APPS SENSOR INSTALLATION INSTRUCTIONS

1. Remove the black plastic APPS cover by removing the two plastic philips screws and then pull out the plastic nutsert each screw went into, with your fingers or carefully with side cutting pliers.

2. Remove the six bolts that hold the “Bellcrank” assembly on, using a 10 mm socket. The sensor is on the back. A T20 Torx is needed here. As these screws have Loctite on them, be sure that the bit is engaged fully into the screw head so it doesn’t strip, or you will need to use vise grips to remove them. Discard old screws.

3. After the old sensor is removed, take the new sensor and look at the side that bolts to the bracket. In the center, you will see the slot that engages in the tang of the bellcrank shaft. Next, line up the slot with the tang and push the sensor onto the mounting surface. If the sensor does not mate flat to the mounting surface, the slot is not engaged properly; try again.

4. When you are sure the tang is engaged properly, rotate the sensor clockwise, until the screw holes are aligned, and start the provided replacement screws. Just before the screws are tight, twist the sensor clockwise and tighten the screws.

5. Remount the bellcrank assembly to the bracket.

6. Using a digital voltmeter, set the idle voltage by adjusting the idle stop screw. This screw also has Loctite on it from factory, so make sure the T20 torx bit is fully engaged into the head before attempting to turn it. If you think it may strip, carefully heat the screw area with a propane torch. This will soften the Loctite and allow it to turn. Only heat it for a couple of seconds at a time and attempt to turn the screw clockwise. After making the screw turn, measure the voltage. Plug the sensor into the factory harness. Using the paperclip provided, insert it in between the orange seal and the green wire on the back of the APPS connector. Push it in until it stops. Or you can measure the voltage on the blue wire with a black tracer in the factory plug, the same way, whichever is easier. Make sure the paperclip does not contact ground and then turn the ignition key to the ON position.  Turn your voltmeter to the low voltage DC scale. Now read the voltmeter, it should read .60 - .67 volt. If it reads higher than that, turn the idle stop screw counter clockwise until the voltage is below .60 volt. Turn the idle stop screw clockwise until the voltage begins to rise, then turn the screw counterclockwise 1/2 turn and you are done with the adjustment.

7. Turn key off, disconnect voltmeter, and replace plastic cover.

8. Turn key ON, press accelerator pedal slowly to the floor and then let up slowly. Turn key off.   Repeat this 2 more times. You are done.

Blue Chip Diesel Performance                                      
888-ISB-Perf or 888-472-7373
or info@bluechipdiesel.com                                                                  

September 17,2008