Installation Instructions PowerStroke Power Chip

Power Chip Installation Instructions
Power Chip Installation Instructions

some 1999 and earlier models computer exits from engine side of firewall
  fordtruck_gaschip_large.jpgFord Power Stroke Diesel

The installation of Power Chip for Ford Power Stroke Diesels in a relatively easy chore. But, there are a few precautions that must be taken. And we emphasize the word MUST. First, all of the components to be addressed in the installation fit very tightly in their respective openings. Therefore, we urge you to use caution and observe all of the components as your remove them to assure they will be re-installed in the proper manner.

Second, an equally as important, is the cleaning of the control module prior to the installation of the Power Chip. This will be addressed later in the instructions but suffice it to say, that if done improperly, the vehicle's performance may suffer, In fact, the engine may not re-start.


Locate the powertrain control module on the firewall between the driver side fender and the brake booster, see Figure 1 (later models the module is located under the dash, just above your left knee). Remove the ground wire that is attached to the firewall or the fender and the multi-pin connector. Using a 1.4" drive ratchet with a 10mm socket, remove the multi-pin connector from the front of the control module. With the same socket, remove the two (2) 10mm nuts holding the retainer seal.






Figure 2

Figure 3

The control Module will be ready to remove, see Figure 2 but, do not attempt to remove it at this time.

Because of the close proximity of the module to the fender shield, there is not enough clearance to pull the unit out see Figure 4. Using a 7/32" socket, remove all the screws in the fender shield from the bottom to the 12 o'clock position at the top of the fender.


There is one additional 8mm screw further in the opening to be removed. Then pull the shield down and toward the tire see Figure 3. This will allow the module to come further out and turn upward. Notice at this time how the module is positioned and mark the top to help assure it's proper re-install.

Figure 4.

Remove the module as shown in Figure 5 and place it on a clean workbench. With the 7/32" socket, remove the six screws holding the two sides on the center main case of the module. Carefully remove the stamped and die-cast covers. This is necessary to expose the control board for cleaning. Now things get a little tricky. The control board has two coatings on the connector; one hard type and one soft. We suggest that you purchase from Radio Shack a can of PCB cleaner and a can of pressurized air. Wipe the soft coating off the connector then using the scraper pad supplied, carefully scrape all of the hard clear coating from both sides of the same see figure 6, ensure that the coating is also removed from in between the tracks. Be very careful to remove all visual particles of the coating, washing with cleaner and blowing off the complete assembly and few times. Double check, then clean again. It's easier now, than removing the control module later and starting completely over again.



Figure 5

Figure 6

Note: Removing the clear coating leaves a "dust" or small particles that tend to cling to the control board. This "dust" must be removed to assure that the Power Chip does not malfunction.

Re-install the covers, then plug the Power Chip onto the control board connector (connector down, chip board on top of computer PCB) push the connecting pin until they are firmly seated. Snap the new plug into place it secures the new circuit board in place.

Slide the module back to its original position. Check to be sure the top is still the top, then re-install the retainer seal, the multi-pin connector, ground wire, and the fender shield.

Start the engine and drive the vehicle for 10-15 minutes. If everything is installed properly the results will startle and please you.... Enjoy!