Please Click here to the Instructions PDF File

9/14/2012
Part # 2001020 Chevy/GM VVB Brake 2006-07LBZ
GMC/CHEVY LBZ DURAMAX (2006-07)
VARIABLE VANE EXHAUST BRAKE
Installation Instructions
P/N# 2001020
PLEASE READ ALL INSTRUCTIONS BEFORE INSTALLATION
UNLESS AN EO# IS LISTED, THIS PRODUCT IS LEGAL IN CALIFORNIA FOR
RACING VEHICLES ONLY, WHICH MAY NEVER BE USED UPON A HIGHWAY.
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 | Fax: 604-853-8749 | Internet: www.bd-power.com
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9/14/2012
Part # 2001020 Chevy/GM VVB Brake 2006-07LBZ
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KIT CONTENTS:
Please check to make sure that you have all the parts listed in this kit before you start
the disassembly of your truck.
2100001
2001121
2001110
Module
Switch Wiring Harness
Qty: 1
Qty: 1
Main Wiring Harness
Qty: 1
1505016
1330052
1330053
M6 Nut
Screw
Alcohol Swab
Qty: 1
Qty: 2
Qty: 1
1300131
1800060
2000106
1330051
2000103
Cable Ties
Velcro
Switch Bracket
Switch Bracket
Velcro
Switch Decal
Qty: 6
Qty: 2 X 4”
Qty: 1
Qty: 2 x 1.5”
Qty: 1
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 | Fax: 604-853-8749 | Internet: www.bd-power.com
9/14/2012
Part # 2001020 Chevy/GM VVB Brake 2006-07LBZ
3
Vehicle Compatibility
Duramax Engine Model
8th Digit of VIN
VVB Application #
LB7
1
Not Applicable
LBZ
D
2001020
LMM
6
2001030
LML
8
Not Applicable
Please check your VIN and cross reference the table below to ensure you have the
correct model for your application.
Note: We cannot guarantee compatibility with all aftermarket products that have a
permanent connection to the OBDII plug inside of the cab.


Older Edge Attitude displays have a known compatibility issue, while the newer Edge CTS and CS are
compatible.
H&S Mini Max are not compatible at this time.
Tools Required
 Socket 8,10mm / 5/16”
 Drill
 Blade Screw Driver
Switch Positioning
 Drill Bit 1/8” & 3/8”
 Wrench 5/16”
 Side Cutters
 Allen Wrench 3/32”
 Needle Nose Pliers
Your switch should come from the factory with the default two positions. If your switch
clicks to more than 2 positions you will need to adjust the positioning ring.
1. Remove the hex nut and washer.
NOTE: the positioning ring should just
fall off as well.
2. Turn the switch to the farthest left
position (position 1). Locate the notch
into slot #3, place the washer and hex
nut back onto the switch and continue
with the installation.
Positioning
Ring Notch
Positioning
Ring
Washer
Hex Nut
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 | Fax: 604-853-8749 | Internet: www.bd-power.com
9/14/2012
Installation
Part # 2001020 Chevy/GM VVB Brake 2006-07LBZ
4
1. Secure vehicle by blocking the wheels then disconnect negative battery terminals on
both batteries.
2. Disconnect upper & lower main
engine
harness
connectors
located at top driver side of
engine.
3. Connect the large connector of
the VVB main harness inline with
the lower engine connection.
Then
connect
the
smaller
connector of the VVB harness
inline with the upper engine
connection.
Once completed ensure the
locking levers are clicked into
position. Route VVB harness
behind the brake master cylinder
to top of fuse box.
UPPER CONNECTION
LOWER CONNECTION
SMALL CONNECTOR
LARGE CONNECTOR
4. Install ground wire onto stud at
firewall using the supplied nut
(1505016).
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 | Fax: 604-853-8749 | Internet: www.bd-power.com
9/14/2012
Part # 2001020 Chevy/GM VVB Brake 2006-07LBZ
5
Methods for mounting the switch to the dash
Mounting Switch with Bracket
MOUNTING
HOLES
5. Velcro: To mount the switch
bracket using the 3M dual lock.
Prep both surfaces with the
supplied alcohol swab. Then
remove backing from dual lock
and press firmly, one onto the
dash location and one onto the
switch bracket mounting surface.
OR
Screws: The switch bracket can
also be mounted using the
supplied self-tapping screws with
a 5/16” socket.
Note the plate can be mounted to
the dash in four positions to
accommodate any location. Skip to
step 7 for mounting the switch.
MOUNTING
SURFACE
MOUNTING
HOLES
Positioning
Pin
Positioning
Pin
Positioning
Pin
Positioning
Pin
Warning: Before mounting the plate
to the dash ensure the area behind
the dash is clear.
Mounting switch into dash
6. Locate a suitable location on the
driver’s side of the dash (fig 6. for
placement recommendations) to
mount switch. Using the decal as
a reference for spacing, double
check behind panel for sufficient
clearance for switch body and
drill clearance.
Fig 6.
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 | Fax: 604-853-8749 | Internet: www.bd-power.com
9/14/2012
Part # 2001020 Chevy/GM VVB Brake 2006-07LBZ
7. Using the decal as a template,
drill center hole using a 3/8”
unibit and locator hole using a
1/8” unibit (1/8” unitbit is
recommended but a standard
drill bit will do).
6
DRILL 3/8”
DRILL 1/8”
OEM DASH
8. Install switch from back side of
panel and secure with nut using
5/16” wrench. Install knob and
tighten the 2 set screws with a
3/32” allen wrench.
DECAL
HEX FLAT NUT
WASHER
POSITIONING RING
NOTE: The set screw on the right
side should fasten to the flat spot on
the switch shaft to align the knob
line to the decal marks.
9. Route switch harness under dash, through firewall and to main VVB harness
connector.
Here you will need to follow steps 10 through 12 to connect the switch harness to the
main harness.
10. To extract the wedge lock out
of the connector use needle nose
pliers into the middle of the
wedge lock and with your other
hand grasping the grey connector
housing and gently pull.
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 | Fax: 604-853-8749 | Internet: www.bd-power.com
9/14/2012
Part # 2001020 Chevy/GM VVB Brake 2006-07LBZ
11. Remove the flagged white wire
from the connector and discard.
Insert the white wire from the
switch harness into pin #4.
Remove the flagged tan wire from
the connector and discard. Insert
the tan wire from the switch
harness into pin #9.
(NOTE: The pins will click into the
connector once into position.)
12. Once both pins are in place
reinsert the wedge lock back into
the connector.
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 | Fax: 604-853-8749 | Internet: www.bd-power.com
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9/14/2012
Part # 2001020 Chevy/GM VVB Brake 2006-07LBZ
13. Plug the harness into the
module
and
secure
both
harnesses using the supplied
cable ties.
14. Mount module to fuse box
using the Velcro provided.
15.
The vehicle is now ready to be road tested. Switch positions are as follows:
Level/Position 0: Off
Level/Position 1: Warm up below 5°C, VVB active in tow/haul mode or manual mode.
Level/Position 2: Warm up below 5°C, VVB active all the time.
General Notes:
 On long descents with the exhaust brake engaged you may hear a momentary
release/relief or discharge of pressure. No need to worry it is the EGR valve
cycling briefly, which is a normal operational characteristic.
 If the main switch or main power is disconnected the vehicle will revert back to
stock and the brake will not function.
TROUBLE SHOOTING GUIDE
PROBLEM
The brake does not
function.
SOLUTION
 Check fuse
 Check battery connections
 Check switch harness connections & pinout connections.
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 | Fax: 604-853-8749 | Internet: www.bd-power.com
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9/14/2012
Part # 2001020 Chevy/GM VVB Brake 2006-07LBZ
Testing the Brake
To test if the brake is functioning.
1. Release the 2 outer tabs on module with
flat blade screw driver and slide board out
of case.
2. Set switch to the off position. Start vehicle
and idle.
3. Depress test button on module and the
INFO led will quickly flash 3 times. Then
the module will activate the vanes. Once
vanes are activated there will be a change
in the vehicles running sound, and the VVB
LED will turn on as follows based on which
version you have.
V1.00-
LED will flash 3 times.
LED will remain constant
V2.00+
during test.
Note: Module version can be found on
the back side of the printed circuit board.
NOTE: The led’s at the two relays will also
light up when the turbo vanes are engaged.
During regular operation the INFO led will
blink a number of times every five seconds to
indicate switch position.
Switch position OFF Once every 5 sec
Switch position 1
Twice every 5 sec
Switch position 2
3 times every 5 sec
4. Reinstall board into case until tabs lock into
place. Set case back onto Velcro.
5. Road test vehicle.
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 | Fax: 604-853-8749 | Internet: www.bd-power.com
9
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