6.7L Dodge Cummins Intake Horn Instruction Manual

6.7L Dodge Cummins Intake Horn Instruction Manual
28 March 2013
1041561 – 6.7L Intake Horn Manual
6.7L Dodge Cummins Intake Horn
Instruction Manual
P/N# 1041560
P/N# 1041561
2008-2010 6.7L Intake Horn
2011-2012 6.7L Intake Horn
U
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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1041561 – 6.7L Intake Horn Manual
28 March 2013
K I T
C O N T E N T S :
Please check to make sure that you have all the parts listed in this kit before you start
the disassembly of your truck.
1041560 - Kit Contents
1401560
1401565P
68024672AB
1401561
6.7L Intake Horn
6.7L Pipe
Gasket
Bracket
Qty: 1
Qty: 1
Qty: 1
Qty: 1
1401562
1405211
Boot 3.5”-4”
3-3.38 Clamps
Qty: 1
Qty: 1
1401557
-10 ORB Plug
Qty: 1
1200208
1/8” NPT
Plug
Qty: 2
1405212
1405213
1453320
3.56-3.91
Clamps
Qty: 3
3.89-4.24
Clamps
Qty: 1
Boot 3”-3.5”
1302020
Thread Lock
Qty: 1
1900015
1401563
Bolt Flange M8-1.25
x 30mm
Qty: 1
Boot 3.5”
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
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1041561 – 6.7L Intake Horn Manual
28 March 2013
1041561 - Kit Contents
1401560
1401564P
68024672AB
1401561
6.7L Intake Horn
6.7L Pipe
Gasket
Bracket
Qty: 1
Qty: 1
Qty: 1
Qty: 1
1405212
1405213
1453320
3.56-3.91
Clamps
Qty: 3
3.89-4.24
Clamps
Qty: 1
Boot 3”-3.5”
1401562
1405211
Boot 3.5”-4”
3-3.38 Clamps
Qty: 1
Qty: 1
1401557
-10 ORB Plug
Qty: 1
1200208
1/8” NPT
Plug
Qty: 2
1302020
Thread Lock
Qty: 1
1900015
1401563
Bolt Flange M8-1.25
x 30mm
Qty: 1
Boot 3.5”
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
28 March 2013
4
1041561 – 6.7L Intake Horn Manual
Options
Description
6.7L Performance Intake Plate
Part #
1041562
Tools Required










8mm, 10mm Deep Socket
7/16”, 1/2”, 1” Deep Socket
Ratchet with Extensions
9/16” , 1” Wrench
17mm, 19mm Wrench
3/32” Allen key
Blade Screwdriver
Side Cutters
Razor Knife
Masking Tape & Pen
Before you install this Kit you must install:
 A tuner with an EGR Delete Function.
 6.7L Exhaust Gas Blocker Kit.
Removal
VEHICLE SHOULD
INSTALLATION.
BE
SAFELY
SECURED
BEFORE
1. Remove the oil dipstick then remove
the four bolts that secure the plastic
cover to the engine. (8mm)
NOTE: Only required if the Exhaust
blocker cover brackets were used.
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
28 March 2013
94-02 Dodge 2wd Steering Box Support (SBS)
2. Remove the bolt holding the dipstick
to the intake horn. (10mm socket)
3. Loosen clamp between the rubber
boot and the intake horn. Use a
blade screwdriver to gently break the
seal. (11mm)
4. Pull off the harness clip from the
intake horn.
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
5
28 March 2013
94-02 Dodge 2wd Steering Box Support (SBS)
5. Disconnect the MAP sensor along
with the bracket securing the wiring
harness to the horn.
6. Also disconnect the 10mm bolt that
holds the injector harness to the
intake horn.
7. Remove the 6 (10mm bolts) that
secure the horn to the engine.
Photo shown on bench for clarity.
8. If you have this rubber isolator on
your fuel line it will need to be
removed in order to fit the BD 6.7L
intake horn. Clean the surface of the
grid heater.
**IMPORTANT**
Careful not to get any debris into the
intake manifold.
9. Disconnect the outlet Boot from the
CAC (Drivers side) and pull out the
pipe with boot and OEM clamp.
(11mm)
Driver’s side CAC Boot
Installation
10. Remove the MAP sensor from the
OEM horn (3/32” Allen wrench).
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
6
28 March 2013
7
94-02 Dodge 2wd Steering Box Support (SBS)
Then apply some pipe dope to the
supplied 1/8” NPT plugs and insert
into the ports on the BD intake horn.
Then lubricate the oring on the MAP
sensor and reinstall the MAP sensor
into the BD horn.
11. Preassemble the supplied boots to the included pipe. Note if you have a BD
CAC you will need to use a different boot than if you have a stock CAC. See chart
on the next page for more information. Only tighten the clamps on the pipe at this
time. Tighten clamps until spring is bound.
2008-2010 Models
Clamp 1405213
Stock CAC
Boot 1453320
Clamp
1405211
Clamp
1405212
Clamp 1405212
Boot 1401562
PIPE 1401565P
Clamp 1405212
OR
Clamp 1405212
BD CAC Boot 1401563
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
28 March 2013
8
94-02 Dodge 2wd Steering Box Support (SBS)
2011-2012 Models
Clamp 1405213
Boot 1401562
Stock CAC
Boot 1453320
Clamp
1405211
Clamp 1405212
Clamp 1405212
OR
Clamp
1405212
Pipe 1401564P
Clamp 1405212
BD CAC Boot 1401563
12. Install the pipe assembly with the
supplied clamp to the driver’s side
CAC. Tighten this connection after
step 16 until spring is bound.
13. Slide the last clamp over the pipe
assembly and insert the intake horn
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
28 March 2013
9
94-02 Dodge 2wd Steering Box Support (SBS)
into the step boot. DO NOT
TIGHTEN CLAMP.
14. Fasten the intake horn into place
with the five OEM bolts. Do not fully
tighten as you may need some wiggle
room for the last bolt.
DO NOT INSTALL
OEM BOLT
15. Apply some supplied RED thread
lock to the supplied flange bolt and
carefully insert it through the horn
using a magnet and tighten into the
last bolt hole. Torque all bolts to 18
ft/lbs.
**IMPORTANT**
It is critical that the bolt does not fall
into the intake of the motor.
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
28 March 2013
94-02 Dodge 2wd Steering Box Support (SBS)
16. Once the final bolt is torqued, lube
the oring and thread in the -10 ORB
plug into the intake and tighten until
the oring is deformed. (6mm) Allen
wrench
17. Apply some dielectric grease to
the MAP sensor connector and
reconnect the MAP sensor.
18. Tighten intake to boot connection
with the supplied clamp. Tighten until
spring is bound. (13mm)
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
10
28 March 2013
94-02 Dodge 2wd Steering Box Support (SBS)
19. Remove the two front bolts from
the valve cover (DS) for the dipstick
bracket. (8mm)
20. Using the OEM hardware install
the dipstick bracket. (1401561)
Torque the 8mm bolts to 89 in/lbs &
10mm to 18 ft/lbs.
21.
Reinsert the oil dipstick and test drive vehicle and check for leaks.
Visit our Internet forums at http://www.dieselperformance.com and share your comments or
technical support questions with some of the industry’s leading experts in the diesel field.
If you have any technical difficulties, concerns, comments, or complaints,
please phone our Technical Support hotline at (800) 887-5030 between
8:30am-5:00pm PST (Pacific Standard Time) Monday to Friday, or post a
message on the BD Discussion Forums located at:
http://forum.bd-power.com/
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
11
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