BD Diesel 2023138 Exhaust Brake Installation Instructions

BD Diesel 2023138 Exhaust Brake Installation Instructions
6 March 2007
Dodge 2003-05 Turbo Mount Exhaust Brake (2023138/2023139)
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2003-05 Dodge Cummins
BD Turbo Mount Exhaust Brake
BD P/N#
2023138
2023139
Application
2003-04 Dodge 5.9L Cummins
2004½-05 Dodge 5.9L Cummins
For 2006 Applications please use part# 1027338
Serial #
Date Purchased
Purchased from
Installed by
OWNER’S MANUAL – LEAVE IN GLOVE BOX
Instruction Manual Part # I2023139
BD Engine Brake, Ltd.
Plant Address: Unit A10, 33733 King Rd., Abbotsford, BC, Canada V2S 7M9
USA Shipping Address: #88-446 Harrison St., Sumas, WA 98295 | USA Mailing Address: PO Box 231, Sumas, WA 98295
Phone: (604) 853-6096 | Fax: (604) 853-8749 | Internet: www.bd-power.com
6 March 2007
Dodge 2003-05 Turbo Mount Exhaust Brake (2023138/2023139)
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TABLE OF CONTENTS
Welcome .................................................................................................................. - 3 Special Tools Required .......................................................................................... - 3 Kit Contents............................................................................................................. - 3 Accessories ............................................................................................................. - 3 Pre-Installation ........................................................................................................ - 3 REGULATOR INSTALLATION (2003-04)................................................................ - 4 REGULATOR INSTALLATION (2004½-2005)......................................................... - 5 AIR COMPRESSOR MOUNTING INSTALLATION ................................................. - 5 IN-CAB EXHAUST BRAKE WIRING ....................................................................... - 7 CRUISE CONTROL WIRING (2003-04)................................................................ - 7 Manual Transmission......................................................................................... - 7 ACCELERATOR PEDAL POSITION SENSOR (2003-04) ................................... - 8 Automatic Transmission (w/PCM)..................................................................... - 8 Manual Transmission (w/o PCM) ...................................................................... - 9 CRUISE CONTROL WIRING (2004½-05)........................................................... - 10 ACCELERATOR PEDAL POSITION SENSOR (2004½-05) ............................... - 11 Automatic & Manual Transmissions (2004½ MODELS) .................................. - 11 Automatic & Manual Transmissions (2005 MODELS) ..................................... - 12 MAIN SWITCH INSTALL (Required If Using Toggle Switch) ............................. - 13 EXHAUST BRAKE WIRING DIAGRAM (2003-05) ................................................ - 15 BRAKE VALVE INSTALLATION (2003-05)........................................................... - 16 BRAKE VALVE INSTALLATION ADDENDUM (2005).......................................... - 17 AIR HOSE INSTALLATION ................................................................................... - 18 DFIV ADJUSTMENT & TESTING .......................................................................... - 19 IDLE PRESSURE ADJUSTMENT.......................................................................... - 20 Maintenance & Troubleshooting ......................................................................... - 20 Operating Guidelines............................................................................................ - 21 Limited Warranty Statement ................................................................................ - 23 -
BD Engine Brake, Ltd.
Plant Address: Unit A10, 33733 King Rd., Abbotsford, BC, Canada V2S 7M9
USA Shipping Address: #88-446 Harrison St., Sumas, WA 98295 | USA Mailing Address: PO Box 231, Sumas, WA 98295
Phone: (604) 853-6096 | Fax: (604) 853-8749 | Internet: www.bd-power.com
6 March 2007
Dodge 2003-05 Turbo Mount Exhaust Brake (2023138/2023139)
-3-
Welcome
Thank you for purchasing a BD Exhaust Brake. This manual is divided into
different areas to assist you with your installation and operation of your braking
unit. We strongly suggest that you write down the kit and serial numbers of your
unit in the spaces provided and retain this manual for any future reference.
** Please fill out and mail registration card as soon as possible. **
Special Tools Required
•
•
•
•
•
•
•
•
Measuring tape or ruler
Drill with 1/8”, 3/16” bits and Unibit
Sawsall or hacksaw
Crimping Pliers
Test light
¼” Drive Socket Set
Small bladed flat tip screwdriver
Welder
Kit Contents
2023138
2023139
2003-04 Dodge Cummins
1030129-DP Air Pump Kit
1220136-B Regulator & Control Kit
1321039 DFIV Install Kit
2123038 Valve Assembly
2004½-05 Dodge Cummins
1030129-DP Air Pump Kit
1220136-B Regulator & Control Kit
1321039 DFIV Install Kit
2123039 Valve Assembly
Accessories
Description
Manual Transmission Shifter Switch Kit
TowLoc Transmission & Converter Package
X-Monitor Digital Gauge Package
Brake Pressure Gauge Kit
Boost Pressure Gauge Kit (30lbs.)
Transmission Gauge Kit (Automatic Transmission)
Exhaust Temperature Gauge (Pyrometer)
Part Number
1300210
CALL
1085220
1030550
1030570
1030583
1030512-I
Pre-Installation
To prevent damage to electronic components, it is recommended that you disconnect
both negative battery terminals before starting. Please read this manual thoroughly
before installing this exhaust brake.
BD Engine Brake, Ltd.
Plant Address: Unit A10, 33733 King Rd., Abbotsford, BC, Canada V2S 7M9
USA Shipping Address: #88-446 Harrison St., Sumas, WA 98295 | USA Mailing Address: PO Box 231, Sumas, WA 98295
Phone: (604) 853-6096 | Fax: (604) 853-8749 | Internet: www.bd-power.com
6 March 2007
Dodge 2003-05 Turbo Mount Exhaust Brake (2023138/2023139)
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REGULATOR INSTALLATION (2003-04)
Locate the two studs with nuts on the passenger side firewall, just below the upper
cowling.
Remove the two nuts from the studs and fit the bracket and regulator assembly onto
these studs.
Secure by reinstalling and tightening the nuts.
BD Engine Brake, Ltd.
Plant Address: Unit A10, 33733 King Rd., Abbotsford, BC, Canada V2S 7M9
USA Shipping Address: #88-446 Harrison St., Sumas, WA 98295 | USA Mailing Address: PO Box 231, Sumas, WA 98295
Phone: (604) 853-6096 | Fax: (604) 853-8749 | Internet: www.bd-power.com
6 March 2007
Dodge 2003-05 Turbo Mount Exhaust Brake (2023138/2023139)
REGULATOR INSTALLATION (2004½-2005)
Locate the large oval hole
on the passenger side of
the vehicle near the upper
cowling of the firewall. To
the right of this you can
either drill a 3/16” hole or
use the existing hole by
removing the factory plastic
locking insert.
Drill or use
existing hole.
Install
the
regulator
assembly underneath the
hole (shown on figure to the
right). The lock washer and
flat washer should be
installed on top of the
plastic cowling with the
Robertson screw holding everything in place.
AIR COMPRESSOR MOUNTING INSTALLATION
You will need to remove the
inner front fender well on
the passenger side of the
vehicle.
There are eight
bolts holding the lining in
place. If you can put the
vehicle on a hoist about 3
feet above the ground it will
ease this installation.
Locate the hood support
bolt up inside of the fender
well; it is very close to the
bottom of the radio antenna.
Remove the bolt closest to
the battery tray or closest to
the front of the vehicle.
Slide
the
compressor
assembly up into this space.
Use these bolt holes for
installation of compressor
assembly. While the hood
support is threaded, you will
need to slide a nut behind
the second mounting hole.
BD Engine Brake, Ltd.
Plant Address: Unit A10, 33733 King Rd., Abbotsford, BC, Canada V2S 7M9
USA Shipping Address: #88-446 Harrison St., Sumas, WA 98295 | USA Mailing Address: PO Box 231, Sumas, WA 98295
Phone: (604) 853-6096 | Fax: (604) 853-8749 | Internet: www.bd-power.com
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6 March 2007
Dodge 2003-05 Turbo Mount Exhaust Brake (2023138/2023139)
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The wires and hoses must be fed
up through the existing hole
before
tightening
the
compressor into place. Once this
is done, re-install the hood support
bolt.
Raise the compressor
assembly so that you can install
the provided bolt through the frame
hole onto the nut.
Route the wires and
hoses through the existing
hole before mounting the
compressor bracket.
Slide bolt in behind
the bracket and frame
support. Install the nut
to secure the
assembly.
Tighten all bolts and secure
assembly. Route the compressor
pigtail wiring harness up towards
the
regulator
assembly
you
previously installed. You will also
need to route a small section of
plastic air hose from the quick
connect fitting of the air compressor
to the regulator assembly. Use the
wiring diagram on page 15-16 as a
reference for the wiring of the air
hoses and the electrical wiring.
NOTE: Be sure to keep all hoses
and wiring harnesses away from
any moving parts or heat sources.
BD Engine Brake, Ltd.
Plant Address: Unit A10, 33733 King Rd., Abbotsford, BC, Canada V2S 7M9
USA Shipping Address: #88-446 Harrison St., Sumas, WA 98295 | USA Mailing Address: PO Box 231, Sumas, WA 98295
Phone: (604) 853-6096 | Fax: (604) 853-8749 | Internet: www.bd-power.com
6 March 2007
Dodge 2003-05 Turbo Mount Exhaust Brake (2023138/2023139)
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IN-CAB EXHAUST BRAKE WIRING
NOTE: IF A BD TOWLOC IS TO BE INSTALLED WITH THIS BRAKE YOU MUST
SKIP THE WIRING SECTION IN THIS MANUAL AND FOLLOW THE TOWLOC
INSTRUCTIONS FOR CORRECT WIRING INSTALLATION. IF INSTALLING A
TOWLOC GO DIRECTLY TO PAGE 17 AND CONTINUE WITH BRAKE VALVE
INSTALLATION.
CRUISE CONTROL WIRING (2003-04)
Manual Transmission
To obtain access to the cruise control wiring harness, remove the lower steering
column panel by removing the mounting screws and unsnapping the panel from the
instrument panel.
Locate the small wiring harness that runs out of the main harness, located under the
dash, running vertically by the left of the steering column.
***DANGER***
THERE IS A BLACK WIRE WITH A TWISTED LIGHT BLUE/GREEN
TRACER. DO NOT CONNECT OR TEST THIS WIRE AS IT IS
CONNECTED TO THE AIR BAG SYSTEM AND THE BAG MAY
DEPLOY CAUSING DAMAGE AND/OR INJURY!
Remove some of the
black electrical tape from
the small harness to gain
access to the small black
wire/light blue tracer and
install a gray Posi-tap onto
it. Insert the blue wire from
the DFIV module into this
connector.
Locate the red wire
w/green tracer and install
another gray Posi-Tap.
Insert the green wire from
the DFIV module into this
connector.
BD Engine Brake, Ltd.
Plant Address: Unit A10, 33733 King Rd., Abbotsford, BC, Canada V2S 7M9
USA Shipping Address: #88-446 Harrison St., Sumas, WA 98295 | USA Mailing Address: PO Box 231, Sumas, WA 98295
Phone: (604) 853-6096 | Fax: (604) 853-8749 | Internet: www.bd-power.com
6 March 2007
Dodge 2003-05 Turbo Mount Exhaust Brake (2023138/2023139)
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Locate a grommet on the
firewall and cut an opening in it
to run the loom covered wiring
through the firewall.
ACCELERATOR PEDAL POSITION SENSOR (2003-04)
Automatic Transmission (w/PCM)
Route the yellow wire from the DFIV
module along the firewall to the
PCM. On 2003 Dodge’s, the PCM is
mounted vertically on the firewall so
that the connectors will be (from top
to bottom):
C3 – Top
C2 – Middle
C1 – Bottom
C3
C2
C1
On connector C1, locate pin 23 (The
orange wire/dark blue tracer and
install a gray Posi-Tap to this wire.
Plug the yellow DFIV wire onto the
Posi-Tap.
BD Engine Brake, Ltd.
Plant Address: Unit A10, 33733 King Rd., Abbotsford, BC, Canada V2S 7M9
USA Shipping Address: #88-446 Harrison St., Sumas, WA 98295 | USA Mailing Address: PO Box 231, Sumas, WA 98295
Phone: (604) 853-6096 | Fax: (604) 853-8749 | Internet: www.bd-power.com
6 March 2007
Dodge 2003-05 Turbo Mount Exhaust Brake (2023138/2023139)
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Manual Transmission (w/o PCM)
Route the yellow wire from
the DFIV module along the
driver’s side of the engine
to the throttle linkage and
APPS sensor.
Remove the cover of the
throttle
linkage,
then
locate and disconnect the
wiring connector for the
APPS.
Open the loom and locate
the yellow wire. Install a
gray Posi-Tap.
Connect the yellow wire
from the DFIV module to
this Posi-Tap and reconnect the APPS connector. Reinstall the throttle linkage cover.
2003 DODGE RAM 3500
NOTE:
On
some
truck
configurations (i.e. 2003
RAM 3500) the throttle
be
cable/APPS
will
located UNDER the driver
side battery tray and is
accessible by removing
the inner fender skirt.
Once the fender skirt is
removed, the APPS wiring
harness can be accessed.
Locate the white with
green tracer wire and
install the gray Posi-Tap
to it.
BD Engine Brake, Ltd.
Plant Address: Unit A10, 33733 King Rd., Abbotsford, BC, Canada V2S 7M9
USA Shipping Address: #88-446 Harrison St., Sumas, WA 98295 | USA Mailing Address: PO Box 231, Sumas, WA 98295
Phone: (604) 853-6096 | Fax: (604) 853-8749 | Internet: www.bd-power.com
6 March 2007
Dodge 2003-05 Turbo Mount Exhaust Brake (2023138/2023139)
- 10 -
CRUISE CONTROL WIRING (2004½-05)
To obtain access to the Cruise Control wiring harness remove the lower steering
column panel by removing the mounting screws and unsnapping the panel from the
instrument panel.
Under the dash running vertical by the left of the steering column, locate the smaller
wiring harness that runs out of the main harness.
Remove some of the black electrical tape to gain access to the smaller wire bundle.
***DANGER***
THERE ARE 2 SETS OF TWISTED PAIR LIGHT GREEN WITH TRACER WIRES IN
THIS WIRE BUNDLE. DO NOT CONNECT OR TEST THESE WIRES AS THEY ARE
CONNECTED TO THE AIR BAG SYSTEM AND THE BAG MAY DEPLOY CAUSING
DAMAGE AND/OR INJURY!
Remove some of the black electrical
tape from the small bundle to gain
access to the small violet wire and
install a gray Posi-Tap to it. Insert the
blue wire from the DFIV module into
this connector.
In this same wiring harness, locate the
violet w/ Brown tracer wire and install
another gray Posi-Tap.
Insert the
green wire from the DFIV module into
this connector.
2004½ - 05 Dodge
2004½ - 05 Dodge
Cruise Wires
Violet
Violet w/ Brown
DFIV
Blue Wire – “Dodge” Input
Green Wire – “Com” Input
Locate a grommet on the firewall
and cut an opening in it to run the
loom covered wiring through the
firewall.
BD Engine Brake, Ltd.
Plant Address: Unit A10, 33733 King Rd., Abbotsford, BC, Canada V2S 7M9
USA Shipping Address: #88-446 Harrison St., Sumas, WA 98295 | USA Mailing Address: PO Box 231, Sumas, WA 98295
Phone: (604) 853-6096 | Fax: (604) 853-8749 | Internet: www.bd-power.com
6 March 2007
Dodge 2003-05 Turbo Mount Exhaust Brake (2023138/2023139)
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ACCELERATOR PEDAL POSITION SENSOR (2004½-05)
Automatic & Manual Transmissions (2004½ MODELS)
Route the yellow wire from the DFIV module along the driver side of the engine
compartment to the throttle linkage and APPS Sensor. Remove the cover of the
throttle linkage. Locate and disconnect the wiring connector for the APPS.
2004½ Dodge
Manual Trans.
Auto Trans.
APPS Wire Color
BR/WT
DB/WT
ECM
C1 Pin 14
C1 Pin 14
Connect the yellow wire from the DFIV Module to this Posi-Tap and reconnect the
APPS connector. Re-install the throttle linkage cover.
APPS Location
APPS Plug
BD Engine Brake, Ltd.
Plant Address: Unit A10, 33733 King Rd., Abbotsford, BC, Canada V2S 7M9
USA Shipping Address: #88-446 Harrison St., Sumas, WA 98295 | USA Mailing Address: PO Box 231, Sumas, WA 98295
Phone: (604) 853-6096 | Fax: (604) 853-8749 | Internet: www.bd-power.com
6 March 2007
Dodge 2003-05 Turbo Mount Exhaust Brake (2023138/2023139)
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Automatic & Manual Transmissions (2005 MODELS)
Route the yellow wire from the DFIV module to the accelerator pedal position sensor
located on the accelerator pedal. Locate and connect a Posi-Tap to the correct wire
color for your application. The yellow DFIV wire should now be connect to the correct
APPS wire.
APPS Location (Accelerator Pedal)
ECM
Plug Pin
5
APPS Plug
Circuit / Wire Color
Function
K23 20BR/WT
APPS NO. 1 SIGNAL
BD Engine Brake, Ltd.
Plant Address: Unit A10, 33733 King Rd., Abbotsford, BC, Canada V2S 7M9
USA Shipping Address: #88-446 Harrison St., Sumas, WA 98295 | USA Mailing Address: PO Box 231, Sumas, WA 98295
Phone: (604) 853-6096 | Fax: (604) 853-8749 | Internet: www.bd-power.com
6 March 2007
Dodge 2003-05 Turbo Mount Exhaust Brake (2023138/2023139)
MAIN SWITCH INSTALL (Required If Using Toggle Switch)
Remove the fastening screws of the
dashboard bezel and remove the
covering trim by pulling back on the
corners of the trim panels.
Note: Placing the transmission all
the way into 1st/low gear and
ensuring the tilt steering is all the
way down will allow for easier
removal.
Pull the left hand and right hand dash
panels away from their secured
positions and let them hang.
Once the dash trim has been
removed, place it on a large working
surface such as a table or workbench.
Measure and mark a spot for the
toggle switch 3/4” up from the bottom
edge of the dash panel and 1” in from
the left edge of the accessory panel
as shown in the photo.
Drill a pilot hole with a 1/8” bit and
finish by enlarging the hole with a
Unibit to exactly ½”.
YOU MAY HAVE TO GRIND DOWN
PART OF THE SUPPORT RIB ON
THE BACK OF THE TRIM PANEL TO
ACCOMMODATE THE SWITCH
BODY.
BD Engine Brake, Ltd.
Plant Address: Unit A10, 33733 King Rd., Abbotsford, BC, Canada V2S 7M9
USA Shipping Address: #88-446 Harrison St., Sumas, WA 98295 | USA Mailing Address: PO Box 231, Sumas, WA 98295
Phone: (604) 853-6096 | Fax: (604) 853-8749 | Internet: www.bd-power.com
- 13 -
6 March 2007
Dodge 2003-05 Turbo Mount Exhaust Brake (2023138/2023139)
Install the switch into the newly
drilled hole and secure it with a
lock ring, then re-install the
dash trim panels by reversing
the removal procedure.
Once the switch is installed,
attach the ground wire to a
good metal ground under the
dash.
With a test light, locate a
switched 12 Volt power source
and install the supplied black
Posi-Tap to it then attach the
red, fused wire, from the switch
to this Posi-Tap.
BD Engine Brake, Ltd.
Plant Address: Unit A10, 33733 King Rd., Abbotsford, BC, Canada V2S 7M9
USA Shipping Address: #88-446 Harrison St., Sumas, WA 98295 | USA Mailing Address: PO Box 231, Sumas, WA 98295
Phone: (604) 853-6096 | Fax: (604) 853-8749 | Internet: www.bd-power.com
- 14 -
6 March 2007
Dodge 2003-05 Turbo Mount Exhaust Brake (2023138/2023139)
EXHAUST BRAKE WIRING DIAGRAM (2003-05)
BD Engine Brake, Ltd.
Plant Address: Unit A10, 33733 King Rd., Abbotsford, BC, Canada V2S 7M9
USA Shipping Address: #88-446 Harrison St., Sumas, WA 98295 | USA Mailing Address: PO Box 231, Sumas, WA 98295
Phone: (604) 853-6096 | Fax: (604) 853-8749 | Internet: www.bd-power.com
- 15 -
6 March 2007
Dodge 2003-05 Turbo Mount Exhaust Brake (2023138/2023139)
- 16 -
BRAKE VALVE INSTALLATION (2003-05)
TO PREVENT INJURY OR DAMAGE, RAISE THE VEHICLE TO A GOOD WORKING
HEIGHT AND SUPPORT IT WITH JACK STANDS OR AXLE STANDS.
From underneath the vehicle, remove
the down pipe-to-turbo elbow band
clamp using a 10mm socket. Support
the down pipe as it may drop down
once the clamp is removed.
Disconnect the Mass Air Flow sensor
harness and remove the plastic turbo
air inlet tube. Loosen the band clamp
that holds the factory exhaust elbow
to the turbocharger.
Remove the exhaust elbow.
Insert the exhaust brake valve
assembly in place of the factory elbow
and reinstall the turbo band clamp.
Tighten all clamps that secure the
brake to the flanges.
BD Engine Brake, Ltd.
Plant Address: Unit A10, 33733 King Rd., Abbotsford, BC, Canada V2S 7M9
USA Shipping Address: #88-446 Harrison St., Sumas, WA 98295 | USA Mailing Address: PO Box 231, Sumas, WA 98295
Phone: (604) 853-6096 | Fax: (604) 853-8749 | Internet: www.bd-power.com
6 March 2007
Dodge 2003-05 Turbo Mount Exhaust Brake (2023138/2023139)
- 17 -
BRAKE VALVE INSTALLATION ADDENDUM (2005)
On 2005 vehicles the rear water heater will contact the side of the brake levers. You
will need to clock (rotate) the brake to minimize this. As well you will need to slightly
bend the heater line. Do not kink the tube as you will sacrifice the rate of cooler
flow. It is recommended to bend the line at the support bracket. Ensure the brake
levers do not contact the silicone hose.
Bend coolant
line to clear
brake levers.
Actuate brake
to gauge
clearance.
Ensure brake
levers do not
contact
silicone hose.
BD Engine Brake, Ltd.
Plant Address: Unit A10, 33733 King Rd., Abbotsford, BC, Canada V2S 7M9
USA Shipping Address: #88-446 Harrison St., Sumas, WA 98295 | USA Mailing Address: PO Box 231, Sumas, WA 98295
Phone: (604) 853-6096 | Fax: (604) 853-8749 | Internet: www.bd-power.com
6 March 2007
Dodge 2003-05 Turbo Mount Exhaust Brake (2023138/2023139)
- 18 -
AIR HOSE INSTALLATION
Now that the brake, pump and regulator assemblies are installed in their correct
positions, we can now install the two air hoses.
Install one end of the first ¼” plastic hose into the quick-connect coupler on the brake’s
air cylinder and route it to the air solenoid.
One end of the second hose should already be installed into the 90° quick-connect
coupler on the air compressor. Install the other end into the coupler attached to the tee
fitting which connects to the pressure switch.
Included in the kit is a snorkel relocation kit, which includes a section of plastic hose
and a breather filter. This filter should be routed to a clean dry location in the engine
compartment. Reference the installation diagram for any instructions.
CARE MUST BE TAKEN NOT TO KINK THE PLASTIC HOSE AND TO POSITION IT
WHERE IT WILL NOT MELT, RUB OR CONTACT ANY MOVING PARTS.
NOTE: Removal of the plastic hose from the quick coupler can be accomplished by
pushing the colored ring towards the fitting and pulling the hose out.
CAUTION: REFER TO THE WIRING DIAGRAM ON PAGE 15-16 FOR CORRECT
HOOK UP OF HOSES AND WIRING.
BD Engine Brake, Ltd.
Plant Address: Unit A10, 33733 King Rd., Abbotsford, BC, Canada V2S 7M9
USA Shipping Address: #88-446 Harrison St., Sumas, WA 98295 | USA Mailing Address: PO Box 231, Sumas, WA 98295
Phone: (604) 853-6096 | Fax: (604) 853-8749 | Internet: www.bd-power.com
6 March 2007
Dodge 2003-05 Turbo Mount Exhaust Brake (2023138/2023139)
- 19 -
DFIV ADJUSTMENT & TESTING
Ensure the connections of the corresponding wires to the DFIV Control Module are
correct as shown in the wiring diagram.
To achieve the correct setting for the
activation of the exhaust brake in relation to
the throttle pedal the DFIV Module must be
calibrated for your vehicle.
With the throttle at idle, start the engine and
turn on brake switch. Using a small flat
bladed screwdriver, turn the small adjusting
screw in the DFIV Module counterclockwise
or clockwise until the pump/brake JUST turns
on.
CAUTION: THE ADJUSTING SCREW IS A MICRO-SWITCH THAT IS VERY
DELICATE, SO TURN USING SMALL ADJUSTMENTS.
Test by revving up the engine to approximately 1200 RPM and releasing the throttle.
As the accelerator pedal is applied the brake should disengage just before then engine
starts to rev, indicating proper calibration of the DFIV Module with the APPS.
The brake should then activate again when the throttle pedal returns to the idle
position. If it does not activate, re-adjust the DFIV Module so that it does.
Check for any exhaust leaks and recheck all connections and hoses for security and
interference from moving or heated items. After about 100 miles (160 km), re-torque
the flange bolts.
BD Engine Brake, Ltd.
Plant Address: Unit A10, 33733 King Rd., Abbotsford, BC, Canada V2S 7M9
USA Shipping Address: #88-446 Harrison St., Sumas, WA 98295 | USA Mailing Address: PO Box 231, Sumas, WA 98295
Phone: (604) 853-6096 | Fax: (604) 853-8749 | Internet: www.bd-power.com
6 March 2007
Dodge 2003-05 Turbo Mount Exhaust Brake (2023138/2023139)
- 20 -
IDLE PRESSURE ADJUSTMENT
Exhaust Brake pressure is preset at the factory but if more holdback performance is
required with the vehicle loaded, adjust the regulator using small increments to give 50
– 55psi under load.
Test the exhaust brake pressure by installing a pressure gauge into the test port on the
bottom of the brake valve. If the brake pressure is not 15 - 17psi at idle, then the
pressure will have to be adjusted.
The maximum REGULATED pressure is adjusted with the pressure regulator under
the hood and under driving conditions.
Turning the regulator clockwise will increase pressure.
Turning the regulator counter clockwise will decrease pressure.
***DO NOT EXCEED 65 LBS. OF EXHAUST BACK PRESSURE***
Always test pressure using the backpressure port running on the stainless steel line off
of the brake’s valve assembly, NOT at the regulator itself.
Maintenance & Troubleshooting
To extend the life of the valve assembly, do not operate your vehicle for extended
periods of time without activating the brake. We suggest activating the exhaust brake
at least a couple times a day while operating the vehicle to prevent any carbon or rust
build-up on internal parts of the valve assembly.
The hoses, wires, fittings and clamps should be inspected on a regular basis for any
deterioration, damage or leaks. Periodically clean the filter on the Air Compressor,
and, when cleaning the engine, cover the filter on the compressor to prevent moisture
from entering the filter.
To increase the life of your exhaust brake we recommend daily operation. By
simply switching the brake on and off a couple times a day, it will prevent the
butterfly from sticking due to carbon build-up.
Following the diagrams in this manual, tracing hoses and wiring, checking continuity
through electric components or checking for any lines that are disconnected, should
solve any problems that may arise. If you have any problems or need replacement
parts, call us at 1-800-887-5030, between 8:30am and 4:30pm Pacific Time.
BD Engine Brake, Ltd.
Plant Address: Unit A10, 33733 King Rd., Abbotsford, BC, Canada V2S 7M9
USA Shipping Address: #88-446 Harrison St., Sumas, WA 98295 | USA Mailing Address: PO Box 231, Sumas, WA 98295
Phone: (604) 853-6096 | Fax: (604) 853-8749 | Internet: www.bd-power.com
6 March 2007
Dodge 2003-05 Turbo Mount Exhaust Brake (2023138/2023139)
- 21 -
Operating Guidelines
Thank you for taking interest in the BD Engine Exhaust Brake. As a driver, you
probably already know the need for extra braking power that your vehicle requires on
the hills and long grades. With loads being towed behind you, the extra push when
slowing down or maintaining speed on downward grades can prove to be a great strain
on your vehicles hydraulic braking system, even to the point of “burn-up”. These
guidelines were designed to offer you a better understanding of the benefits of exhaust
brakes and are partly based upon material developed by the U.S. Department of
Transportation National Highway Traffic Safety Administration.
The emphasis on today’s vehicles is to give the consumer a product that can give
them usable power with fuel efficiency. But, in the transition, the vehicles have lost
their natural braking power, making it more easy for the vehicle to continue to roll and
harder to stop. Of course, this gets more noticeable with the increase of weight, on or
behind the vehicle. This is where an exhaust brake becomes a useful tool in
increasing the driveline drag of the vehicle without the use of the hydraulic brakes; a
tool that with maximum use or even occasional use can reduce wear on hydraulic
braking parts and at the same time increase safety.
The BD Exhaust Brake can be used to help maintain a controlled vehicle speed on a
downward grade, as well as slowing the vehicle down for such times as turns or exit
ramps, without you using your hydraulic brakes. But, the exhaust brake cannot be
used as a parking brake or will not bring your vehicle to a complete stop. By
using a BD Exhaust Brake, the life and effectiveness of your hydraulic brakes will
increase.
This is because of the decreased use of the hydraulic brakes in situations like hills, the
wear factor is reduced and there is less opportunity for your hydraulic brakes to heat
up which would reduce the efficiency. When you ride your hydraulic brakes, make
hard stops or have poorly adjusted brakes, this creates high temperatures and as your
brakes get hotter, the more chance there is for fade or failure.
With terrain that is a series of up and down grades, the BD Exhaust Brake will aid in
reducing exhaust valve warping. Because of the power needed to pull your vehicle
and load up a hill, this generates a lot of heat. When you have reached the crest of
the hill and are now coasting down the other side, the heated valves are too quickly
cooled. With the exhaust brake engaged, the heat loss to the valves will be reduced,
which can prevent valve warping.
When the toggle switch is turned to the “On” position, the valve is activated every time
the driver takes his foot off of the throttle pedal. When the driver puts pressure back
on the throttle pedal, the throttle switch is deactivated and the valve opens again.
BD Engine Brake, Ltd.
Plant Address: Unit A10, 33733 King Rd., Abbotsford, BC, Canada V2S 7M9
USA Shipping Address: #88-446 Harrison St., Sumas, WA 98295 | USA Mailing Address: PO Box 231, Sumas, WA 98295
Phone: (604) 853-6096 | Fax: (604) 853-8749 | Internet: www.bd-power.com
6 March 2007
Dodge 2003-05 Turbo Mount Exhaust Brake (2023138/2023139)
- 22 -
Exhaust brakes are designed to operate with the throttle at idle, not to be used in
conjunction with cruise controls, and not designed to aid in gear shifting.
Such cases may cause damage to engine and/or exhaust brake. Incorporated with the
BD Exhaust Brake, there is a pressure regulating system that will control the created
backpressure. If the backpressure reaches the set limit of 55 psi while under engine
braking, the exhaust valve will open slightly to relieve the excess pressure.
The best scenario for exhaust braking is when going down hill, select a gear that lets
you maintain a constant speed with little or no use of the hydraulic brakes, or the same
gear that would be used to go up the same grade of hill. This also depends on the
weight, load or road conditions that the vehicle will come upon. So, in summary, by
using the BD Exhaust Brake, you reduce the need for use of your hydraulic brakes in
situations where you need to slow down or maintain (i.e. hills, off ramps, corners,
approaching speed changes or traffic lights). Reducing the use of your hydraulic
brakes in these situations will reduce the heat build up, as well as wear and damage to
linings and drums. And, when you reduce these factors, you save your hydraulic
brakes for when you really need them (for stopping or emergencies).
The BD Exhaust Brake is not a substitute for your hydraulic brakes and, cannot correct
or compensate for poorly maintained or misadjusted brakes. But, when you need to
slow down or maintain a constant speed, the BD Exhaust Brake will be a valuable and
effective tool. Exhaust Brakes are more efficient at preventing rather than correcting
an over speed condition.
Thank you and happy motoring.
BD Engine Brake, Inc.
BD Engine Brake, Ltd.
Plant Address: Unit A10, 33733 King Rd., Abbotsford, BC, Canada V2S 7M9
USA Shipping Address: #88-446 Harrison St., Sumas, WA 98295 | USA Mailing Address: PO Box 231, Sumas, WA 98295
Phone: (604) 853-6096 | Fax: (604) 853-8749 | Internet: www.bd-power.com
6 March 2007
Dodge 2003-05 Turbo Mount Exhaust Brake (2023138/2023139)
- 23 -
BD Engine Brake, Inc.
Limited Warranty Statement
THE INSTALLATION OF THIS PRODUCT INDICATES THAT THE BUYER HAS READ AND
UNDERSTANDS THIS AGREEMENT AND ACCEPTS ITS TERMS AND CONDITIONS.
DISCLAIMER OF LIABILITY
BD Engine Brake Inc., its successors, distributors, jobbers, and dealers (hereafter “BD”) shall in no way be
responsible for the product's proper use and service. THE BUYER HEREBY WAIVES ALL LIABILITY
CLAIMS.
BD disclaims any warranty and expressly disclaims any liability for personal injury or damages. BD also
disclaims any liability for incidental or consequential damages including, but not limited to, repair labor, rental
vehicles, hotel costs, or any other inconvenience costs by reason of use or sale of any such equipment. The
BUYER acknowledges and agrees that the disclaimer of any liability for personal injury is a material term for
this agreement and the BUYER agrees to indemnify BD and to hold BD harmless from any claim related to
the item of any equipment purchased.
This warranty shall not apply to any unit that has been improperly stored or installed, or to misapplication,
improper operation conditions, accidents, neglect, or which has been improperly repaired or altered or
otherwise mistreated by the BUYER or his agent. BD also assumes no liability regarding the improper
installation or misapplication of its products. It is the installer's responsibility to check for proper installation
and if in doubt, contact the manufacturer.
LIMITATION OF WARRANTY
BD Engine Brake Inc. (hereafter "BD") warrants to the BUYER that any parts purchased shall be free from
defects in material workmanship. A defect is defined as a condition within the product that would render the
product inoperable. BD gives Limited Warranty as to description, quality, merchantability, fitness for any
product’s purpose, productiveness, or any other matter of BD's product sold herewith. BD 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 BD and the BUYER.
The warranty is limited to two (2) years from the date of sale. Labor costs incurred by the removal and
replacement of the BD product, while performing warranty work, will be covered for 1 (one) year,
payable at BD rates, at authorized centers and with prior approval. Until BD has approved the claim,
the consumer may be responsible for these costs.
A Return Materials Authorization (RMA) number, obtained in advance from BD, must accompany all products
returned for warranty consideration. All products must be returned, shipping prepaid, to BD and must be
accompanied by a dated proof of purchase receipt. All warranty claims are subject to approval by BD and
repaired or replaced product will be returned to the customer freight collect. Accepted warranty units, which
have been replaced, become the sole property of BD.
This warranty is in lieu of all other warranties or guaranties, either expressed or implied, and shall not extend
to any consumer or to any person other than the original purchaser residing within the boundaries of the
continental U.S. or Canada.
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.
BD Engine Brake, Ltd.
Plant Address: Unit A10, 33733 King Rd., Abbotsford, BC, Canada V2S 7M9
USA Shipping Address: #88-446 Harrison St., Sumas, WA 98295 | USA Mailing Address: PO Box 231, Sumas, WA 98295
Phone: (604) 853-6096 | Fax: (604) 853-8749 | Internet: www.bd-power.com
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