Install Instructions

Install Instructions
1998.5-2002 Dodge Cummins 5.9L 24 Valve
Edge Products EZ Module
Installation Instructions & Manual
P/N’s: 30200 / 30201
READ IMPORTANT SAFETY INFORMATION IN THIS MANUAL
California Air Resources Board
Executive Order D-541 (30200 98-99 Only)
Edge EZ User Manual
Edge Products
TABLE OF CONTENTS
IMPORTANT SAFETY INFORMATION _________________________________________ 3
SAFETY TERMS __________________________________________________________________3
SAFETY GUIDELINES ____________________________________________________________3
PRODUCT REGISTRATION ___________________________________________________ 4
Benefits of product registration: ______________________________________________________4
CARB/EPA Compliance _______________________________________________________ 5
About the Dodge EZ___________________________________________________________ 5
Introduction ______________________________________________________________________5
Power Level 1 and 2 ________________________________________________________________6
Power Level 3 _____________________________________________________________________6
Towing ___________________________________________________________________________6
Exhaust Gas Temperature___________________________________________________________7
EZ Installation Instructions ____________________________________________________ 7
Tools Required: ___________________________________________________________________7
Supplied Items: ____________________________________________________________________7
The Edge EZ Module: ______________________________________________________________8
Module Installation ________________________________________________________________8
Harness Connector _________________________________________________________________8
Data Link Connection ______________________________________________________________9
MAP Connection _________________________________________________________________10
Attach and Install the 3 Position Switch_______________________________________________11
Boost Elbow Installation (Optional) __________________________________________________11
Final Inspection and Operation _____________________________________________________13
Using the EZ and Power Level Adjustment _______________________________________ 13
Power Levels _____________________________________________________________________13
Power Gains _____________________________________________________________________13
Warranty Information ________________________________________________________ 14
LIMITED 1 YEAR WARRANTY ___________________________________________________14
Technical Support: ________________________________________________________________15
© 2007 Edge Products
All rights reserved.
Edge Products
1080 South Depot Dr.
Ogden, UT 84404
1-888-360-3343
www.edgeproducts.com
Manual Version 7
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IMPORTANT SAFETY INFORMATION
SAFETY TERMS
Throughout this User Guide (hereafter referred to as User Manual or Manual) you will see important
messages regarding your safety or the protection of your vehicle. These messages will be designated by
the words WARNING or CAUTION.
WARNING indicates a condition that may cause serious injury or death to you, your passengers
or others nearby. Pay careful attention to these Warning messages, and always comply with them. They
could save a life.
CAUTION indicates a condition that could cause damage to your vehicle. It is important to install and
operate your EDGE product in conformance with instructions in this Manual. Caution messages alert you
to particularly important things to watch for to keep your vehicle operating the way you want it to.
The Edge product you have bought is a high-performance product. As such, it does present some risks
of which you should be fully aware. Do not use this product until you have carefully read all the following
safety information and the Owner Agreement.
WARNING
Misapplication or misuse of this product could lead to a serious or fatal accident.
Comply with all safety information below, and in your vehicle owner’s manual. Follow
safety, installation and operating instructions in this User Manual to assure proper
use.
SAFETY GUIDELINES
1. Do not exceed legal speed limits on public roadways. Use any enhanced speed capabilities of
this product only in closed circuit, legally sanctioned racing environments expressly for this
purpose. Loss of control from speeding on a public road could seriously injure you, your
passengers, or others on the roadway.
2. Select a position on the windshield or dashboard to mount the device where it will not impair your
view. You must be able to see the road, traffic, and pedestrians without interference. Be sure
your mounting location meets state and local laws regarding placement of devices on the
windshield or dashboard.
3. Do not operate the device while driving. Perform all adjustments or changes while stopped.
Changing a setting while under way can interfere with your attention to roadway conditions.
4. “Stacking” performance-enhancing devices or other improper installation could cause powertrain
failure on the road. Other products may have features incompatible with your Edge device.
Follow all installation and operating instructions, and don’t stack products.
5. Some modifications may affect other parts of your vehicle. For example, if you remove/adjust the
speed limiter in your vehicle, be sure your tires and other components are rated for the increased
speeds they will have to withstand. Not doing so can lead to loss of vehicle control. Modify the
speed limiter only for use in closed circuit, legally sanctioned racing environments, not for use on
public roadways.
6. Do not use the Performance Tests feature to break any traffic laws. Perform these tests only
where they are legal and safe.
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7. Some features may not function on all vehicle models. Check a newly-installed device for all
features you intend to use. Do not rely on their working without checking first.
NOTE: Dispose of this product consistent with local codes. Return to your electronics supplier for proper
handling.
PRODUCT REGISTRATION
Please take the time to register your product. To register your product, follow the
instructions at this link. http://www.edgeproducts.com/product_registration.php
Benefits of product registration:

Your Safety – registering your product allows us to know exactly which product you have and provide
important product updates to you that improve the quality and/or safety of the product

Enhanced Features – almost all Edge products are easily updated via the internet. We are constantly
adding new features and improvements to our product that we know you will want to enjoy

Confirmation of Ownership – provides a record in case of product loss, theft, or required warranty work.
When you call us for support our team will already have much of the information they need to help you!

Improved Product Development – helps us better understand you (our customers) and design products
that meet your needs

Special Offers – allows us to inform you about special offers on accessories and/or new products that fit
your vehicle and enhance your driving experience

AND…

Extended Warranty Plan Opportunity – within the first 90 days of ownership, Edge offers the option to
buy a 1-year warranty extension to all customers who register their product!
All Edge modules and programmers are built to operate with OEM calibrations. When
you take your vehicle to a service center they may, by your request or otherwise, update
your vehicles calibrations. Therefore it is important that you return your vehicle to stock
before taking it in for service. Edge updates its active products (i.e. those currently being
manufactured) to work effectively with updated OEM calibrations. However, this process
can take some time as Edge is not always made aware of calibration changes made by the
OEM. In the case of discontinued products, Edge cannot ensure that your unit will work
effectively if you take your vehicle to a dealership and you are given, by your request or
otherwise, a new calibration.
If you have used another tuner/programmer on your vehicle, you will need to program
back to stock and remove the device before using the Edge Products Device.
Failure to return to stock may result in PCM failure or engine damage.
Because the Power Edge EZ module is a high performance product, it is strongly
recommended that EGT gauges and Boost gauges be installed with the use of this product.
Programming your vehicle may expose existing defects in your vehicle’s PCM that
could disable your vehicle. It is advised that you do not program your vehicle in
remote locations in case of vehicle failure.
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CARB/EPA Compliance
This E.O. number only applies to the Edge PN 30200 for model years 1998-1999
and indicates the installation of this product meets the emissions compliance
requirements of the California Air Resources Board and Federal Environmental
Protection Agency and is legal for sale and use on pollution-controlled vehicles
operated on public streets and highways. It must be installed and operated
according to the instructions provided in this user’s manual. Included with this
product is a sticker like the one pictured below for you to retain with your vehicle.
You can either apply it somewhere on the vehicle (e.g., the inside end of driver’s
door) or simply retain it in your glove box. The purpose of the sticker is to inform
anyone who may have questions regarding the use of your Edge product and how it
affects emissions. For example, it would be something to show an emissions
technician if questioned when taking your vehicle in for an emissions check to let
him/her know the product is CARB emissions compliant.
About the Dodge EZ
Introduction
Thank you for purchasing the Edge EZ Module for the Dodge Cummins® Diesel. The
Edge EZ module has been developed and produced from the highest quality materials
available to ensure the best performance for years to come. If you have any questions,
please contact Edge Products. We will be very happy to answer your questions about
our complete product line.
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 The Edge EZ Module is an add-on Engine Control Module (ECM) for the
Cummins® Engine that offers additional features not available on a stock
engine. Since it is an “add on” ECM, it uses all the factory data, and then
enhances the factory settings to optimize your truck’s performance.
The EZ module offers a power increase over stock throughout the RPM range, but
the power is most noticeable in midrange RPM’s. This greatly improves
drivability and towing performance. Transmission downshifting is greatly
reduced, especially while passing or towing.
The first thing you will probably notice is improved performance, especially if this
is your first time driving a diesel truck with a performance module. You will
experience more power, better throttle response, better passing and acceleration,
and even better fuel economy. Power level one is specifically designed to
maximize fuel economy improvements.
Power Level 1 and 2
WARNING Towing: Do not exceed your vehicle’s max GVWR as outlined
in the vehicle’s owner’s manual. Doing so may result in loss of vehicle control and
cause bodily injury.
These settings will provide additional engine performance. These levels are
appropriate for most towing situations.
Power Level 3
This setting will provide the highest engine performance for your vehicle. You
should see an improvement in fuel economy as well as added horsepower and
torque. Due to the high performance nature of this setting, towing or hauling heavy
loads is not recommended.
Towing
The Edge EZ Module and all the other Edge® power modules were made for
towing. That is why Edge built them, and why we keep making them better. Let’s
assume that in a stock truck you would pull your 5,000lb load up the grades in 3rd
gear. Your EGT (Exhaust Gas Temperature) may run at about 1200 F. With the
EZ module on level 2, you have effectively increased the horsepower by 35, and
the torque by 77 Foot-pounds. That is like adding a fifth horse to pull a four horse
carriage. That is representative of how much your power has increased. That
means you will be running at a lower rpm and your EGT has decreased. And best
of all you are going faster and the truck may have already shifted into 4th gear.
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Power level 3 is designed to match fueling with any additional upgrades you may
have done to your vehicle. Level 3 should never be used while towing. Level 3 is
designed to take advantage of the built-in safety margins the manufacture needs to
add in order to make sure your vehicle can operate at its maximum capacity.
When driven responsibly, and used with an EGT gauge, level 3 will not stress the
stock engine or transmission as long as you are not towing.
Exhaust Gas Temperature
Now let’s talk about the different power levels and the Exhaust Gas Temperature
(EGT) readings, and what they mean. As mentioned earlier the EGT tells you how
hot the exhaust gases are in the exhaust manifold coming from the engine. This is
important because you shouldn’t let them run for long periods above 1350 F. The
higher the level, the more fuel is fed to the engine, and potentially, the higher the
EGT's. Since towing is harder on the engine and the transmission, we recommend
that you tow in level 1 for a heavy load, or, on a light load level 2. This will
protect you from putting too much stress on the engine and transmission. Level 2
is a good all-around mode, allowing for better economy and better performance,
while not stressing the engine and transmission. We recommend that you run your
truck in level 2 or lower for your normal daily activities.
EZ Installation Instructions
IMPORTANT: Read all Safety, Warranty, and Installation Instructions before
installing this product. Read through these instructions completely so that you
understand each step prior to installation.
Tools Required:
Pliers
Flat tip Screwdriver
1/2” Wrench
3/8” Drive Ratchet & Sockets
1/4” Socket
5/16” Socket
7/16“ Deep Well Socket
Supplied Items:
1.
2.
3.
4.
5.
6.
Edge EZ Module
Three Wire Ties
Two Velcro Strips
One Hose Clamp
One 90° Brass Fitting
3 Position Toggle Switch
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The Edge EZ Module:
This picture shows the Edge EZ Module with the harness cable (Note: Harness
shown is for years 1998.5-2000. 2001+ is slightly different)
Data Link
connector(May require
adapter)
Edge EZ
power Module
MAP Sensor.
Disconnect
engine
harness and
insert this
harness ‘T’
Data Link (2000)
adapter- use to
adapt Data Link
to engine.
Power Level Selector
Switch Connection.
(connect to pwr lvl switch.)
FIGURE 1A
Power Level
Selector Switch.
Connect this
green connector to
green connector
on EZ harness
FIGURE 1B
Module Installation
The Edge EZ Module can mount on the flat black plastic fuse box cover located on
the driver’s side fender. Adhere the module using the supplied Velcro, allowing
enough harness movement for removal of the cover.
Harness Connector
Your EZ module is equipped with a harness that can be disconnected at the EZ
module itself (See figure 1C). It is important to make sure that your EZ module is
always connected to the harness when the wiring harness is connected to the truck,
otherwise the truck may not run properly, or may trip engine “codes.”
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FIGURE 1C
Data Link Connection
1. The Data Link connector is located
in different locations based on the
year of the truck:
 98.5-99 the triangle shaped
connector is located on the drivers
side of the engine in the wiring
harness near the power steering
pump
 2000-2001 the three prong flat
connector is located on top of the
fuel lift pump that is located on the
driver’s side of the engine directly
below the MAP sensor, note: on
some 2001 truck’s the connector is
located on the drivers side of the
engine in the wiring harness near
the power steering pump
2. A plug is installed in the data link
connector on the truck to resist
corrosion, remove this and install
the supplied connector.
MAP Sensor
& 2000-2002
Data Link
1998.5-1999 Data
Link
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MAP Connection
Connect the supplied MAP sensor wiring
harness to the supplied main wiring
harness in the engine compartment.
Disconnect the stock wiring harness at the
boost sensor located to the rear of the fuel
filter housing near the top of and on the
engine block. Plug the supplied MAP
sensor connector into the stock engine
boost sensor and the stock engine wiring
harness connector into the supplied MAP
sensor connector. The MAP sensor
shown in the image is for a 2001, the
1998.5-2000 are a different sensor but in
the same location.
Adapter #1
MAP Sensor
2000-2002
Data Link
Adapter #2
Map Sensor Connection
(2001 Shown)
For 2002,
locate
adapter #2
between
sensor and
Edge harness.
For 2002,
locate adapter
#1 between
Edge and truck
harness.
Front of vehicle
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Attach and Install the 3 Position Switch
1. Attach the 3-position switch cable with the green connector to the mating green
connector on the harness (see Figure 1A and 1B) and pass it through or around
the rubber boot in the driver side firewall behind the battery. (see Figure 2)
After routing the switch under the dash, mount the switch to the lower dash
panel at the left of the steering column. (Note: The cable and switch may also
be routed around the outside door pillar and placed on the dash.)
Pass the power switch
cable through the boot
on the driver side firewall
to access the dash
board inside the cab.
FIGURE #2
2. Using a 1/4 inch drill, carefully drill a hole through the lower plastic dash panel.
Insert the switch through the hole and secure in order: the tab ring, internal star
washer and then tightening the nut. Caution: Make sure the location you select
to drill the hole does not drill into wires or other critical components.
Boost Elbow Installation (Optional)
The installation of the brass elbow permits turbo boost pressures of greater than 20
psi without the wastegate opening. The Edge EZ Module will operate equally well
with or without this installed. (The turbo is located on the passenger side of the
engine compartment.)
1. Using the 5/16” socket, loosen the two clamps securing the air induction hose to
the air filter housing and the turbo inlet. Remove the hose and set it aside.
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2. Using the pliers, remove the crimp style clamp from the hose on the brass
fitting located on the now exposed lower front side of the turbocharger.
Remove the hose from the brass fitting and dispose of the crimp style clamp.
3. Using the 7/16” wrench, unscrew the stock brass fitting out of the turbocharger
housing. Using the 7/16” wrench, install the supplied brass fitting, tighten-be
careful not to over-tighten. Slip the supplied hose clamp onto the stock hose,
install the stock hose onto the supplied brass fitting and tighten the hose clamp
with the ¼” socket. Reinstall the stock air hose onto the air filter housing and
turbocharger inlet. Using the 5/16” socket, tighten both clamps securely.
4. Using the 7/16 deep socket tighten all of the intercooler hose clamps on the air
intake.
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Note: On 2001 auto’s turbos, the wastegate is a solid line and does not have a
brass elbow to be replaced
Final Inspection and Operation
1. Recheck all connections, fittings and fasteners for a properly secure installation.
2. Using the supplied wire ties, secure the wiring harness from possible damage.
Using the EZ and Power Level Adjustment
Power Levels
The Edge EZ Module offers 3
levels of power beyond stock. The
power from the Edge EZ Module
begins by plugging the module into
your truck. The power levels are
adjusted by changing the “in cab”
switch position to the level you
need. Level 3 is switch position
farthest from the Tab. Adjusting
power levels on an EZ module has
never been EZier!
-Level 3
-Level 2
-Level 1
Tab (Switch
shown in level
1 position)
Power Level
Adjustment Switch
Refer to the power level switch
picture for position and power level
selection.
Do not combine, or “stack” chips (modules) to gain more
horsepower. The chips could be incompatible and result in powertrain failure or
create dangerous conditions (such as adverse running conditions, high idle, DTC
codes, etc.) leading to a serious or fatal accident.
WARNING
Power Gains
The following power gains are representative of an actual test vehicle. These gains
were measured on a Super Flow Dyno at an altitude of 4400 Ft. above sea level,
and represent power delivered to the rear wheels of the test truck. The only
modification made to the test truck was the addition of the Evolution. Power gains
may vary somewhat on a different vehicle or in different geographic settings.
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Level 1:
Level 2:
Level 3:
Horsepower
20
35
65
Edge Products
Torque
45 (Timing Only)
77
180
Warranty Information
LIMITED 1 YEAR WARRANTY
Edge Products, LLC, (hereafter "SELLER") gives Limited Warranty as to description, quality, merchantability,
fitness for any product’s purpose, productiveness, or any other matter of SELLER's product sold herewith.
The SELLER shall be in no way responsible for the product’s open use and service and the BUYER hereby
waives all rights other than those expressly written herein. This Warranty shall not be extended or varied
except by a written instrument signed by SELLER and BUYER.
The Warranty is Limited to one (1) year from the date of sale and limited solely to the parts contained within
the product's kit. All products that are in question of Warranty must be returned shipping prepaid to the
SELLER and must be accompanied by a dated proof of purchase receipt. All Warranty claims are subject to
approval by Edge Products Inc.
Under no circumstances shall the SELLER be liable for any labor charged or travel time incurred in diagnosis
for defects, removal, or reinstallation of this product, or any other contingent expenses.
If the BUYER sends back a failed unit that is out of warranty and chooses to buy a refurbished unit, the
refurbished unit will only carry a 90 day warranty. If the BUYER purchases a new unit at a predetermined
discounted rate, it will have the standard 1 year warranty.
Under no circumstances will the SELLER be liable for any damage or expenses insured by reason of the use
or sale of any such equipment.
THE INSTALLATION OF THIS PRODUCT INDICATES THAT THE BUYER HAS READ AND
UNDERSTANDS THIS AGREEMENT AND ACCEPTS ITS TERMS AND CONDITIONS.
IN THE EVENT THAT THE BUYER DOES NOT AGREE WITH THIS AGREEMENT, THE BUYER MAY
PROMPTLY RETURN THIS PRODUCT, IN A NEW AND UNUSED CONDITION, WITH A DATED PROOF
OF PURCHASE, TO THE PLACE OF PURCHASE WITHIN THIRTY (30) DAYS FROM DATE OF
PURCHASE FOR A FULL REFUND.
IMPORTANT INFORMATION ABOUT YOUR VEHICLE’S WARRANTY
Many of our customers ask, “Will your product void my vehicle’s manufacturer’s warranty?” While the
answer is straightforward from a legal standpoint, it’s important to educate our customers (and all
aftermarket consumers) on some industry realities and offer some common sense precautions to
minimize your risk. Edge is committed to providing quality products that are safe to use. Our products do
not cause damage to a vehicle when used as intended. Please keep in mind that towing in anything
higher than the towing level and hard driving in race or extreme performance levels is not recommended.
Consumers of aftermarket products are protected by the Federal Magnusson-Moss Warranty Act. The Act
states that if something breaks on your vehicle and you take it in for warranty repair, the dealer must
honor your warranty unless whatever modifications you have added to your vehicle actually caused the
problem in question.
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However, the reality is that many dealerships have been known to void warranties on vehicles that use
aftermarket products as a matter of policy. This applies in particular to those aftermarket products that
produce horsepower, such as performance enhancement “chips,” modified intake manifolds, or
aftermarket exhaust systems, regardless of product brand.
You have strong legal protection as a consumer in regard to your vehicle’s warranty. However, Edge
strongly recommends you always disconnect and remove your module/programmer and monitor when
you take your vehicle to a dealer for warranty work. In addition, leaving the product connected may affect
dealer diagnostic analysis and CAN tool functions. Edge makes every effort to produce product that can
be easily removed. NOTE: Even if you disconnect your unit, your dealer can detect the use of any
programmer—even if the unit has been removed.
Thank you for purchasing the Power Edge EZ Module by Edge Products, LLC for the Dodge 24 Valve
Cummins®. The EZ Module has been developed and produced from the highest quality materials
available to ensure the best performance for years to come. If you have any concerns or questions,
please contact us.
Note: This warranty is void for any new products purchased through auction websites. Warranty is valid
only for new products purchased through Authorized Dealers (proof of purchase required for all warranty
claims).
Technical Support:
888-360-3343
To expedite your support call, please have your Vehicle Information,
Part Number, Serial Number, and Date of Manufacture ready prior to
calling Technical Support. The Edge Products information is found on
the label located on the bottom of the device.
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