1999-2005 GM Installation Instructions

1. Release the hood latch and lift the hood of the vehicle.

2. Locate the brake lines connected to the brake master cylinder. There is a service tee included in the hookup kit. Figure 1 shows an installation using the rear port for the service tee. Either port may be used.

3. Remove the brake line from the

master cylinder . Install the service tee into the master cylinder. Tighten securely. Reinstall the brake line to the end of the service tee as shown in Figure 2. Tighten securely.

4. Install the brake hose to the side port of the service tee as shown in Figure

3. Position the hose fitting to avoid abrasion with surrounding objects. Tighten securely.

5. Install the pressure sensor included in the kit to the end of the brake hose. Hand tighten only.

6. Bleed entrapped air from the brake hose by the following procedure. Have someone apply and hold pressure on the brake pedal. Wrap a rag or paper towel around the pressure sensor and open the connection by hand. Brake fluid and air will escape as the brake pedal is depressed to the floor of the vehicle. Close off the connection at the pressure sensor hand tight. Have the helper release the brake pedal. Repeat the bleed procedure a second time. Tighten the pressure sensor securely to the brake hose.

7. Install the pressure sensor harness provided in the kit to the pressure sensor electrical receptacle..

8. Figure 4 shows an access area where a hole can be drilled through the firewall of the vehicle to allow entry of the pressure sensor harness to the brake controller. If another access route cannot be used, this is the preferred method of routing the harness. An 11/16” diameter hole is

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required. The location shown is to the right of the steering column. Drilling a 1/4” pilot hole before using a larger bit is helpful.

9. Remove the cord restraint nut from the cord restraint on the pressure sensor harness. Feed the white connector of the harness through the hole drilled in step 8 .

10. Refer to Figure 5. The hole drilled in step 9 will penetrate the interior of the vehicle in the area shown by the arrow.

11. From the interior of the vehicle slide the cord restraint retaining nut over the harness and tighten securely to the cord restraint.

12. Pull excess slack of the harness from inside the interior of the vehicle. Route the harness in a secure location in the engine compartment and secure to other harnesses or stationary lines in the engine compartment using wire ties provided. Avoid moving objects such as the steering sector and hot objects such as the exhaust system.

13. Refer to Figure 6. This area is visible from underneath the dash on the drivers side. Remove the retaining nut from the connector panel cover. The nut is shown by the arrow in Figure 6.

14. Plug the brake controller power harness into the connector socket shown in Figure 7. Route the wire out to the top and reinstall the connector access cover removed in step 13.

15. Plug the pressure sensor harness, key side up as shown in Figure 8, into the brake controller. Plug the power connector into the brake controller. The power connector will only fit one way.

16. The two pin connector on the controller is reserved for future use. The round port hole on the controller is used to reprogram the unit and also accommodates an Exhaust Gas Temperature and Boost module option for diesel engines.

17. Find a suitable location for the brake controller. This should be a place easily visible by the driver and also allow easy access to the control buttons of the controller.

18. Mount the brake controller mounting bracket at the chosen location using the two self drilling screws provided.

19. Start the engine and depress the brake pedal. “Braking” should appear on the top line of the brake controller. A bar graph appears on the bottom line of the display. As pressure is increased on the brake pedal, the bar graph extends to the right on the display.

20. Inspect the brake line connections to assure there are no leaks.

21. Close the hood.

Figure 8

22. Stop the engine. 23. Installation complete. 24. Enjoy the many features of your new

brake controller.

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