Remote Heat Sink and FSD Install

FSD Article · Diesel Trouble Shooting · Hard Starting · Cracked Block

There are a number of vendors selling FSD heatsinks.

The heat sink I used was from Hucksdorf diesel and cost me 210.00 when this article was written. They have a shop in Franklin Wisconsin which is down by Mitchell Airport (Milwaukee). I believe that this product is comparable to the other heat sinks available for the HUMMER although I have never seen the other heat sinks up close.

Hucksdorf told me that if I needed a new injector pump down the road they would sell me one without the FSD for 650.00 which would be a nice savings.

 

You can get fsd resistors from (877) 375-7867 They are $16 each. (These are the prices when the article was written so they probably have changed)

Flash Off-Road Heatsink Kit

Other Sources of Coolers:

Hucksdorf
Polar Flow
SS Diesel Supply
Midwest Fuel Injection
J&H Diesel Service

Another owner bought his heatsink from Midwest Fuel Injection Corporation, They'll try to sell you the Van adopter kit but you don't really need it unless you mount it on the intake.

 

A company is making an improved version of the FSD. The SOL-D module from RemarQ is a complete redesign of the original Stanadyne FSD (Fuel Solenoid Driver) module using automotive and military grade Mosfet power transistor technology.

 

(1/2006) I had a SOL-D for almost a year, it worked great, than just flat quit on me. No warning, no nothing. I sent a couple of E-mails as it has a 5 year warranty. After a week or so they said they would replace it if I could find the warranty card and FAX it to them. Well I could not find the thing so I replied advising them I could provide all of the information that was on the card. In fact, I am still on the system on their website. I have heard nothing since and that was several weeks ago. I replied to two separate E-mails, no response, no replaced unit. Go Figure!

 

SOL-D had a minor issue as well. They ended up recalling their first generation units and replaced them with upgraded ones. This is even documented on their web site in the FAQ. Supposedly, they use MOSFET transistors rather than the Darlingtons that are present in the stock FSD. They also admit that there is an increase in noise over the stock FSD.

The first step in installing the FSD and heat sink

is to remove the harness that connects to the old FSD located on the injector pump. I removed the large intake hose that runs to the air filter, which seemed to make it a little easier to get at the injector pump

 

Also remove the ground, a black wire on the top of the injector pump, which is secured by a TORX head. Attach the new extended ground wire to the top of the injector pump, where the old ground was removed.

Next prepare to drill the holes to mount the heat sink.

I found that just to the right of the center hood snubber on the firewall worked perfectly. Lay a strip of masking tape down, then place the new heat sink on top the tape, and then trace the holes. I used a ¼ inch drill bit to drill the holes. Drilling through the masking tape ensures that the metal flakes from the drill bit will not chip your paint. I had to remove one of the windshield washer lines to allow the placement of the new heat sink.

 

NOTE: I think that the best place to mount a FSD Cooler is as far away from the engine as you can so it's away from all of the heat. Some have mounted it in a wheel well which is fine as long as mud and road dirt don't clog the cooling fins. You will need to extend the wiring harness. The heat sink should be large enough to absorb and dissipate heat for an indefinite period.


FSD and Heatsink
This is the Hucksdorf Cooler
Parts:
  • New PMD
  • New #5 resistor
  • Torx bits (to move the grounding wire)
  • An extension harness from Kennedy or Heath Diesel
  • A flat bladed screwdriver
  • A drill and some bits
  • A heat sink
  • A mounting method (assorted screws/bolts/etc to mount the heat sink to the PMD and the PMD/Heat Sink to somewhere)
  • A length of 12 gauge wire (to extend the ground wire)
  • Artic Silver or some other high quality CPU Thermal Conductive paste
What you need to do (on a basic level):
  • Mount heat sink onto PMD, slathering Artic Silver onto the transistor side
  • Insert #5 resistor into the PMD
  • Remove the old ground lug
  • Take a flat screwdriver and remove the harness from the old PMD
  • Reroute cable upward
  • Attach extension cable onto harness end
  • Attach other end of the extension cable to the PMD/Heat Sink unit
  • Mount unit to some lower temp location. Common areas include next to the center hood block, next to the PS cooler, near the battery tray, etc.
  • Extend grounding lug to some other clean ground using the 12ga wire.

Prepare the holes to mount the heatsink


This photo shows the heatsink mounting Holes Drilled.
Mount the FSD to the heatsink tighting to 25 inch pounds. This is fairly tight. An invoice for a FSD that I recently bought (8/2007) said that if the FSD wasn't tightened to 25 inch pounds it wouldn't be warrantied. I like to use some locktite on the screws.

This is the hardware that I used for the install. I used two 2-inch long bolts, mated to two 7/16 hex heads, and two ¾ inch nylon spacers to allow proper clearance of the hood.


Glue the mounting spacers onto the heatsink to make mounting them easier.


Mount the heatsink on the truck.


Plug the harness that was removed from the old FSD; and connect it to the new one. Take the ground that was removed from the injector pump, and the other end of the extended ground that is mounted on the injector pump and secure them to the bolt on the front of the heat sink. This ground isn't that critical because the FSD digital circuit is grounded through the wiring harness.