BD-1045987 Exhaust Manifold Installation

BD-1045987 Exhaust Manifold Installation
1/8/2014
Part # 1045987 Exhaust Manifold (I-00107)
BD PERFORMANCE DODGE 5.9L CUMMINS
EXHAUST MANIFOLD
-- Installation Instructions -Application List
1045987 2003-2007 Dodge 24V
-- PLEASE READ ALL INSTRUCTIONS BEFORE INSTALLATION -** Important notice on page 3 **
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
1
1/8/2014
Part # 1045987 Exhaust Manifold (I-00107)
2
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.
1045987 – Dodge 2-piece Exhaust Manifold (2003-07)
1405990R-M / 1405990F-M
1 405981
1405982
1200208
Front & Back Manifold Assembly
M10x35mm S/S Bolt
10mm S/S Washer
1/8” NPT Plug
Qty: 1
Qty: 1
Qty: 1
Qty: 2
1405998
1100110
1100111
1100112
1100113
Coolant Bracket
¼” Bolt
¼” Flat Washer
¼” Lock Washer
¼” Nut
Qty: 1
Qty: 1
Qty: 1
Qty: 1
Qty: 1
1462430
1462431
1462441
M10 x 1.5 x 030 Stud
M10 x 1.5 x 025 Stud
Nut M10 -1.5
Qty: 2
Qty: 2
Qty : 4
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
1/8/2014
Part # 1045987 Exhaust Manifold (I-00107)
3
Options
Description
24V Exhaust Manifold Gasket Set
Part #
1045986
ATTENTION!
YOUR MANIFOLD IS COATED WITH A CERAMIC BASED PAINT. THE PAINT WILL
NEED AT LEAST ONE HEAT CYCLE TO FULLY CURE. UNTIL THEN, THE PAINT
WILL BE SOMEWHAT SOFT AND WILL BE EASY TO SCRATCH.
TO HEAT CYCLE THE MANIFOLD, ALLOW THE VEHICLE TO IDLE FOR ABOUT 15
MINUTES, AND THEN LET THE MANIFOLD COOL TO AMBIENT TEMPERATURE.
SCRAP OFF ANY EXCESS PAINT ON THE GASKET MATING SURFACES. A THIN
COAT WILL NOT AFFECT THE SEALING PROPERTIES.
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
1/8/2014
Part # 1045987 Exhaust Manifold (I-00107)
4
Installation
Disconnect both battery ground cables.
Remove the intake air hose from the front of the turbo and set to the side. You can also
remove the air box to aid in additional room.
Remove the V-band clamp that
connects the turbo elbow
casting to the exhaust down
pipe.
Disconnect
outlet boot.
the
compressor
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
1/8/2014
Part # 1045987 Exhaust Manifold (I-00107)
Disconnect the turbo oil supply
and the turbo oil drain.
Using a cutoff wheel, cut the
coolant line support bracket
about 1-1.5” from the coolant
tube. Leave enough material to
re-connect the new supplied
bracket to this tab.
This technique should save you
approximately
1
hour
of
installation time and eliminate
the need to drain the coolant.
Remove the factory heat shield that covers the front of the manifold.
Remove the factory manifold and turbo assembly. Be sure to save the OE bolts and
spacers as you will be reusing them.
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
5
1/8/2014
Part # 1045987 Exhaust Manifold (I-00107)
Once the factory manifold is
removed, clean the head surface
of any carbon or soot build up.
With the manifold and turbo assembly on the bench, remove the turbo.
Remove the factory studs from
the OEM manifold and discard
them. Place the provided M10 x
1.5 x 30mm (1462430) studs
into the manifold.
Remove factory studs from the turbo and discard. Install the provided M10 x 1.5 x
25mm (1462431) studs into the turbo.
Re-install the turbo onto the
manifold, using the supplied
M10-1.5 nuts. (1462441)
Don’t forget to install a new
gasket between the turbo and
manifold. It does not matter
which way the ridge on the
gasket faces.
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
6
1/8/2014
Part # 1045987 Exhaust Manifold (I-00107)
With the whole assembly tight,
re-install it to the engine.
Be sure to install a new gasket
for each cylinder. It does not
matter which way the ridge on
the gasket faces.
Torque the bolts to 35 lbs-ft.
Note that you may need to align
the front or rear manifold to
match the threaded holes on the
cylinder head. You can use a
rubber mallet to do this.
When installing the lower bolt to
cylinder #5, discard the factory
bolt and spacer.
Place the
coolant pipe bracket against the
manifold and install the M10 SS
socket head bolt (1405981)
and the M10 Washer (1405982)
to secure the bracket and the
manifold to the head.
Before tightening the bolt, line up
the bracket to the OEM coolant
pipe tab that you cut earlier.
Torque the bolt to 35 lbs-ft.
Note: On 2006 model year
vehicles, you will need to secure
the bracket to cylinder # 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
7
1/8/2014
Part # 1045987 Exhaust Manifold (I-00107)
You now have the option to drill
a hole through the OEM coolant
pipe tab and secure the brackets
together using the ¼ bolt
(1100110), ¼” flat washer
(1100111), ¼” lock washer
(1100112), and the ¼” nut
(1100113) supplied. Use a 5/16”
drill bit to accomplish this.
Or, you can spot weld the
bracket and the OEM coolant
pipe tab together.
If you choose to weld, be sure to
paint the weld after.
Once that is secure, you can
now reconnect the V-band
clamps from the exhaust pipe to
the turbo exhaust elbow and the
compressor outlet.
Reconnect the turbo oil drain and oil supply.
Reconnect the air inlet pipe to the front of the turbo and re-install the air box if you had
removed it.
RE-TORQUE ALL BOLTS AFTER AT LEAST ONE HEAT CYCLE
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
8
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