3 October 2016 (2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083) 1 DOWNLOAD ENHANCED INSTALL MANUALS AT dieselperformance.com BD Dodge Turbo Mount Exhaust Brake 2004½-07 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.
3 October 2016 (2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083) Table of Contents Kit Contents ............................................................................................... 3 Introduction ................................................................................................ 4 Optional Accessories ................................................................................ 4 Notes on Connectors .............................................................
October 2016 (2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083) 3 Kit Contents Please check to make sure that you have received all parts for your kit 2123330-A 1030129-D 1300146 Brake Valve Assembly Qty: 1 Kit 2023331 Only 1321039 DFIV Controller and Wiring Kit Qty: 1 Kit 2023330 Only 1321031 Toggle Switch Kit Qty: 1 Compressor Assembly Qty: 1 1/8” Diameter Air Tubing Qty: 3ft 1220139-A Regulator/Control Assy. Qty: 1 1220131-C Regulator/Control Assy.
3 October 2016 (2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083) Introduction 4 Thank you for purchasing a BD Exhaust Brake. This exhaust brake kit installs on the backside of the stock turbocharger. It requires either the stock turbocharger or a compatible aftermarket turbocharger be used. For vehicles where this will not be applicable, the BD Remote Mount exhaust brake may be used.
3 October 2016 (2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083) Tools Required 5 Measuring tape or ruler Drill with 1/8”, 3/16” bits and Unibit Crimping Pliers Test light Socket Set Small bladed flat tip screwdriver Installation To prevent damage to electronic components, it is recommended that both battery negative terminals be disconnected while working on the vehicle. Please read this manual thoroughly before installing this exhaust brake.
3 October 2016 (2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083) 6 Tighten all clamps that secure the brake to the flanges. Make sure the exhaust brake bracket is at least 1” away from the exhaust manifold. Air Compressor Mounting Installation Remove the passenger side front wheel and remove the plastic fender liner from the vehicle to gain access to the inner fender area. Install the supplied vibration dampening foam tape to the bottom back side of the compressor bracket assembly.
3 October 2016 (2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083) Secure using the hood hinge support Secure using the 8mm nut, washer and bolt provided Feed the compressor air lines and wire through the fender into the engine bay, they will be connected later. Lift the compressor into place. Secure the compressor in place by reinstalling the hood hinge bolt through the compressor bracket. Then install the nut and bolt to hold the front of the bracket. BD Engine Brake Inc.
3 October 2016 (2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083) Regulator Assembly Installation 8 The air pressure regulator assembly is to be mounted at the top of the firewall on the passenger side of the engine bay. The included washer should go directly under the head of the screw to sandwich the sheet metal against the regulator bracket. Locate the large oval hole on the passenger side of the Drill or use vehicle near the upper cowling existing hole. of the firewall.
3 October 2016 (2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083) Regulator Plumbing and Electrical Connect the air pressure line from the pump to the inlet of the regulator assembly. This is the shorter of the two 1/4" tubes from the compressor that does not have a fitting on the end. This connects to the passenger side of the regulator assembly, behind the relay. Trim this tube to length and insert it into the fitting. The other line of the compressor is the air suction line.
3 October 2016 (2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083) 10 Connect the main ground connection to the body ground on the passenger side of the engine bay near the regulator assembly. This is the black wire with a ring terminal installed on the end. Alternatively this may be connected directly to the battery negative terminal if desired. Connect the main power feed to the passenger side positive battery terminal clamp.
3 October 2016 (2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083) In-Cab Exhaust Brake Wiring (2006-07) 11 ECM Activation Wire Install In-cab wiring has been made easier with the addition to Exhaust Brake programming through the Chrysler ECM for 2006-2007 model years. 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.
3 October 2016 (2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083) In-Cab Exhaust Brake Wiring (2004-05) 12 DFIV Installation 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 22 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.
3 October 2016 (2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083) Sensor Location 2004 Automatic Engine Application Sensor Pin/Wire Color APPS Pin 3 – BR/WT 13 ECM Pin/Wire Color ECM C1 Pin 14 – BR/WT 2004 Manual Battery Tray APPS Pin 5 – BR/WT ECM C1 Pin 14 – DB/WT NOTE: 2004 Manual transmission trucks change the wire color between the sensor and ECM. Engine Mounted APPS Battery Tray Mounted APPS BD Engine Brake Inc. Plant Address: 33541 MacLure Rd.
3 October 2016 (2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083) 14 2003-2004 ECM Connector Accelerator Pedal Position Sensor Wiring (2005) 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 posi-tap 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.
3 October 2016 (2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083) Cruise Control Wiring (2004½-05) 15 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.
3 October 2016 (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 19 to 19 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.
3 October 2016 (2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083) 17 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.
3 October 2016 (2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083) Attaching the switch relay (2006-07 Only) 18 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.
3 October 2016 (2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083) 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.
3 October 2016 (2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083) 20 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.
3 October 2016 (2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083) 21 Wiring & Plumbing Diagram (2004½-05) Switched 12V+ Posi-Tap Connector APPS Wire Cruise Control Wires (under steering column) Posi-Tap Connector Posi-Tap Connector Blue Yellow 15A Fuse Ground Dodge APPS Com Gnd DFIV Switch Brake Black Green Red “Amber” Adjust Red Pink Black Firewall Relay Installer to crimp Regulator 1/4” Suction Line Blue Air Solenoid 1/4” Air Line 30A Pink Pink Red Battery Connec
3 October 2016 (2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083) Wiring & Plumbing Diagram (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.
3 October 2016 (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.
3 October 2016 (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.
3 October 2016 (2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083) DFIV Adjustment & Testing 25 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. Connect one end of a test light to the “BRAKE” terminal of the DFIV module and the other end to a good ground. With the throttle at idle, turn the key to run and turn on toggle switch (switch should light up).
3 October 2016 (2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083) Exhaust Back Pressure Testing for Air Actuated Brakes 26 To test exhaust brake system pressure, a minimum 0-100psi pressure gauge is required. We recommend purchase of a BD brake pressure gauge kit #1030050. You do not need to measure the air pressure in the system, just the exhaust backpressure, which is located on the cast valve.
3 October 2016 (2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083) Off-Idle Pressure Test & Adjustment 27 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.
3 October 2016 (2023330-2023331) 2004½-07 Dodge Turbo Mount Exhaust Brake (I-00083) Maintenance 28 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.
3 October 2016 (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.
