Hypertech POWER PROGRAMMER III User manual

HYPERTECH®
POWER PROGRAMMER III™
FOR GM VEHICLES WITH
4.3/4.8/5.3/6.0/8.1L VORTEC ENGINES
STEP-BY-STEP INSTALLATION
INSTRUCTIONS
PP4
OnStar
Equipped Vehicles
See Pages 4-6
BEFORE
Programming
Part #761
© 2000-2005 Hypertech, Inc.
5.1.05

TABLE OF CONTENTS
Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section 1: OnStar Equipped Vehicles . . . . . . . . . . . . . . . . . .4
Section 2: PowerStat™Installation for 4.8/5.3/6.0L . . . . . . . .7
Section 3: Programming Instructions . . . . . . . . . . . . . . . . . . .9
Diagnostic Trouble Code (DTC) Information . 10-11
Engine Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Rev Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Top-Speed Limiter . . . . . . . . . . . . . . . . . . . . . . . 13
Tire Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Rear Gear Ratio . . . . . . . . . . . . . . . . . . . . . . . . . 14
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Transmission Shift Point MPH & RPM . . . . . . 15
Transmission Shift Firmness . . . . . . . . . . . . . . . .18
Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Section 4: Programming Back-To-Stock/Changing Options 20
Section 5: Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . 21

2
IMPORTANT
• The Power Programmer for 1999-2005 4.3/4.8/5.3/6.0/8.1L GM trucks
and SUVs is legal for 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’s computer will not be programmed at the end of the
programming menus until you select “PRESS ‘Y’ TO
BEGIN
PROGRAMMING”, on page 18. Feel free to experiment with the
programming choices without the fear of accidentally programming
the wrong information into your vehicle’s computer. You can make any
choice that you want and change it again and again, without program-
ming it into your vehicle’s 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 and you decide to change the
tuning, It is recommended that you recharge your vehicle’s
battery. You may either drive the vehicle to charge the battery
or use a battery charger. But either way, MAKE sure that 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.

3
Any of these actions will interrupt the programming process.
The programmer is designed to recover from these conditions,
but they should be avoided.
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’s computer 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 ▲arrow 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.

4
SECTION 1: ONSTAR EQUIPPED VEHICLES
If your GM vehicle is equipped with the OnStar system, you
MUST temporarily disable the system BEFORE programming
your vehicle with the Power Programmer III. Please follow the
steps below to temporarily disable the OnStar system.
General Precautions
Many new vehicles are equipped with daytime running lights,
or sensors that turn the headlights on in dim situations automatically
when the ignition is on. For the purposes of programming the
vehicle this presents an unnecessary extra drain on the vehicle
battery. Many new vehicles have a procedure for turning off
the lights. Often this is accomplished by pressing the “Dome
Override” button two (2) to four (4) times in succession.
We recommend that your headlights be off when programming
your vehicle for added safety against corrupt programming due
to battery failure. See your owner’s manual for vehicle specific
information regarding your headlights.
Recommended Precautions
The OnStar system by GM periodically communicates with the
vehicle. This periodic communication with the vehicle has been
known to disrupt the programming process. In order to
prevent
disruption of the programming process, it is recommended
that
the OnStar system be disabled while programming the vehicle.
To temporarily disable your OnStar system in 4.8/5.3/6.0/8.1L
GM vehicles, remove the fuse(s) associated with OnStar. Please
refer to the fuse section of your owner’s manual for instructions
and locations of fuse(s).
The fuse panel will be under the hood of
the vehicle on the driver’s
side behind the battery. In most cases
there will be one (1) fuse in that fuse panel the OnStar system
relies on. See page 5 for an example. For 4.3L GM SUVs, follow
the steps on page 6 to temporarily disable the OnStar system.
When the OnStar system is successfully disabled, its indicator
light on the dash or rearview mirror will be OFF. Be sure that
this light is off when the key is in the ON position (engine not
running) BEFORE programming the vehicle. This will ensure
that there are no OnStar related problems.
Recovery From OnStar Related
Power Programmer Hang-up
If the programmer stops programming for an extended period of
time, perform the following steps to recover and/or continue pro-
gramming (see next page):

5
INFO
SBA
RADIO AMP
TREC
SEO B1RADIO
EAP
W/S WASH
W/S WASH
CRANK
BTSI
A/C COMP
RR WPR
The fuse panel is located on the driver’s
side of the vehicle behind the vehicle battery.
Lift off the cover to access the fuse block.
You now can remove the fuse. To remove
the fuse, hold the end of the fuse between
your thumb and index finger and pull
straight out. Make sure you remember
to re-install the fuse in the proper location
and re-install the fuse panel cover after
programming your vehicle.
Fuse panel
cover
For All 4.8/5.3/6.0/8.1L
GM vehicles
TBC
HAZ LP
RR WPR
RDO AMP
CIGAR
HTD MIR
SEO 2
RADIO
CTSY LP
IGN C
FOG LP
BTSI
FOG LP
AUX PWR
A/C
A/C
HORN
HORN
W/W PMP
DRL
SEO 1
1999-2002 GM vehicle fuse diagram
** Do Not Turn The Ignition Key Off**
1. Disconnect the programmer from the vehicle.
2. Reconnect the programmer to the vehicle.
3. Press the START button on the programmer.
The programmer will resume communications with the vehicle
where it left off. If the programmer fails to re-establish communi-
cations with the vehicle, repeat the procedure. If the programmer
still fails to resume, disconnect the programmer and turn the
vehicle off. Attempt to start your vehicle. If your vehicle fails to
start, the vehicle computer may have been corrupted, and you
will need to send your vehicle computer and programmer to
Hypertech for repair. If the vehicle starts, you will need to return
your programmer to Hypertech for re-initialization, no harm was
done to the vehicle computer.
For 1999-2002 vehicles, the one (1) fuse that must be removed is
as follows: (see highlighted fuse location above.)
Location Description
SEO1 Special Equipment Option, OnStar
For 2003-2005 vehicles, the one (1) fuse that must be removed is
as follows: (see highlighted fuse location below.)
Location
INFO
Description
OnStar
NOTE:Owner’s manual fuse diagram may vary from examples shown.
2003-2005 GM vehicle fuse diagram
(Illustration does not represent entire fuse diagram)

6
NOTE for 1999-2002 GM vehicles: If the previous step
did not turn off the OnStar light on the dash, follow these
steps to remove three (3) other OnStar related fuses:
The three (3) fuses that must
be removed are as follows:
(see highlighted
fuse locations to the right.)
Location Description
SEO IGN Special Equipment
Option, Ignition,
OnStar
RDO 1 Audio System,
OnStar
RAP #2 Rear Power Windows,
Sunroof, Radio,
OnStar
NOTE: Owner’s manual
fuse diagram may vary
from example shown.
Disabling OnStar
in 4.3L GM SUVs
To temporarily disable the OnStar
system in 4.3L GM SUVs, the plug
to the OnStar computer must be
disconnected. The OnStar computer is
located in the back of the vehicle under
the passenger’s side rear interior cover
(See Figure A). To remove the cover,
release the clip and swing out. See
Figure B. Squeeze the blue and grey
tabs on the connector and pull up
to temporarily disconnect the OnStar
system in the vehicle.
What To Do After Programming Your Vehicle
After the vehicle computer has been successfully programmed,
reinstall the fuse(s) removed that are OnStar related to enable the
system for 4.8/5.3/6.0/8.1L vehicles, making sure the proper
amperage fuse is in each location and the fuse panel cover(s)
arereinstalled.For 4.3L GM vehicles, plug the OnStar connector
back to the original location and reinstall the interior cover.
Figure A
Figure B
OnStar
computer
OnStar
connector
➚
➚

7
SECTION 2: POWERSTAT INSTALLATION
For 1999-2003 4.8/5.3/6.0L GM vehicles
Tools needed:
10mm socket, ratchet, and extension
Slip joint pliers
DEX-COOL anti-freeze coolant
NOTE: The thermostat in this engine is a “housing” style
thermostat. It is located on the front of the water pump
assembly at the bottom edge of the passenger side
cylinder head. (See Figure C)
Part #1015 - 180° PowerStat (1999-2003 ONLY)
1. Make sure that the vehicle is parked on a level surface before
installing the Hypertech PowerStat.
2. Allow the vehicle coolant to cool.
3. Turn the surge tank cap counter-clockwise very slowly to
remove the pressure from the cooling system. If you hear a
hissing or spurting sound, stop and let the pressure bleed off.
When the hissing or spurting sound goes away, finish
removing the surge tank cap.
4. Open the radiator drain plug and drain the coolant from the
vehicle.
5. Remove the radiator hose from the stock thermostat.
6. Remove the two (2) 10mm bolts holding the stock thermostat
to the engine. (You may want to use an extension on the
socket wrench for easier access.)
7. Lift out the stock thermostat. Use a flathead screwdriver to
gently pry, if necessary. Clean all the sealing surfaces.
8. Install the Hypertech PowerStat, making sure the O Ring is
sealed properly. For ease of installation, you may want to
apply a small amount of grease to the PowerStat to help
retain the O Ring.
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.
To complete your performance package, you may choose to use
a low-temp thermostat. Replacing the factory thermostat with a
Hypertech PowerStat will allow the engine to run cooler, increasing
power, and reducing the engine’s tendency to detonate.
•For 4.3 & 8.1L vehicles, Hypertech recommends using
the stock
thermostat. For 1999-2003 4.8/5.3/6.0L vehicles,
Hypertech recommends
using the 180° PowerStat. The
PowerStat is NOT available for 2004-2005 GM trucks/SUVs.
• 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.

8
9. Reinstall the thermostat bolts and any hoses removed. Torque
the bolts to 7 ft.-lbs.
10. Close the radiator drain plug.
11. Fill the cooling system with the proper water/coolant
mixture. Refer to the owners manual for the correct ratio.
Pour the coolant into the surge tank.
12. Start the engine and let it idle for approximately one (1)
minute.
13. Reinstall the surge tank cap.14. Cycle the engine from idle to
3000 RPM in thirty (30) to forty (40) second intervals. This
needs to be done until the engine coolant temperature reaches
210°F or 99°C.
15. When the cooling system is at the proper temperature, shut
off the engine. Remove the surge tank cap as described in
Step 3.
16. Leaving the surge tank cap off, start the engine and let it idle
for one (1) minute. Then, fill the surge tank with the coolant
mixture to 1/2” above the “Fill Cold” mark on the surge tank.
Now reinstall the surge tank cap.
17. Repeat Step 14 once more, then shut off the engine.
18. Allow the vehicle coolant to cool, then remove the surge tank
cap again as described in Step 3. Top off the coolant system
to 1/2” above the “Fill Cold” mark on the surge tank, then
tighten the surge tank cap.
Figure C
IMPORTANT:
NEVER MIX ORDINARY ANTI-FREEZE (GREEN)
WITH DEX-COOL ANTI-FREEZE (ORANGE)
OR YOU MAY DAMAGE THE COOLING SYSTEM

9
SECTION 3: PROGRAMMING INSTRUCTIONS
• Connect one (1) end of the provided cable to the programmer
as in Figure D and tighten the two (2) thumbscrews.
• See Figure E. Locate the Data Link Connector (DLC) under the
driver’s side of the dash panel above the emergency brake.
• Plug the programmer cable into the DLC. Make sure the cable
is plugged in completely to ensure a good connection.
• Set the parking brake to turn off the DRLs (Day-Light Running
Lamps) 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.
- If the vehicle is equipped with an OnStar system, make sure
the system is temporarily disabled (see Section 1 for details).
- DO NOT attempt programming while the
vehicle is connected to a battery charger.
Figure D
Programmer
Thumbscrew
Thumbscrew
Figure E