the Ferrule Fitting Cap and Ferrule onto the Boost Line. (Refer to diagram below) 6. Insert the line into the Ferrule Fitting Adapter and tighten with a 3/8” Wrench. Note: Do not overtighten the Ferrule Fitting. 7. Route the Boost Hose, without kinking, up to the firewall on the driver side of the engine bay and use Zip Ties to secure the Boost Hose. Make sure there is no contact with any direct heat source or moving parts. 1. 3. 6. PROPER ORIENTATION
1995-1998 INSTALLATION GUIDE 3 GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved 6.5L TURBO DIESEL 3. 6. 14. Option 2: DRILLING AND TAPPING THE INTAKE MANIFOLD 1. Start by loosening the turbo coupling using a 5/16” Wrench. 2. Using a 13mm Socket remove the bolt for the support bracket, and unplug the two sensors. 3. Remove the Intake Manifold from the truck by removing the 6x10mm Intake Manifold bolts with a Socket. This will ensure that no shavings enter the Intake during the drilling and tapping process. 4. Mark the drilling location on the Intake Manifold using a marker and a Center Punch. 5. Starting with a 1/8” drill bit, drill your pilot hole into the Intake Manifold and gradually step up in drill bit size until you reach the Size R Drill Bit. 6. Use a 1/8-27 NPT tap to thread the hole. 7. Clean the Manifold with brake clean to remove all shavings. 8. Prepare the Boost Hose for installation by installing the Compression Nut and Ferrule Fitting over the Boost Hose. Apply Teflon Tape to the Ferrule Fitting Adapter. Wrap the tape clockwise on the male threads. 9. Install the Compression Adapter into the 1/8-27 NPT hole you tapped using an 11mm Wrench. 10. Reinstall the manifold to the engine and tighten bolts with a torque Wrench to 17 ft lbs. Note: Using a new gasket when reinstalling the manifold is highly recommended. 11. Plug in the two sensors. 12. Tighten the turbo coupling using a 5/16”Wrench. 13. Slide the Ferrule Fitting Cap and Ferrule onto the Boost Line. (Refer to diagram on previous page) 14. Insert the line into the Ferrule Fitting Adapter and tighten with a 3/8” Wrench. Note: Do not overtighten the Ferrule Fitting 15. Route the Boost Hose, without kinking, up to the firewall to the driver side of the engine bay and use Zip Ties to secure the boost line. Make sure there is no contact with any direct heat source or moving parts of the truck.
1995-1998 INSTALLATION GUIDE GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved 6.5L TURBO DIESEL 4 Fuel Pressure Gauge Installation SECTION 3 1. Thread the Fuel Pressure Sensor into the Fuel Pressure Adapter using a 19mm and 22mm Wrench. 2. Locate the Fuel Filter Housing behind the intake manifold and remove the Fuel Filter Bleeder Valve. Note: Have a Drain Pan available to catch the fuel. 3. Thread the Fuel Pressure Adapter into the Fuel Filter Cap and hand tighten. 4. Plug the Fuel Pressure Sensor Harness into the sensor. 5. Route the Sensor Harness up to the firewall on the driver side of the engine bay and use Zip Ties to secure. Make sure there is no contact with any direct heating source or moving parts. 6. Cycle the key on and loosen the Pressure Adapter until the pump sound changes. Then hand tighten the Sensor Adapter. Note: You must temporarily reconnect the battery to complete this step. 7. Locate the brass T-handle valve next to the oil fill and open the valve. Cycle the key on until you have a steady stream of fuel, and then close the valve. Note: Have a Drain Pan available to catch the fuel. 8. Make sure to clean up any excess fuel that may have not been captured by the Drain Pan. Note: Recommended fuel pressure is 5-7PSI at idle. 1. 2. 7. 6.5L Fuel Pressure Adapter
1995-1998 INSTALLATION GUIDE 5 GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved 6.5L TURBO DIESEL Transmission Temp Gauge Installation SECTION 4 1. Safely jack up the truck, if not raised already. 2. Unclip the shift linkage using a Flathead Screwdriver and remove the bracket bolts from the shift linkage assembly using a 13mm Socket. 3. Rotate the Shift Assembly to gain access to the Transmission Test Port. 4. Remove the Transmission Temperature Test Port Bolt using an 11mm Socket. 5. Wrap Teflon Tape clockwise around the Transmission Temperature Sensor Threads and screw into the Transmission Case. Tighten using a 14mm Wrench. 6. Attach the female silver connector and the longer rubber cover to a piece of 18 gauge automotive grade wire and connect to the white wire of the Transmission Temperature Sensor. 7. Attach the male silver connector and short rubber cover to a piece of 18 gauge automotive grade wire and connect to the black wire from the sensor. 8. Rotate the Shift Assembly back into place and reinstall the bracket bolts. 9. Reconnect the Shift Linkage Cable. 10. Route the wires up to the firewall on the driver side of the engine bay and use Zip Ties to secure the sensor wires to ensure there is no contact with any direct heat source or moving parts. 11. Connect the sensor ground wire to a good ground source under the hood. 5. 2. 6.
1995-1998 INSTALLATION GUIDE GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved 6.5L TURBO DIESEL 6 Pyrometer EGT Gauge Installation 1. Confirm the exhaust is cool to the touch during this process. 2. We recommend installing the EGT probe in a pre-turbo location on the manifold to ensure the most accurate readings. Installing the EGT probe in any other locations can cause significantly inaccurate readings. 3. In order to gain access to the Exhaust Manifold, remove the passenger front wheel with a 22mm Socket. 4. Remove the inner wheel liner using a 13mm Socket and a panel pop tool. 5. Locate the Exhaust Manifold on the passenger side of the engine bay. Mark the manifold using a Center Punch in a location where the crossover pipe from the driver side manifold meets the passenger side manifold. 6. Starting with a 1/8” drill bit, drill your pilot hole into the manifold and gradually step up in drill bit size until you reach the Size R Drill Bit. Note: Clean the manifold with a Pen Magnet and Vacuum to ensure no shavings are present in the manifold. 7. Use a 1/8-27 NPT tap to thread the hole. Cutting Oil should be used to make threading the hole easier. Once again, use a Pen Magnet and Vacuum to remove any shavings. 8. Use Anti-Seize on the EGT Probe Threads. 9. Using a 14mm Wrench, slowly thread the Ferrule Fitting Adapter into the 1/8-27 NPT hole you just tapped and tighten until snug. 10. Slide the EGT Probe into the Ferrule Fitting Adapter so that the tip of the probe is in the center of the exhaust and tighten using a 14mm Wrench. Note: Do not overtighten the Ferrule Fitting. SECTION 5 6. 10. 11. Now that the EGT Probe is installed, run the lead wires up to the firewall on the driver side of the engine bay and secure the wires using Zip Ties to ensure there is no contact with any direct heat source or moving parts. 12. Reinstall the wheel well liner. 13. Reinstall the wheel to manufacturer specifications. 14. Lower the vehicle.
1995-1998 INSTALLATION GUIDE 7 GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved 6.5L TURBO DIESEL Preparing The Pillar Pod SECTION 6 1. Place the Triple Pillar Pod on top of the factory A-pillar trim. Using a marker, note placement of where the wires will pass through the A-pillar. 2. Using a Step Bit, drill the 3 holes for the gauge wires to pass through. 3. Drill (4) 7/32” holes in the respective corners of the pod and A-pillar trim and secure using the provided push-in fasteners. 4. Mount the gauges in the Triple Pillar Pod. No specific order is required. 5. This step features the use of GlowShift’s 3 Gauge Wiring Kit (Optional): Using the yellow wire from the wiring harness, connect all of the yellow wires together; using the red wire from the wiring harness, connect all of the red wires together; using the orange wire from the wiring harness, connect all of the orange wires together; using the black wire from the wiring harness, connect all of the black wires together. 6. Wrap Teflon Tape clockwise on the fitting located on the back of the Boost Gauge. This will ensure a leak-free connection. 7. Secure wiring with Zip Ties. 2. 4. 5.
1995-1998 INSTALLATION GUIDE GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved 6.5L TURBO DIESEL 8 1. Now that all of your gauges are mounted, sensors and fittings are installed to their sources and their secured sensor wires are ran to the driver’s side of the engine bay, route the wires through the firewall and into the cab of the truck, keeping clear of any moving parts. Note: You may need to drill a hole in the firewall if there isn’t one already. It is important to use a Grommet on the hole to ensure the wires are not sliced or cut on the firewall. 2. Run the sensor wires and the Boost Line up to the A-pillar location. 3. Insert the line into the Ferrule Fitting Adapter and thread onto the back of the gauge and tighten with a 3/8” Wrench. (Refer to diagram below) 4. Route the EGT Probe Harness and connect to the back of the Pyrometer EGT Gauge. 5. Connect the wire from the Transmission Temperature Sensor to the green wire on the back of the Transmission Temperature Gauge using a Butt Connector. 6. Route the Fuel Pressure Sensor Harness and connect to the back of the Fuel Pressure Gauge. 7. Reinstall the pillar pod. Mounting The Pillar Pod SECTION 7 3. 5. 8. PROPER ORIENTATION
1995-1998 INSTALLATION GUIDE 9 GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved 6.5L TURBO DIESEL 1. Reconnect the negative terminals of both batteries to provide power. 2. Remove the dashboard side cover to gain more access by unclipping the spring tabs. 3. Route the yellow and red wires to the Passenger Compartment Fuse Box. 4. Using an Expandable Circuit, connect the yellow constant wire to fuse #13 which is labeled 20A CIG-LTR. 5. Once again using an Expandable Circuit, connect the red ignition switch wire to fuse #17 which is labeled 10A RADIO. 6. Unclip the gauge cluster trim panel to gain access to the headlight switch, and connect the orange wire to the brown wire in Terminal S, which is a headlamp source on the back of the headlight switch. 7. Connect the black ground wire to a clean, reliable grounding source underneath the dashboard. 8. Reinstall the Dashboard Side Cover. 9. Power the truck on to see if the gauges are functioning properly and check for any leaks or loose sensor connections. Top off any fluids if necessary. 10. Press the color changing button on the gauge to ensure it is working correctly. 11. Test drive your vehicle to ensure all gauges are functioning properly. Connecting to Power SECTION 8 A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 20 20 10 10 10 20 10 10 25 25 20 20 10 20 10 10 10 10 25 25 B 4. 5. 9.
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