INSTALLATION GUIDE 00-06 GMC SIERRA 00-06 CHEVY SILVERADO FITS 2007 CLASSIC DURAMAX 2000-2006
2000-2006 INSTALLATION GUIDE GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved GMC SIERRA CHEVY SILVERADO DURAMAX TOOLS & ACCESSORIES NOT INCLUDED OPTIONAL ADD-ONS AND ADAPTERS SOLD SEPARATELY AT GLOWSHIFT.COM • 3 Gauge Wiring Kit • Mini Expandable Circuits • 1/8-27 NPT Drill and Tap Kit • 3/16” Map Line Boost T-fitting Adapter • Air Intake Heater Plug Thread Adapter • 5/8” Transmission Line T-Fitting Adapter for Allison 1000 TABLE OF CONTENTS SECTION 1 Boost Gauge Installation 1 SECTION 2 Pyrometer EGT Gauge Installation 3 SECTION 3 Transmission Temp Gauge Installation 4 SECTION 4 Fuel Pressure Gauge Installation 6 SECTION 5 Rail Pressure Gauge Installation 7 SECTION 6 Installing the Pillar Pod 8 SECTION 7 Connecting to Power 9 • Hose Cutters • Shop Vacuum • Pen Magnet • Pipe Cutter • Panel Pop Tool • Cutting Oil • Pick Tool • Zip Ties • Grommet • Drain Pan • Teflon Tape • Wire Connectors • Anti-Seize • Transmission Fluid • Allison 1000 Transmission Test Port Adapter • 6.6L Duramax Fuel Pressure Adapter • Fuel Rail Pressure Gauge Wiring Harness • Extended Pressure Harness • Safety Glasses & Gloves • Assorted Wrenches • Socket Set • Flat Head Screwdriver • Phillips Screwdriver • Center Punch • Marker • Tape Measure • Drill & Drill Bits • Tap Handle • Multi-Meter/Test Light • Wire Strippers & Crimper • Deburring Tool • Allen Keys 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. Wiring Schematic Red: 12v Constant Source (+) White: 12v Ignition Switched Source (+) Orange: 12v Headlight Switched Source (+) Black: Vehicle/Engine Ground (-) CHECK OUT THE FULL INSTALL VIDEO FOR THIS DURAMAX: GLOWSHIFT.COM/DMAXVIDEO 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 2000-2006 Chevy Silverado and GMC Sierra with a 6.6L Duramax. Before getting started, confirm you have the tools and accessories below and let’s get to work.
2000-2006 INSTALLATION GUIDE 1 GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved GMC SIERRA CHEVY SILVERADO DURAMAX Disclaimer: In order to install a fuel pressure gauge an aftermarket lift pump must be installed as the factory fuel system operates under a vacuum. • Check that you have all parts required for installation, and that the engine is cool. • Open the hood and locate the truck’s two batteries. Disconnect the negative terminal of each battery, using an 8mm Wrench, to ensure there is no power running through the truck during the installation. Note: When it comes time to wire and connect the gauges to their power source, you will be able to reconnect the negative terminals on the batteries. Note: Before starting remove the factory intake pipe using a Flat Head Screwdriver. A: Boost T-Fitting Adapter 1. Locate the wastegate actuator hose and cut it in half using Hose Cutters. 2. Insert the T-Fitting along with the supplied hose clamps. 3. Tighten the hose clamps using a Flat Head Screwdriver. 4. Wrap teflon tape around the 1/8-27 NPT threads of the boost line adapter and install into the 1/8-27 NPT port using an 11mm Wrench. 5. Slide the Ferrule Fitting Cap and Ferrule onto the Boost Line. (Refer to diagram) 6. Insert the line into the Ferrule Fitting Adapter and tighten with a 3/8” wrench. Note: Do not overtighten the Ferrule Fitting. 7. Reinstall the factory intake pipe using a Flat Head Screwdriver. 8. Route the boost line up to the location of the firewall where you will be passing the wires into the cab. Be sure not to pinch or crimp the line and keep it away from moving parts and heat using Zip Ties. PROPER ORIENTATION Boost Gauge Installation SECTION � A1. A2.
2000-2006 INSTALLATION GUIDE GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved 2 GMC SIERRA CHEVY SILVERADO DURAMAX C1. C7. B4. B: Drill & Tap Intake Manifold 1. Remove the intercooler coupler using an 11mm deep Socket. 2. Using a Center Punch, mark the drill location. 3. Use a Vacuum in the intake manifold. In some cases you can use the coupler to attach the Vacuum to the manifold. 4. Starting with a 1/8” Drill Bit, drill a pilot hole. 5. Continue increasing the size of the pilot hole using various Drill Bits until you reach size R. 6. Slowly tap the drilled hole to 1/8-27 NPT. 7. Ensure all the shavings are out of the manifold. 8. Wrap teflon tape around the 1/8-27 NPT threads of the boost line adapter and install into the 1/8-27 NPT port using an 11mm Wrench. 9. Slide the Ferrule Fitting Cap and Ferrule onto the Boost Line. (Refer to diagram on page 1) 10. Insert the line into the Ferrule Fitting Adapter and tighten with a 3/8” wrench. Note: Do not overtighten the Ferrule Fitting. 11. Reinstall the intercooler coupler using an 11mm Socket. 12. Reinstall the factory intake pipe using a Flat Head Screwdriver. 13. Route the boost line up to the location of the firewall where you will be passing it through into the cab. Be sure not to pinch or crimp the line and keep it away from moving parts and heat using Zip Ties. C: Intake Air Heater Delete Plug 1. Locate the Intake Air Heater (IAH) on the cold side of the intake on the passenger side. 2. Using a 10mm Socket, remove the bolt that is holding the intake pressure sensor for proper clearance and place to the side. 3. Using a 10mm Socket, remove the captured nut and power wire from the stud on the IAH. 4. The main power wire that energizes the air intake heater element runs from the IAH over to the solenoid. Using a 12mm Socket, remove the nut and washer from the solenoid and disconnect the power wire. Secure the wire off to the side away from extreme heat or moving parts using a Zip Tie. The wire will remain secured in case you choose to use it again in the future. After disconnecting the wire, reinstall the lock washer and nut back onto the solenoid. 5. Using a 26mm Socket, remove the IAH from the intake. 6. Using a 27mm Socket, install and tighten the IAH Delete Plug. 7. Wrap teflon tape around the 1/8-27 NPT threads of the boost line adapter and install into the 1/8-27 NPT port using an 11mm Wrench. 8. Slide the Ferrule Fitting Cap and Ferrule onto the Boost Line. (Refer to diagram on page 1) 9. Insert the line into the Ferrule Fitting Adapter and tighten with a 3/8” wrench. Note: Do not overtighten the Ferrule Fitting. 10. Reinstall the intake pressure sensor and bolt using a 10mm Wrench. 11. Route the boost line up to the location of the firewall where you will be passing through into the cab. Be sure not to pinch or crimp the line and keep it away from moving parts and any direct heat sources using Zip Ties.
2000-2006 INSTALLATION GUIDE 3 GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved GMC SIERRA CHEVY SILVERADO DURAMAX Pyrometer EGT Gauge Installation SECTION 2 Warning: Make sure the exhaust is cooled off during this process. 1. We are going to install the EGT probe in a pre-turbo location on the manifold to ensure the most accurate readings. Installing the EGT probe further downstream can display a lower temperature reading on the gauge. Optional: To install the EGT probe, we are going to use GlowShift’s Drill and Tap Kit. 2. Remove the passenger-side inner fender liner. 3. Locate the exhaust manifold on the passenger side of the engine bay. Mark the manifold using a Center Punch to prepare the drilling and tapping process. 4. 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. 5. Take the 1/8-27 NPT Tap and slowly tap the size R hole in the manifold using Cutting Oil. Again, clean the manifold with a Pen Magnet and Vacuum to remove all shavings. 6. Using a 14mm Wrench, slowly thread the ferrule fitting adapter into the 1/8-27 NPT hole you just tapped and tighten until snug. Note: Do not overtighten the ferrule fitting. We also recommend using anti-seize on all EGT probe threads. 7. Slide the EGT probe into the ferrule fitting adapter and tighten until snug using a 14mm Wrench. Note: Probe depth should be in the center of the manifold. 8. Route the EGT probe harness up to the location of the firewall where you will be passing through into the cab. Be sure not to pinch or crimp the line and keep it away from moving parts and any direct heat sources using Zip Ties. 9. Reinstall the passenger-side inner fender liner. 3. 4. 8.
2000-2006 INSTALLATION GUIDE GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved 4 GMC SIERRA CHEVY SILVERADO DURAMAX Transmission Temp Gauge Installation SECTION 3 Warning: Be sure that the transmission is cool before removing the transmission cooler line. A: Using a Transmission Line T-Fitting Adapter for GM Duramax Allison 1000 1. Safely jack up the truck, if not raised already. Locate the cooler feed line on the passenger side of the transmission housing. Note: The lower line is the cooler feed line and the upper line is the return line from the cooler. 2. Using a Pick Tool, release the plastic retaining clip cover and slide it out of the way. Release and remove the retaining clip from the transmission. Slide the line out of the transmission case and drain the fluid from the line. Note: Use a drain pan to catch the fluid. 3. Using a Marker measure and mark the location where you would like to install the T-Fitting. Cut 1-7/8” out of the cooler feed line with a Pipe Cutter (make sure to always use a new blade). Note: You can also remove the cooler feed line entirely from the truck and cut it on a work bench. If the cooler feed line is removed from the truck, up to 4 quarts of transmission fluid will drain from the system and must be refilled with fresh transmission fluid once the T-Fitting has been installed. 4. Deburr both ends of the cut line with a Deburring Tool to ensure a proper fit of the T-Fitting onto the cooler feed line. Note: Check the dipstick to ensure the proper amount of fluid is in the transmission according to manufacturer’s specifications. 5. Install the cooler line T-Fitting’s female fittings over each end of the cut line. Then, place the metal cutting rings over each end of the cooler line. (Refer to diagram) 6. Hold the body of the T-Fitting with a 24mm Wrench and hand-tighten each nut. Then, tighten one and one-quarter more turns with a 26mm Wrench to ensure proper sealing of the cutting rings. A3. A6. 7. Now you can install the 1/8-27 NPT temperature sensor into the port on the T-Fitting housing. Note: Be sure to use Teflon tape on the threads of the temperature sensor to prevent any leaks. 8. If the line was removed, reinstall the line onto the truck and refill the transmission with up to 4 quarts of proper grade transmission fluid. PROPER ORIENTATION
2000-2006 INSTALLATION GUIDE 5 GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved GMC SIERRA CHEVY SILVERADO DURAMAX B: Using an Allison 1000 Transmission Test Port Adapter 1. Safely jack up the truck, if not raised already. Locate and remove the factory plug from the bell housing located next to the spin on transmission filter using a 15mm Wrench. Note: Have a drain pan ready to catch any fluid loss. 2. Wrap Teflon Tape on the male threads of the sensor. Thread the sensor into the test port extender adapter and tighten using a 14mm Wrench and 14mm Wrench. 3. Thread the test port extender with the sensor attached into the transmission test port and tighten using a 14mm Wrench. DURAMAX ALLISON 1000 TEST PORT ADAPTER Finalizing the Transmission Temperature Gauge: 1. Connect the signal wire of the gauge to the white wire of the temperature sensor and connect the black wire of the sensor to any reliable grounding location. 2. Route the transmission temperature sensor signal and ground wires up to the location of the firewall where you will be passing through into the cab. Be sure not to pinch or crimp the line and keep it away from moving parts and any direct heat sources using Zip Ties. 3. Lower the vehicle if it was raised. 4. Top off the transmission fluid to factory specifications and check for leaks. Note: Refer to the vehicle’s repair manual as fluid check procedures may vary. B3. Finalizing 2. B1.
2000-2006 INSTALLATION GUIDE GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved 6 GMC SIERRA CHEVY SILVERADO DURAMAX Fuel Pressure Gauge Installation SECTION 4 Note: An aftermarket lift pump must be installed in order to read fuel pressure. Note: Be sure not to pinch or crimp the harness and keep it away from moving parts and heat using Zip Ties. A: Aftermarket Lift Pump 1. Remove the test port plug from the aftermarket lift pump, and check to be sure it is 1/8-27 NPT. Note: If not use an appropriate adapter to install the pressure sensor. 2. Thread in the pressure sensor using a 22mm Wrench. 3. Plug in and route the sensor harness forward towards the firewall where it will be passing through into the cab and secure with Zip Ties. An extended harness may be required depending on the mounting location of your lift pump which is available at www.GlowShift.com B: Factory Bleeder Screw Adapter 1. Using a 13mm Socket, remove the factory bleeder screw. Note: Have a drain pan ready to catch any fluid loss. 2. Using a 22mm and 12mm Wrench, attach the pressure sensor to the bleeder screw adapter. 3. Thread the sensor and adapter into the port and tighten with the 12mm Wrench. 4. Plug in the sensor harness. Route the wire into the location of the firewall, where it will pass through into the cab and secure with Zip Ties. C: Optional Fuel Filter Delete 1. Remove the inner wheel well using a Panel Pop Tool. 2. Have a drain pan ready to catch any fuel. Using a 5mm Allen Key, remove the test port plug. 3. Thread in the pressure sensor and tighten with a 22mm Wrench. 4. Plug in the sensor harness. Route the wire into the location of the firewall, where it will pass through into the cab, and secure with Zip Ties. 5. Reinstall the inner fender liner. A2. B3. C3.
2000-2006 INSTALLATION GUIDE 7 GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved GMC SIERRA CHEVY SILVERADO DURAMAX Rail Pressure Gauge Installation SECTION 5 1. Using an 11mm Socket, remove the intercooler coupler from the intake horn. 2. Using a 10mm Socket, remove the three bolts connecting the intake horn to the turbo. 3. Unclip the fuel rail pressure sensor harness. 4. If a rail pressure harness adapter is not being used, splice the signal wire into the yellow wire and the ground wire into the orange/black wire. Please refer to the chart below for switch postions. Optional: To avoid splicing into the factory wiring harness, purchase the Fuel Rail Pressure Gauge Wiring Harness for a quicker and easier installation available at GlowShift.com. 5. Connect the sensor harness adapter to the rail pressure sensor and factory harness. 6. Route wire to location on the firewall, where it will pass through into the cab and secure with Zip Ties to keep away from direct heat sources and moving parts. 7. Reinstall the intake horn using a 10mm Socket. 8. Reinstall the intercooler coupler using an 11mm Socket. 1. 3. 2. 7. & 8. YEAR SIGNAL WIRE GROUND SWITCH POSITION 02-05 Yellow Orange/Black 1 and 2 Up 06 Orange/Black White 1 and 2 Down Rail Pressure Gauge Settings
2000-2006 INSTALLATION GUIDE GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved 8 GMC SIERRA CHEVY SILVERADO DURAMAX Installing the Pillar Pod SECTION 6 1. Carefully remove the factory trim from the truck by pulling and releasing the spring clips. Note: This gauge pod mounts directly on top of your truck’s A-pillar using the supplied pushin clips and is not a complete replacement. 2. Place the triple pillar pod overtop of the removed factory trim. Mark and drill (4) 7/32” holes and secure with the flush mount fasteners. 3. Mark and drill holes using a Step Bit for the wiring to pass through the factory trim. 4. Now you can mount the gauges in the triple pillar gauge pod in any configuration you prefer. There is no specific order required. 5. Wrap Teflon Tape around the brass fitting on the back of the Boost gauge, then attach the brass fitting using a 13mm Wrench. Note: Do not overtighten. 6. Feed the wires from each gauge into the pillar pod. 7. Insert each gauge into the pod. 8. If you are using the optional 3 Gauge Wiring Kit, attach all of the wires together. 9. Connect all of the yellow wires using a crimp connector. 10. Connect all of the red wires using a crimp connector. 11. Connect all of the orange wires using a crimp connector. This enables the dimming function that will lower the brightness of your gauges 30% for easier viewing when driving at night. 12. Connect all of the black wires using a crimp connector. 13. Secure all wires with Zip Ties. 14. Route the sensor harnesses and boost line 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. 15. Insert the boost line into the Ferrule Fitting Adapter, thread onto the back of the gauge and tighten with a 3/8” Wrench. (Refer to diagram) Note: Do not overtighten the Ferrule Fitting. 16. Plug the EGT Sensor Harness into the back of the EGT Gauge. (If used) 17. Splice the green signal wire from the Transmission Temperature Gauge to the green signal wire from the sensor. (If used) 18. Plug the Fuel Pressure Sensor Harness into the back of the Fuel Pressure Gauge. (If used) 19. Splice the green and black wires from the Fuel Rail Pressure Gauge to the green and black wires from the Fuel Rail Pressure Pigtail Harness. (If used) 20. Mount the pillar pod and factory trim assembly to the truck cab A-pillar, securing it with the factory spring clips. 1. 8. 15. PROPER ORIENTATION
2000-2006 INSTALLATION GUIDE 9 GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved GMC SIERRA CHEVY SILVERADO DURAMAX 4. Connecting to Power SECTION 7 Reconnect the negative terminals of the two batteries to prepare power for the gauges and to test the fuses for power with a Test Light or multi meter. 1. Attach Mini-Expandable circuits to both the yellow wire and the red wire. 2. Remove the 3amp mir/lock fuse. Plug the fuse into the open section of the expandable circuit for the yellow wire and reinstall in the fuse box for a constant 12-volt source. 3. Remove the 10amp ignition 0 fuse. Plug the fuse into the open section of the expandable circuit for the red wire and reinstall in the fuse box for an ignition switched 12-volt source. 4. Place the vehicle gear selector into first gear and lower the tilt wheel. Remove the dash trim by releasing the spring clips in order to gain access to the headlamp switch. Locate the light-blue wire and connect the orange wire using a splice connector for a headlamp switched source. 5. Reinstall the headlight switch and the dash trim. 6. Connect the black wire to a reliable, clean and unpainted ground source such as the mounting bolt under the dash. 7. Secure any excess wiring with Zip Ties. Note: Be sure not to pinch or crimp the harness and keep it away from moving parts and heat using Zip Ties. 8. Power up the truck to confirm the gauges are functioning properly and check for any leaks or loose sensor connections. With the vehicle running, cycle through the gears to help the transmission fluid circulate through the transmission (if the transmission temperature gauge is installed). Top off any fluids if necessary. 9. Press the Color Change Button on the gauges to ensure they are working correctly. Note: MaxTow Gauges do not change colors. The button allows you to change the 3 Daytime and 3 Nighttime Brightness Levels. 10. Test drive your vehicle to ensure all gauges are functioning properly. Note: The Boost Gauge will only read while driving. 3. 3. 2. 2. 6.
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