BD Turbo Mount Engine Exhaust Brake

BD Turbo Mount Engine Exhaust Brake
7 January 2014
(2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083)
1
2004½-07 Dodge Cummins
BD Turbo Mount Exhaust Brake
Installation Instructions
BD P/N#
2023331
2023330
Application
2004½-2005 Dodge Cummins
2006-2007 Dodge Cummins
Serial #
Date Purchased
Installed by
*** Please read this manual before starting installation. ***
OWNER’S MANUAL - LEAVE IN GLOVE BOX
The brake pressure at idle is required to be checked and adjusted at time of install,
at least two weeks after install, and at regular twice a year intervals.
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 January 2014
(2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083)
TABLE OF CONTENTS
Welcome ..................................................................................................... 3
Kit Contents ............................................................................................... 3
Pre-Installation ........................................................................................... 3
Special Tools Required ............................................................................. 3
Accessories ................................................................................................ 3
Notes On Connectors ................................................................................ 4
Installation .................................................................................................. 5
BRAKE VALVE INSTALLATION ...................................................................5
Regulator & Air Solenoid Installation .............................................................6
Air Compressor Mounting Installation..................................................7
IN-CAB EXHAUST BRAKE WIRING (2006-07) ............................................9
ECM Activation Wire Install .................................................................9
DFIV INSTALLATION ..................................................................................10
ACCELERATOR PEDAL POSITION SENSOR (2004½) ............................11
Automatic & Manual Transmissions (2005 MODELS).......................12
IN-CAB EXHAUST BRAKE WIRING (2004½-05) .......................................13
Cruise Control Wiring (2004½-05) .....................................................13
SWITCH INSTALL (Required if using main toggle switch)..........................14
Attaching the switch relay (2006-07 Only) .........................................16
Optional Manual Shifter Switch (Push-Pull Style) ................................. 17
Optional Manual Shifter Switch (Rocker Switch Style) ......................... 18
WIRING & PLUMBING DIAGRAMS (2004½-05) ........................................19
WIRING & PLUMBING DIAGRAMS (2006-07) ...........................................20
Using Main Toggle Switch Only.........................................................20
Using Push/Pull Shifter Switch (Manual Trans) .................................21
Using Rocker Switch (Manual Trans) ................................................22
DFIV Adjustment & Testing .........................................................................23
DFIV Operation............................................................................................24
Maintenance ............................................................................................. 24
Exhaust Back Pressure Testing Air Actuated Brakes ........................... 25
Operating Guidelines............................................................................... 27
Air Brake Troubleshooting Guide ........................................................... 29
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
2
7 January 2014
(2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083)
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.
Kit Contents
2023331
2004½-05 Dodge Cummins
1030129-C Air Pump Kit
1220136-C Regulator & Control Kit
1321039 DFIV Install Kit
2123330 Valve Assembly
2023330
2006-07 Dodge Cummins
1030129-C Air Pump Kit
1220131-B Regulator/Control Kit
1321031 Toggle Switch Kit
2123330 Valve Assembly
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.
Special Tools Required







Measuring tape or ruler
Drill with 1/8”, 3/16” bits and Unibit
Sawsall or hacksaw
Crimping Pliers
Test light
1/4” Drive Socket Set
Small bladed flat tip screwdriver
Accessories
Description
Manual Transmission Push-Pull Shifter Switch Kit
Manual Transmission Rocker Switch Kit
Transmission & Converter Package
X-Monitor Digital Gauge Package
Brake Pressure Gauge Kit
Part #
1300210
1030900
CALL
1085220
1030050
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 January 2014
(2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083)
4
Notes On Connectors
The kit includes a number of Posi-Tap™ connectors (Gray or Red/Black/Green or
Yellow) to tap onto OEM wiring. It is important to select the correct color of
connector so that it matches the gauge of the OEM wire that it is being installed on.
Using the incorrect connector could cause an inadequate connection and/or the
OEM wire could be severed.
OEM Wire
18-22ga
12-18ga
10-12ga
Posi-Tap™ Color
Red
Black
Yellow
Though these connectors offer a quicker installation, the best option would be to
solder the wires and isolate the joints with heat shrink or liquid electrical tape.
Proper soldering techniques should be used to ensure adequate connections.
Posi-Tap™ Connector Usage Diagram
Insert Hot Wire
Tighten
Strip Leads
Insert & Tighten
Make sure to center the wire when tightening the pierced portion of the hot wire to make a solid connection.
The ground terminals of the vehicle’s batteries should be disconnected before
performing any piercing/posi-tapping onto any ECM/PCM wire.
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 January 2014
(2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083)
Installation
BRAKE VALVE INSTALLATION
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.
From underneath the vehicle,
remove
the
downpipe-to-turbo
elbow band clamp using a 10mm
socket. Support the down pipe as it
may drop down once the clamp is
removed.
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.
Make sure that that the exhaust
brake main bracket is at least 1”
away from the exhaust manifold.
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
7 January 2014
(2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083)
6
Regulator & Air Solenoid Installation
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 3/8” hole or use the
existing hole by removing the factory plastic locking insert.
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 Phillips screw holding everything in place.
Now hook up the wiring harness on the regulator assembly:
Attach the ring terminal on the red wire with the fuse holder in it to the positive
terminal of the passenger side battery. Connect the ring terminal on the black wire
to the negative terminal. Connect the female 2-pin connector to the corresponding
male connector on the air pump. The other wires will be connected later.
And finish the pump install:
Run the hose from the pump outlet (coming out of the pump head) to the INLET
fitting on the regulator. Run the inlet hose for the air pump (going into the front body
of the pump) to a clean, dry location in the engine bay. Install the grey “pancake”
filter onto the end of the inlet hose. Reinstall the fender liner.
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 January 2014
(2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083)
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 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.
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.
Attach the foam tape to the
bottom backside of the
bracket.
Slide
the
compressor
assembly up into this space
and re-install the hood
support bolt. Now raise the
compressor assembly so that
you can install the provided
bolt through the bracket and
frame hole into the nut. Note
that you can use a magnet to
assist in holding this nut in
place will you slide the bolt
through.
Slide bolt in behind the bracket and
frame support. Install the nut to
secure the assembly.
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
7 January 2014
(2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083)
8
Tighten all bolts to secure the
assembly.
Route
the
compressor hoses & wiring
harness up through the body
opening at the rear of the
battery. They will be hooked
up later.
Use the wiring diagram 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.
Use the wiring diagram on page 19 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.
Secure
using the
hood latch
support
Secure using
the 8mm nut,
washer and
bolt provided
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 January 2014
(2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083)
IN-CAB EXHAUST BRAKE WIRING (2006-07)
9
ECM Activation Wire Install
In-cab wiring has been made easier with the addition to Exhaust Brake
programming through the Chrysler ECM. What used to take 4 wires and multiple
OEM wire cutting has now been easily changed to two wire leads going to the ECM.
There are two separate ECM wiring
blocks – one 60-pin connector and a 50pin connector.
Remove the 50-pin connector (#3 on
picture to the right).
Locate Pin #39 (for the activation wire
from the cab) and Pin #42 (for the black
wire in the control harness). These pins
have a plug in them from the factory.
They will have to be removed.
For this step you will need a pair of
needle-nose pliers and a paper clip.
Bend out the paper clip enough so that
there is a straight shaft.
The easiest way to remove the OEM
plug pins is to take the paper clip and
insert it into the bottom end of the pin
connector hole. This will poke out the
top of the plug which then can be
removed with pliers.
The two wire leads from the exhaust brake control harness (with the ECM pins precrimped) can now be plugged into the ECM. Insert the tan wire into Pin #39, and the
black wire to Pin #42. They should snap into place. Once this is complete, you can
re-install the ECM plug. Secure the wiring loom using the supplied tie wraps.
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 January 2014
(2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083)
DFIV INSTALLATION
10
If your truck is a 2006 or 2007 you do not need to install a DFIV module as this
function is built into the trucks factory programming. Skip ahead to page XX for 0607 ECM wiring.
Mount the DFIV module in a secure location under the dash using the cable ties
provided. Locate a grommet on the firewall and cut an opening in it to run the wiring
through the firewall. Route the pink and yellow wires (for 2004) or just the pink wire
(for 2005) through the firewall into the engine bay. Crimp the pink DFIV wire to the
pink wire from the regulator & relay assembly, using the crimp connector with the
clear plastic heatshrink. The yellow wire will be hooked up later.
Attach the black ground wire to the “Gnd” terminal on the DFIV and attach the ring
terminal to a good ground.
Locate a grommet on the firewall
and cut an opening in it to run the
loom covered wiring through the
firewall.
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 January 2014
(2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083)
ACCELERATOR PEDAL POSITION SENSOR (2004½)
11
Route the yellow wire from the apps terminal of 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 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 January 2014
(2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083)
12
Automatic & Manual Transmissions (2005 MODELS)
Route the yellow wire from the apps terminal of the DFIV module to the accelerator
pedal position sensor located on the accelerator pedal. Use the positap to connect
the yellow wire to the factory wire indicated below.
APPS Location (Accelerator Pedal)
ECM
Plug Pin
5
APPS Plug
Circuit / Wire Color
Function
K23 20BR/WT
APPS NO. 1 SIGNAL
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 January 2014
(2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083)
IN-CAB EXHAUST BRAKE WIRING (2004½-05)
13
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 14 AND CONTINUE WITH BRAKE VALVE
INSTALLATION.
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 “Dodge” terminal of
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 “Com” terminal of
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
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 January 2014
(2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083)
SWITCH INSTALL (Required if using main toggle switch)
If you wish to use an optional
shifter mounted switch skip this
step. See pages 17 to 18 for shifter
switch install.
Remove attaching screws of the
dashboard bezel and remove
covering trim by pulling rearward
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 easy
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 like 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 1/2”.
NOTE: 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 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
14
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(2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083)
15
Install the switch into the drilled hole and
secure it with the plastic lock ring. Reinstall 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 (quite frequently a pink w/ white
tracer wire) and install the supplied black (1218ga) Posi-Tap™ to it then attach the red
fused wire from the switch to this Posi-Tap™.
On 2004-2005 trucks connect the remaining
switch wire to the “Switch” terminal on the
DFIV. On 2006-2007 trucks it will be
connected to the under-dash relay assembly
(see following page).
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 January 2014
(2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083)
16
Attaching the switch relay (2006-07 Only)
Due to the characteristics of running the exhaust brake controls through the ECM, a
relay kit has to be installed (unless you are installing the push-pull switch for the
manual transmissions). This is so the light on the toggle switch (or rocker switch for
the manual transmissions) can be lit while the exhaust brake is engaged. This relay
comes pre-wired from the factory and is included in the main toggle switch kit.
Connect the tan wire coming from the ECM to terminal #87 on the relay. Connect
the green wire leading from the switch to terminal #85 on the relay. Connect the
black Y-wire to a ground source nearby. Blade terminals have been included loose
in the bag, but not pre-crimped, so you can strip the wire to the desired length.
Wiring With The Default Toggle Switch (2006-07 Only)
Wiring With The Rocker Switch (Manual Trans) (2006-07 Only)
This switch relay is not required when wiring the exhaust brake with the push-pull
style switch.
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 January 2014
(2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083)
17
Optional Manual Shifter Switch (Push-Pull Style)
Mount the shifter switch onto the shift
lever using the clamp supplied (either
5/8” or 3/4”).
Run the electrical cable down the
shifter shaft, securing the cable with
zip-ties or electrical tape, and run it
under the carpet to the firewall and
under the dash, leaving enough slack
for proper shifting of the transmission
lever and to prevent any rubbing of
wire.
At the end of the cable, cut off any
excess and strip away about 1 to 2
inches of the black rubber covering
exposing the black and white (or
green) wires, and then strip the
insulation from the ends of the two
wires.
Connect the white (or green) wire to the Tan brake activation wire leading to the
ECM. Connect the black wire to a nearby ground source.
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 January 2014
(2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083)
Optional Manual Shifter Switch (Rocker Switch Style)
18
Mount the shifter switch onto the shift lever using the clamp supplied (either 5/8” or
3/4”). Run the electrical cable down the shifter shaft, securing the cable with zipties or electrical tape, and run it under
the carpet to the firewall and under the
dash, leaving enough slack for proper
shifting of the transmission lever and to
prevent any rubbing of wire.
At the end of the cable, cut off any
excess and strip away about 1-2” of the
black rubber insulation exposing the
black, white and green wires, then strip
the insulation from the ends of the three
wires.
Connect the green 12V output green
wire to #85 on the switch relay, which
then leads to the Tan brake activation
wire going to the ECM.
Attach the 5/16” ring connector to the
black ground wire and attach it to a good
ground nearby.
Locate one of the ignition switched
power fuses in the fuse panel
underneath
the
steering
column.
Traditionally this wire will be pink with a
white tracer. Use a voltmeter to check
the voltage of the wire. Use the supplied
fuse tap to supply ignition switched
power to the “Keyed 12 Volts” (white)
wire of the rocker switch assembly.
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 January 2014
(2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083)
WIRING & PLUMBING DIAGRAMS (2004½-05)
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
19
7 January 2014
(2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083)
WIRING & PLUMBING DIAGRAMS (2006-07)
Using Main Toggle Switch Only
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
20
7 January 2014
(2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083)
Using Push/Pull Shifter Switch (Manual Trans)
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
21
7 January 2014
(2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083)
Using Rocker Switch (Manual Trans)
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
22
7 January 2014
(2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083)
23
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. Then, 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.
Then the brake should activate again when the throttle pedal returned to idle. If not,
readjust 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), retorque the flange bolts.
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 January 2014
(2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083)
24
DFIV Operation
Input
TPS/APPS
Ground
Switch (12V)
Dodge
Common
Ford
Brake
Description
Locate the TPS/APPS wire from the Accelerator pedal position assembly.
This wire is referred to as sensor circuit #1 on the rising signal circuit, and
should rise linearly in voltage with the amount of throttle depressed.
Typical values range from 0.5 Volts and rise to 4.5 Volts.
Connect to Vehicle electrical ground
This connection will supply 12 volt power to the DFIV. This will come from
the toggle or shifter switch.
This input should only be used for Dodge applications as it disables the
cruise control specifically for Dodge trucks.
Common cruise inputs between the Dodge and Ford inputs.
This input can be used for other generic applications. When the brake is
activated the connection between the Ford input and the Common is
severed.
You should have 12 volts at this terminal when the key is in “run”, the
brake switch is on and the throttle is at idle. There should be no power at
this terminal if any of those conditions are not met.
Maintenance
To extend life of the exhaust brake, do not operate the 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 inner parts of the brake valve assembly.
The hoses, wires, fittings and clamps should be inspected on a regular basis for any
deterioration, damage or leaks.
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 valve 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 5:00pm Pacific Time.
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 January 2014
(2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083)
Exhaust Back Pressure Testing Air Actuated Brakes
25
It is recommend that you purchase the BD pressure gauge kit #1030050
NOTE: The brake stop-bolt and regulator have been preset at the factory and
should not need to be adjusted.
You do not need to measure the air pressure in the system, just the
exhaust backpressure, which is located on the cast valve.
Idle Pressure Test
With the BD brake engaged and the engine at idle check the exhaust backpressure using a
pressure gauge (such as BD PN 1030050) at the test port on the brake valve.
If the back pressure is below 13 psi at idle you have a number of likely causes. The most
common being an exhaust leak either at the clamp joint or at the welds (only on some models).
Apply the exhaust brake and have someone assist you looking for soot trails or the visible leak.
Another culprit would be an exhaust manifold leak, turbocharger gasket leak, turbocharger
problem or an EGR issue.
If the back pressure is greater than 25psi, you will need to make an adjustment on the stop bolt.
Loosen the jam nut, and lengthen the stop bolt towards the actuator, this will shorten the stroke
distance. Only turn 1/4 rotation at a time and re-secure the jam nut. Retest idle pressure.
We generally do not recommend adjusting the stop bolt, please consult BD before doing this as it
may void your warranty.
Off-Idle Pressure Test & Adjustment
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 January 2014
(2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083)
26
Your BD exhaust brake is a variable-orifice design so when the brake is active and the engine
is at higher RPM the brake lever does not rest on the stop bolt. Off-idle backpressure is set by
adjusting the air pressure regulator which will in turn increase or decrease off-idle exhaust
backpressure. You will need to secure your pressure gauge somewhere that you can see it while
you are driving. Using a long extension hose & bringing the gauge into the cab through an open
window or clipping it under a windshield wiper works well.
Get the truck up to speed (a downhill grade or a load in the truck is helpful) and activate the
exhaust brake. Note the maximum backpressure achieved. You should get peak backpressure at
higher RPM (try 3000 RPM in Drive). If you cannot reach the desired backpressure (compare
table below) you can begin troubleshooting, the first step is to look for exhaust leaks either from
the clamps, exhaust manifolds or feed pipes. Also look for leaks at the clamps located at the back
of the turbo and also at the down pipe. If all connections are sealed, you can then use the
adjusting regulator to increase the backpressure. Note that small regulator adjustments can have
a significant effect on off-idle backpressure.
Turning the regulator clockwise will increase pressure.
Turning the regulator counter clockwise will decrease pressure.
NOTE: Over the next two weeks, the backpressure at idle may rise due to initial carbon build up
on the inside of the brake housing and on the butterfly. The stop bolt may need to be adjusted
again to compensate.
Application
GM/Chevy 6.5
GM/Chevy Duramax
Ford Powerstroke
Dodge Cummins 1988-98 12V w/o 60lbs Springs
Dodge Cummins 1988-98 12V with 60lbs Springs
Dodge Cummins 2002 and Newer
Maximum Back Pressure
35 psi
55 psi
45 psi
40 psi
60 psi
60 psi
*HD Spring part# is 1030060.
CAUTION: Do NOT exceed the maximum back pressure value in the exhaust system. Exceeding
this pressure will force the exhaust valves open during the intake stroke which could cause engine
damage.
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 January 2014
(2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083)
27
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 “burnup”. 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 failure.
With terrain that is a series of up and down grades, the BD Exhaust Brake will help
reduce warping in the exhaust valves. 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 coasting down the other side, the heated valves are cooled
too quickly. 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 brake is deactivated and the valve opens again.
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.
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 January 2014
(2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083)
28
Such cases may cause damage to engine and/or exhaust brake. There is a
pressure regulating system incorporated with the BD Exhaust Brake that will control
the created backpressure. If the backpressure reaches the set limit 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.
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 January 2014
(2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083)
29
Air Brake Troubleshooting Guide
This guide assumes that your exhaust brake system is using a DFIV and a BD air compressor. If you system uses a
microswitch for throttle activation, the operation of the air solenoid and pump are the same as with the DFIV. If you are
using existing on-board air, check that system as appropriate.
When I let off the throttle
nothing happens.
Is the DFIV powering its “brake”
output when the throttle is at idle
and brake switch and ignition are
both on?
No
Yes
Check if DFIV has good power, ground
and throttle signal. Check DFIV
adjustment. If these things check out,
but the DFIV won’t power the “brake”
output, the DFIV is likely faulty.
Also check power & ground at pump
relay and make sure the air solenoid
has a good ground.
The brake comes on but
there’s little or no holdback
Check that when air solenoid is
powered it will allow air to flow from
the #2 port out the #1 port.
Check that pump relay is powering
pump. If pump has power but does
not run, pump is likely faulty. Check
for power & ground at pump relay, if
these are good but relay does not
click or does not power pump, relay is
likely faulty.
No
Yes
Check for exhaust leaks. A small leak
can result in a significant decrease in
back pressure. If no leaks are found try
adjusting air regulator. Check for air
leaks in brake system.
Try down shifting more aggressively.
More RPM will give more holdback.
Transmission or torque converter
could be slipping internally.
Everything seems to work, but
the brake valve won’t close.
No
Yes
Check that air is reaching brake air
cylinder?
Air solenoid or quick release valve are
likely stuck, plugged or faulty. Clean or
replace as required.
Cylinder or brake valve are seized.
Remove the clevis pin on the end of
the cylinder rod & see if the valve
lever can be moved freely.
The valve lever can be moved
freely?
Try dismounting the brake & cleaning
the carbon out of it. If this does not
work the brake valve will need to be
replaced.
The cylinder is stuck and will need to
be replaced.
See if torque converter is staying
locked up during deceleration. If not,
the engine RPM will fall to idle when
the throttle is released. The brake
will be ineffective without the torque
converter locked up.
Check off idle brake pressure.
(See back pressure chart)
Are you getting maximum allowable
backpressure?
Problem
Solution
Air compressor runs in short bursts
and brake is slow to apply.
There is a restriction in the air system, normally in the regulator or air solenoid.
Remove the fittings from the regulator and air solenoid, you will likely find some
corrosion or debris caught in them. Clean this out with a pick, small brush,
compressed air and WD40 or similar lubricant.
Air compressor runs continually.
Pump relay is likely stuck on. Check operation of relay & replace as required.
Brake is slow to release.
Debris or corrosion is restricting the quick release valve or air solenoid. Clean
as required. Air solenoid could be too far from brake.
Thank you and happy motoring.
BD Engine Brake, Inc.
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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