Bully Dog 42980 Dodge 5.9L Cummins Torque Dog Module El manual del propietario

Marca: Bully Dog

Modelo: 42980 Dodge 5.9L Cummins Torque Dog Module

Tipo: El manual del propietario

INSTALLATION MANUAL

Applications Torque Dog Part #

Dodge 5.9L Cummins 98.5-’00 42980

Dodge 5.9L Cummins ‘01-’02 42002

Dodge 5.9L Cummins ‘03-’04 42013

TROUBLESHOOTING:

If you have questions during the installation of this product,

please visit www.bullydog.com/Product_Updates.php.

The latest version of these instructions can be found at the same

location. Please review the Troubleshooting section on page 9

before calling technical support to cover most common issues.

Technical support is available by calling 866-bullydog

(866-285-5936).

TABLE OF CONTENTS

IntroductIon ................................................................................................PG 2

BILL oF MAtErIALS ..........................................................................................PG 2

InStALLAtIon ............................................................................................PGS 3-8

Quick Overview .............................................................................................................................. Pg 3

’98.5-’02 Install ............................................................................................................................ Pg 4-5

’03-’04 Install ............................................................................................................................. Pgs 6-7

Flip Switch Install ...........................................................................................................................Pg 8

trouBLESHootInG .........................................................................................PG 9

WArrAntY & dIScLAIMEr ..............................................................................PG10

INTRODUCTION

INTrOduCTION

The Torque Dog Module from Bully dog is a simple to install plug in module. The Torque Dog makes it easy for

you to add additional horsepower and even easier to adjust that horsepower on the y.

Note: Bully Dog highly recommends that gauges such as pyrometer and boost gauges be installed if towing or hauling

heavy loads..

IMPORTANT: Performance modules must always be removed before taking the vehicle in for any kind of service as it may

interfere with diagnostic tools, and cause the Torque Dog to be erased.

BILL oF MAtErIALS

1. Torque Dog Module

2. Flip Switch

3. Zip Ties (not shown)

4. Velcro (not shown)

5. Boost Fitting (if applicable)

6. Adaptor (if applicable)

tooLS nEEdEd

¼” Socket or Wrench (If Applicable)

5/16” Socket or Wrench (If Applicable)

7/16” Deep Socket or Wrench (If Applicable)

Socket Wrench (If Applicable)

Pliers (If Applicable)

Part #42002Part #42013

Part #42980

Flip Switch

Torque Dog Module

re wall grommet

Fuel Rail Sensor

MAP Sensor Plug

fuse box

Flip Switch

Torque Dog Module

ﬁre wall grommet

Data Link Plug

MAP Sensor Plug

fuse box

INSTALLATION OVERVIEW

ModuLE LocAtIon ovErvIEW ‘98-’02

ModuLE LocAtIon ovErvIEW ‘03-’04

INSTALLATION

Data Link Plug Location

Data Link Plug

InStALLAtIon oF tHE torQuE doG on ’98.5-02’ vEHIcLES

IMPORTANT: The steps on the next two pages are only applicable on ’98.5-’02

vehicles. If your vehicle is not ’98.5-’02 Dodge Cummins, skip these steps.

In these steps you will connect the Data Link and the MAP Sen-

sor plugs into ‘98.5-’02 Dodge Cummins trucks.

dAtA LInK PLuG:

1. Locate the stock Data Link Plug which is half way down the side of the engine on the driver’s side. Remove the stock

Data Link plug, which is covered with the retainer, from the stock Data Link Plug. Remove the retainer from the stock

Data Link Plug and store in a safe place. You may need to replace it when taking the vehicle in for service.

2. Plug the Bully Dog Data Link Plug (that is attached to the sub harness) into the truck’s Data Plug receiver. Press the

two plugs together until they snap into place.

MAP Sensor Plug

Data Link Plug

‘98-’02 Dodge

Torque Dog

INSTALLATION

MAP SEnSor PLuG:

1. Unplug the stock MAP Sensor Plug, located about 7 ½” from the re wall on the driver’s side of the cylinder head,

and plug the Bully Dog MAP Sensor Plug coming o the ‘98.5-’02 Dodge Sub-Harness into the stock MAP Sensor

Plug receiver until they snap together.

2. Plug the stock MAP Sensor Plug into the Bully Dog MAP Sensor Plug receiver on the ’98.5-’02 Dodge Sub-Harness

until they snap together.

Note: Supplied with the ’98.5-’02 Torque Dog is a boost ﬁtting. You do

not need to install the boost ﬁtting, but installing the boost ﬁtting is

beneﬁcial for those that are competing in competitions such as sled pulls

where building boost pressure is important. These optional steps are not

applicable on the ’01 5.9L Cummins.

3. Use a 5/16” socket or wrench and undo the two clamps that hold the air induction hose to the air lter housing and

turbo inlet.

4. With a pair of pliers, remove the crimp clamp from the hose on the stock brass tting located on the front side of

the turbo. Remove the hose from the brass tting.

5. Use a 7/16” wrench to remove the stock brass tting. Install the Bully Dog brass tting in place of the stock brass

tting.

6. Reconnect the air induction hose and tighten all of the intercooler hose clamps on the air intake.

MAP sensor Plug

INSTALLATION

InStALLAtIon oF tHE torQuE doG on ’03-’04 vEHIcLES

IMPORTANT: The steps on the next two pages are only applicable on ’03-’04

vehicles. If your vehicle is not ’03-’04 Dodge Cummins, skip these steps.

In this step you will connect the Fuel Rail Sensor and the MAP

Sensor plugs to ‘03-’04 Dodge.

FuEL rAIL SEnSor

1. Locate the stock Fuel Rail Sensor which is half way down the side of the engine on the driver’s side. Remove the stock

Fuel Rail Sensor, which is covered with the retainer, from the stock Fuel Rail Sensor. Remove the retainer from the

stock Fuel Rail Sensor and store in a safe place. You may need to replace it when taking the vehicle in for service.

2. Plug the Bully Dog Fuel Rail Sensor (that is attached to the sub harness) into the truck’s Data Plug Receiver. Press the

two plugs together until they snap into place.

‘03-’04 Torque Dog

Fuel Rail Sensor

MAP Sensor Plug

Fuel Rail Sensor Location

INSTALLATION

MAP Sensor Stock Plug Map Sensor with Sub Harness

(valve cover)

InStALLAtIon oF tHE torQuE doG on ’03-’04 vEHIcLES

MAP SEnSor PLuG:

1. Unplug the stock MAP Sensor Plug, located about 7 ½” from the re wall on the driver’s side of the valve cover, and

plug the Bully Dog MAP Sensor Plug coming o the ’03-’05 Dodge Sub-Harness into the stock MAP Sensor Plug

receiver until they snap together.

2. Plug the stock MAP Sensor Plug into the Bully Dog MAP Sensor Plug receiver on the ’03-’05 Dodge Sub-Harness

until they snap together.

INSTALLATION

InStALLInG And oPErAtInG tHE FLIP SWItcH

1. Connect the ip switch provided to the module via the green

connector coming out from the top of the module.

2. Now mount the switch in a location that gives you conve-

nient access to the switch when driving. You may drill a hole

in your lower dash for the quickest and cleanest mounting

area.

OPERATING THE INCAB SWITCH:

This module comes with a ﬂip switch which allows for on

the ﬂy power adjustments. This means that the module can

be adjusted between the power levels under any driving

conditions. The diagram to the right illustrates where the

diﬀerent power levels are located on the switch. Toward the

thread groove is the stock power position.

Flip Switch (#3)

Stock Position

Stock

50Hp

90Hp

Stock

30Hp

65Hp

‘98.5-’02

‘03-’04

Possible Switch Mount Location

TROUBLE SHOOTING

MOduLE TrOuBLEShOOTINg

CONDITION POSSIBLE SOURCES ACTION

Truck not starting Connection

Make sure the connectors are plugged in securely. Push

the connectors all the way in before pushing the latch up

if it is not installed that way the latch could break. If the

connectors are not tight make sure the middle red part

of the connector is pushed in securely, otherwise it could

fall out of place and cause problems in hooking up the

connector. If the connectors are not plugged in securely,

the truck will not start. Make sure that none of the pins are

bent inside the connector.

More black smoke Programming

To reduce black smoke, set the module at a lower

horsepower level.

Feeling no power Connection

Push the connectors all the way in before pushing the latch

up. If not installed correctly the latch could break.If the

connectors are not tight make sure that the middle part

of the connector is pushed in securely. It could fall out of

place and cause problems in hooking up the connector.

Check Engine Light. Programming

The service engine light could come on at the higher hor-

sepower setting. This is generally because the ECU is seeing

an over boost. The over boost is not causing any damage.

For more information on an up-to-date troubleshooting guide, please visit:

www.bullydog.com/Product_Updates.php

NOTES

Free Technical Support at:

866-bullydog (866-285-5936)

See More at: bullydog.com

Check out more of our ADRENALINE PUMPING products!

Doc.# 42980-99 V1.0

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Bully Dog 42980 Dodge 5.9L Cummins Torque Dog Module El manual del propietario

Marca: Bully Dog

Modelo: 42980 Dodge 5.9L Cummins Torque Dog Module

Tipo: El manual del propietario

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