Pittsburgh Power Detroit DDEC III User manual

“Pittsburgh Power”Detroit DDEC III and IV
Installation Instructions
By: Pittsburgh Power
Congratulations on the purchase of your “Pittsburgh Power” performance computer
system. The only product of its kind! These installation instructions will guide you through the
process required to make your engine perform like a winner. Be sure to read these instructions
in their entirety prior to installing your performance computer. Aside from basic hand tools
you will need the following:
1 3/8" hole saw 1/4" pipe tap
1/2" drill 1/8" & 15/32" drill bit.

Note: It is not necessary to disconnect the battery during the installation process. However, do
not turn the key on. This may result in trouble codes being logged to the ECM. Keep all wires
and connections free from dirt and grease. Any contamination on the connectors or terminals
could effect the operation of the unit. Also, we have found many instances of charge air coolers
and or intake plumbing leaking manifold pressure to atmosphere. This causes low boost, high
pyrometer heat, lack of power and engine damage. It is recommended to pressure test your
intake system and charge air cooler prior to installing the “Pittsburgh Power”. We also
suggest that you make sure your computer system is not generating any trouble codes.
1). Mounting the “Pittsburgh Power” computer/ECU. Find a suitable location inside the
cab around the dash area for the ECU (engine control unit). It can be mounted in any orientation
making sure you will have access to the connections on the one end, and the on-off switch on the
other. If possible try to mount it so the operator can view the green LED's. The ECU can be
securely mounted to any flat surface utilizing the mounting plate and screws supplied with your
unit or it can be held in place with Velcro or wire ties as the situation permits.
2). Preparing to install the new harness. Inspect the firewall for accessibility and, using a hole
saw, drill a 1-3/8" hole (see figure 1) in a location that will allow you to pass the wiring harness
through. This harness will be connected to the ECM (engine control module) that is located on
the drivers side of the engine and the “Pittsburgh Power” ECU that is located inside the
vehicle. After drilling the hole remove any burrs from the area with sandpaper or a small file.
3). Installing the new harness . Being careful not to damage the connectors, feed the main
wiring harness (double round black connector end. See figure 6) through the hole in the firewall
from the engine side, towards the inside of the vehicle. Pull enough through the firewall so the
yellow lead wire for the EGT sensor breaks out of the new harness at the left rear corner of the
engine (figure 2). Carefully insert the supplied grommet into the pass-through hole in the
firewall and around the harness (see figure 3).

Figure 1
Figure 2
Figure 3
4.) Attach the new harness to the ECU that you mounted in step #1. Push each black connector
(small & large) on to the receptacles of the “Pittsburgh Power” ECU. Turn the lock nut till
you feel it "click". Do not over tighten.
5.) Connect the new harness to the ECM connectors. We will be working with the connectors
on the front of the ECM for the following procedure. The ECM is located on the drivers side of
the engine just above the oil pan. (see figure 4). Remove the top male connector of the factory
wiring harness from the ECM. Plug the grey male connector from the new harness into the ECM
where the factory connector was just removed from. (figure 5) Next, plug the male factory
connector, previously removed, into the black female connector of the new harness. Follow the
same procedure with the connection on the ECM that is right below the connection you just
changed. Remove the male connector from the ECM. Plug the white male connector from the
new harness into the ECM where you just removed the factory connector from. Next, plug the
factory male connector into the white female connector of the new harness.
6.) Connect the power and ground leads. (12V only) There is a wire with a 3/8" eyelet
connector that breaks out of the new harness in the same area as the ECM connectors. Using the
supplied 10x1.5-20mm metric bolt, bolt the eyelet to one of the threaded bolt holes that is
predrilled in the side of the engine block. (see figure 7) Make certain that there is no paint or
rust in the threaded bolt hole as a good ground connection is very important. Run a tap in there
to clean it out if necessary. The positive terminal connection is the red wire with a 1/4" eyelet
that breaks out of the new harness at the two black ECU connectors. (see figure 6) Run this wire
to the switched side of the ignition switch or fuse box. It must supply power only when the key
is turned on.

Figure 4
Figure 5
Figure 6
Figure 7
7.) Connect the new harness to the boost sensor that is located on the left side of the engine. This
sensor is located on the intake manifold right in the center of the engine on the drivers side. See
figure 8. Disconnect the original connector from the sensor. Find the boost sensor wires that
brake out of the new harness in the same area as the ECM connectors are located. Plug the male
connector from the new harness into the boost sensor. Next, plug the original male connector,
removed previously, into the female connector of the new harness. If your engine is a 1997 or
older, use the supplied adapter harness to make these connections.
8.) Drill and tap the exhaust manifold and install the EGT sensor (thermocouple). Note: The
thermocouple must be located in the exhaust manifold in order for proper temperature
monitoring. Removal of the turbocharger is not necessary as the small amount of shavings
created will pass through on engine start up. Referring to figure 9 & 10, drill a 1/8" pilot hole in
the center of the flat boss on top of the manifold by the turbo. After the pilot hole is drilled re-
drill with a 15/32" bit to open the hole to accept a 1/4" pipe tap. Run the tap in and thread the
hole. Use caution not to turn the tap in to deep as this will open the hole beyond
specifications. Use the EGT sensor as a guideline by removing the tap and checking for a proper
fit. After the hole is tapped, install the sensor into the manifold. It is recommended to use anti-
seize on the sensors threaded areas. Caution:Do not drill the manifold in the center of the turbo
mounting flange.

Figure 8
Figure 9 Top View
Figure 10 Side View
9.) EGT Wire Connections. Connect the yellow EGT sensor lead wire, (built into the new
harness) to the EGT sensor. Attach the longer red lead wire to the shorter red wire on the EGT
sensor and the shorter yellow lead wire to the longer yellow wire on the EGT sensor. Slide the
protective cover over the connectors and tape or heat shrink it closed on the end.
10.) Final Wiring Steps. Using the supplied wire ties, fasten the EGT lead wire and the
“Pittsburgh Power” harness at several locations under the hood and under the dash to prevent
vibration. Be sure to route all wiring away from any heat source.
11.) Install the remote control unit . Using the supplied Velcro, attach the remote to a
convenient location. Route the wire from the remote unit to the “Pittsburgh Power” ECU
and plug it into the connector that breaks out of the harness at the ECU (see figure 6). Use wire
ties were necessary to hold the lead in place. When routing the lead from the remote, do not run
it near any other electrical wires and keep it separated from the big wires of the new harness that
plugs into the back of the “Pittsburgh Power”. In other words, do not tie wrap the excess
lead wire to the ECU harness. If the cable is near any other electrical wires or devices, electrical
interference may cause the remote to display erroneous characters. If this occurs, reroute the
lead and cycle the key on and off and the remote will reset.