Hypertech POWER PROGRAMMER III User manual

HYPERTECH®
POWER PROGRAMMER III™
FOR 5.7L LT1/LT4 CAMARO/FIREBIRD/CORVETTE
IMPALA SS/CAPRICE/ROADMASTER
STEP-BY-STEP INSTALLATION
INSTRUCTIONS
PP2
Part #895
© 2006 Hypertech, Inc.
7.7.06

TABLE OF CONTENTS
Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section 1: PowerStat™Installation . . . . . . . . . . . . . . . . . . . . .4
Section 2: Programming Instructions . . . . . . . . . . . . . . . . . . 6
Engine Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Rev Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electric Cooling Fan Operating Range . . . . . . . . 9
Top-Speed Limiter . . . . . . . . . . . . . . . . . . . . . . . 10
Tire Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Rear Gear Ratio . . . . . . . . . . . . . . . . . . . . . . . . 11
Transmission Shift Point MPH & RPM . . . . . . 12
Transmission Shift Firmness . . . . . . . . . . . . . . . 15
Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Section 3:
Programming Back To Stock/Changing Options 18
Section 4: Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . 19

IMPORTANT
• The Power Programmer for GM LT1/LT4 vehicles is legal for sale or
use on California pollution-controlled motor vehicles according to the
CARB Executive Order process. In the interest of improved air quality,
the California Air Resources Board (CARB) requires new vehicle and
manufacturers of aftermarket parts to develop engine and emissions
equipment that either reduce or maintain specific air pollutants affected
by vehicle use. Both the California Vehicle Code (section 27156) and
Federal Clean Air Act (administered by the Environmental Protection
Agency) prohibit modifications that increase vehicle emissions.
Aftermarket parts manufacturers, particularly in the high-performance
segment, are required to obtain CARB approval in the form of executive
Orders (E.O.s) for any product not qualifying as a direct replacement
for an original equipment part. Hypertech includes meeting all E.O.
requirements in its product development process. This guarantees
that users of Hypertech “Power Tuning” products will meet certification
requirements when registering, selling, or needing to pass various
emissions tests or Inspection and Maintenance (I&M) programs
administered by state or local enforcement agencies. Make sure
that any emissions-related product you buy and install carries an E.O.
number or is pending an E.O. Without this verification you are at
risk, in potential violation of regulations and may incur unnecessary
financial obligations during vehicle inspections or emissions tests.
A CARB E.O. sticker is supplied. Keep this sticker in your vehicle or
attach it inside the door jam as proof that the Power Programmer is
street legal.
• Your vehicle’scomputer will not be programmed at the end
of the programming menus until you select “PRESS ‘Y’ TO
BEGIN PROGRAMMING” on page 15. Feel free to experiment
with the programming choices without the fear of accidentally
programming the wrong thing into your vehicle computer.
You can make any choice that you want to, change it again
and again, without programming it into your vehicle computer
until you are absolutely ready.
•While the programmer is programming:
*DO NOT leave the vehicle while programming is in process.
*DO NOT program your vehicle without a fully charged battery.
If after you have programmed your vehicle’s computer with the
Hypertech Power Programmer, you decide to change the tuning,
It is recommended that you recharge your vehicle’sbattery.
You may either drive the vehicle to charge the batteryor use a
batterycharger.But either way,MAKE surethat the battery
holds a full charge.
*DO NOT disturb the cable while programming.
*The ONLYtime you may remove the programmer cable from
the DLC safely is PRIOR to pressing ‘Y’ to program your
entries. However, any programming choices you have made
WILL NOT be saved. NOTE: It is NOT safe to unplug the
programmer cable any time AFTER you have pressed ‘Y’ to
program.
*DO NOT turn the key off UNLESS
instructed by the programmer.
*DO NOT start the engine.
2

Any of these actions will interrupt the programming process.
The programmer is designed to recover from these conditions,
but they should be avoided.
• You will achieve best performance if you replace your
stock thermostat with a Hypertech 160° or 180° PowerStat.
The programmer will work with a stock thermostat but our
best performance tuning was specifically developed for a
cooler running engine.
• Hypertech Power Tuning was developed for premium grade
gasoline (the highest octane rating available in your area).
Make sure you have premium gasoline in your vehicle
before installing Hypertech’s engine Power Tuning.
HYPERTECH POWER PROGRAMMER III
INSTALLATION INSTRUCTIONS OVERVIEW
Congratulations! You are the owner of the Power Programmer III,
the latest in high-performance tuning technology. Now you can optimize
your engine’s tuning, as well as adjust other vehicle parameters
(see table of contents), all at the touch of a button.
Your vehicle has an onboard computer that controls the engine
and transmission. Inside your vehicle’scomputer is a FLASH
memory chip which contains the vehicle’s programming. The
programmer actually reprograms this FLASH computer chip,
according to your specifications, with Hypertech’s Power Tuning.
This is the only way an individual can reprogram some 1994-1995
and all 1996 and newer vehicles sold in the United States.
To reprogram your vehicle’s computer, simply plug the
programmer cable into the vehicle’s diagnostic connector
located under the dash panel on the driver’s side. Set the parking
brake. Next, turn the ignition key to RUN but do not start the
engine. Press the sarrow on the programmer.It will then identify
your vehicle and display a series of options on its screen. When
completed, turn the key to OFF and disconnect the cable from the
diagnostic connector.Now you’re ready to Feel the Power!
Hypertech’s Power Tuning can be stored in only one (1)
vehicle at a time. The Power Programmer can be reconnected
to remove the Power Tuning and return the vehicle to the factory
programming at any time. After you have performed this step,
your vehicle will be in its stock configuration.
You may also reconnect your programmer at any time to change
the programming. For example, if you have replaced your factory
tires with different diameter tires, you will want to correct your
speedometer, odometer, and automatic transmission shift points.
Simply reconnect your programmer, answer the necessary option(s),
and reprogram your vehicle. You do not have to return to stock first.
3

SECTION 1: POWERSTAT INSTALLATION
Tools and supplies required
8mm socket and ratchet
1/4” flathead screwdriver
DEX-COOL anti-freeze coolant (GM part #1234-6290)
Part#1008 - 160° PowerStat
Part #1022 - 180° PowerStat
1.
See Figures A or B. Disconnect the intake air temperature sensor
connector located in the air intake duct between the mass air
flow sensor and the throttle body.
2. Use a flathead screwdriver to loosen the clamps on the air
intake duct and remove the duct.
3. With the radiator cap on, remove the two (2) thermostat
housing bolts. Remove the thermostat housing leaving the
radiator hose attached to expose the stock thermostat. A small
amount of coolant may be lost at this point.
4. Lift out the stock thermostat. Use a screwdriver to gently pry,
if necessary. Clean all the sealing surfaces.
5. Make sure that the rubber “O” ring is positioned flat side
down on the PowerStat. Next, install the PowerStat, making
sure that it’s positioned correctly (spring end facing down into
intake manifold).
6. Reinstall the thermostat housing and bolts. Torque the bolts to
7ft.-lbs.
7. Remove the radiator cap (or coolant reservoir cap on
Corvette). Place a rag or towel under the pressure side bleed
screw on the thermostat housing to prevent coolant from
splashing on the distributor. Open the pressure side bleed
screw while watching the coolant level in the radiator (or
coolant reservoir on Corvette). The coolant level will drop
when the bleed screw is fully opened.
8. Slowly fill the radiator with the DEX-COOL coolant. Close
the bleed screw when the bubbles disappear and only coolant
is escaping from the bleed screw.At this point, finish filling
the radiator and reinstall the radiator cap.
IMPORTANT:
NEVER MIX ORDINARYANTI-FREEZE (GREEN)
WITH THE DEX-COOL ANTI-FREEZE (ORANGE)
OR YOU MAYDAMAGE THE COOLING SYSTEM.
4
• WARNING: NEVER ATTEMPT TO CHANGE
A THERMOSTAT ON A HOT ENGINE
• SERIOUS INJURY CAN OCCUR IF THE
RADIATOR CAP IS REMOVED WHILE THE
COOLING SYSTEM IS HOT
• THE ENGINE SHOULD ALWAYS BE COLD
WHEN INSTALLING THE POWERSTAT
NOTE: After installing the
PowerStat, if any coolant
needs to be added to the
vehicle, make sure you
put the same color coolant
back into the vehicle. If
your vehicle has orange
coolant, replace with orange
coolant. If green, replace
with green.

9. Reinstall the mass air flow sensor side of the air intake duct.
To install the throttle body side of the duct, use the flathead
screwdriver to secure the lower side of the duct onto the
underside of the throttle body, then work the sides and the top
of the duct onto the throttle body assembly.
10. Tighten the hose clamp using the flathead screwdriver.
11. Reconnect the intake air temperature sensor connector.
12. Start the vehicle and allow it to warm up to normal operating
temperature.
13. Check the coolant level in the radiator overflow/fill reservoir
and fill as needed.
5
Figure A
Throttle
body
Thermostat
housing
Pressure side
bleed screw
Mass air
flow sensor
CAMARO/FIREBIRD/IMPALA SS/CAPRICE/
ROADMASTER POWERSTAT INSTALLATION
CORVETTE POWERSTAT INSTALLATION
Figure B
Throttle
body
Thermostat
housing
Mass air
flow sensor
Pressure side
bleed screw

SECTION 2: PROGRAMMING INSTRUCTIONS
• Connect one (1) end of the provided cable to the black plastic
adapter using the thumbscrews as in Figure C. Connect the
other end of the cable to the programmer as shown in Figure D,
and tighten the thumbscrews.
•Connect one (1) end of the provided cable to the programmer
as in Figure E and tighten the two (2) thumbscrews.
• See Figure F. Locate the Data Link Connector (DLC) under the
driver’s side of the dash panel near the driver’s right knee.
6
Figure F
Figure E
Programmer
FOR 1994 CAMARO/FIREBIRD AND
1994-1995 IMPALA SS/CAPRICE/ROADMASTER:
FOR ALL OTHER LT1/LT4 VEHICLES:
Data link cable
Data link
adapter
Programmer
cable
Programmer
Figure D
Figure C
Thumbscrew
Thumbscrew

• Plug the programmer cable (or adapter) into the DLC. Make sure
the cable is plugged in completely to ensure a good connection.
• Set the parking brake and turn the ignition key to the RUN
position but do not start the engine.
IMPORTANT:
-DO NOT leave the vehicle while programming is in process.
-Make sure the vehicle battery is fully charged before programming.
-The key must remain in the RUN position, without the engine
running, during the entire programming process..
-DO NOT operate electrical accessories
(radio, windows, wipers, etc.) while programming.
-DO NOT attempt programming while the
vehicle is connected to a batterycharger.
• Press the sarrow on the programmer. The following displays
should appear immediately on the LCD screen (where X.X.X.X
is the version number):
•If these screens do not appear, for 1994-1997 LT1/LT4 vehicles
make sure that both ends of the cable are securely attached
and press the sarrow again. For 1994-1995 LT1 vehicles,
check and/or replace the battery as described in #6 of the
Troubleshooting Guide.
• Next, the programmer will show applications and copyright
information. Then, a screen similar to this should appear with
adescription of your vehicle:
•If this screen does not appear, make sure that the key is in the
RUN position with the engine NOT running.
7
YOUR VEHICLE IS:
1996 CHEVROLET CAMARO 5.7L LT1
VERSION
X.X.X.X
HYPERTECH
POWER PROGRAMMER
SYSTEM TEST
WAIT
FOR XXXX-XXXX
LT1/LT4 VEHICLES

• The programmer will display a series of options. For each
option, press the ‘Y’ button to make a change. Press the ‘N’
button to make no change and proceed to the next option. For
some options, you will use the sand tarrows to point to a
particular option. Pressing the ‘Y’ button will then lock in your
selection. For example, use the sand tarrows to select your
top-speed limiter, then press the ‘Y’ button to lock in your choice.
A. ENGINE TUNING
• Press the ‘Y’ button to install engine tuning. Press ‘N’ to keep
the stock vehicle tuning.
B. REV LIMITER
• Press ‘N’ to keep the stock engine rev limiter. Making this
choice will skip to the next option.
• Press ‘Y’ to adjust the engine rev limiter to a value other than
stock. The stock rev limiter may vary depending on year and
engine size of the vehicle. Please refer to the owner’s manual
for the stock engine rev limiter.
• Press the sand tarrows to increase or decrease the engine
rev limiter.The rev limiter can be increased or decreased in
100 RPM increments. Press ‘Y’ to lock in the desired value.
NOTE: At any time, you may press ‘N’ to allow you to either
try again or skip to the next option.
8
PRESS Y TO INSTALL HYPERTECH POWER TUNING
PRESS N TO KEEP FACTORY ENGINE TUNING
PRESS Y TO ADJUST ENGINE REV LIMITER
PRESS N TO KEEP STOCK ENGINE REV LIMIT
USE UP/DOWN ARROWS TO ADJUST ENGINE REV LIMITER, THEN PRESS Y TO SELECT OR N TO EXIT.
_ _ _ _RPM

C. ELECTRIC COOLING FAN OPERATING RANGE
•Press ‘N’ if you do not wish to change the temperature at which
the electric cooling fans turn on and turn off.
• Press ‘Y’ if you want to lower the temperature at which the
electric cooling fans turn on and turn off, even with the stock
thermostat. A cooler combustion chamber will produce more
power. By making this selection, you will now go to the next
screen to pick the operating temperature range of the cooling
fans. This screen will appear:
• Use the sand tarrows to select between optimizing the
cooling fan temperature settings for:
180°Hypertech PowerStat
Fans on/off at: 213°F/205°
160° Hypertech PowerStat
Fans on/off at: 192°F/185°F
Stock Cooling Fan Temperatures:
Fans on/offat: 240°F/225°F
9
USE UP/DOWN ARROWS TO SELECT THERMOSTAT TEMP, THEN PRESS Y TO SELECT OR N TO EXIT.
_ _ _F
PRESS Y TO PROGRAM ENGINE COOLING FAN TEMPERATURE RANGE
PRESS N TO LEAVE COOLING FAN TEMPERATURE UNALTERED