1994-1997 Ford Powerstroke

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November 09      Ford 7.3L 1994-1997 Powerstroke Vacuum Exhaust Brake (Turbo Mount) #2033143                         1




1994-1997 Ford Powerstroke
BD Turbo Mount Vacuum Exhaust Brake
                                          Part# 2033143
                                     Serial #


                           Date Purchased


                           Purchased from


                                Installed by



                              OWNER'S MANUAL  LEAVE IN GLOVE BOX
                                 Installation Manual Part # I2033143


                                                     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
November 09       Ford 7.3L 1994-1997 Powerstroke Vacuum Exhaust Brake (Turbo Mount) #2033143                         2




          -- TABLE OF CONTENTS --

Welcome................................................................................................... 3
Kit Contents ............................................................................................. 3
Options ..................................................................................................... 3
Exhaust Brake Installation ..................................................................... 4
     Valve Installation ............................................................................... 4
     Control (Spool) Valve INSTALLATION.............................................. 6
     Wiring Diagram ................................................................................. 7
     Optional Shifter Switch ...................................................................... 8
     Cruise Control Disconnect Wiring (if equipped) ................................ 9
     Control Wiring ................................................................................. 10
     Battery Reinstall .............................................................................. 10
DFIV Calibration .................................................................................... 10
Testing .................................................................................................... 11
Maintenance & Trouble Shooting ........................................................ 11
Measuring Idle Brake Pressure ............................................................ 12
Spool Valve Maintenance ..................................................................... 12
     Disassembly .................................................................................... 12
     Cleaning .......................................................................................... 12
     Re-assembly ................................................................................... 13
     Testing ............................................................................................ 13
     Helpful Hints .................................................................................... 13
Operating Guidelines ............................................................................ 14
Questions? ............................................................................................. 16




                                                      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
November 09      Ford 7.3L 1994-1997 Powerstroke Vacuum Exhaust Brake (Turbo Mount) #2033143                         3




WELCOME
Thank you for purchasing a BD Engine Exhaust Brake. Your kit should have the
items mentioned for your installation. Please check to make sure that you have
everything. This manual is to aid you with your installation and operation of your
braking unit. We strongly suggest that you fill out the information below and retain
this manual for any future reference.

         * Please fill out and mail registration card as soon as possible. *



KIT CONTENTS
      2033143  Ford 7.3L Powerstroke Exhaust Brake
        Part #           Qty.         Description
       2133043            1           Valve Assembly
       1230043            1           Control Kit
       1230430            1           Vacuum Spool Valve Kit
       1321039            1           DFIV Application Kit




OPTIONS
       Description                                                              Part #
       Manual Transmission Shifter Switch Kit                                   1300240 / 1030910
       AutoLoc Convertor Lock-up Kit                                            1030390
       Brake Pressure Gauge Kit                                                 1030551
       Exhaust Temperature (Pyrometer) Gauge Kit                                1030512
       Boost Pressure Gauge Kit                                                 1030570
       Transmission Gauge Kit                                                   1030585




                                                     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
November 09      Ford 7.3L 1994-1997 Powerstroke Vacuum Exhaust Brake (Turbo Mount) #2033143                         4




EXHAUST BRAKE INSTALLATION
   VALVE INSTALLATION

Disconnect the negative terminals on both of the vehicle's batteries, and then
disconnect the positive terminals. Remove the passenger side battery.

Remove       the  top    cover
housing of the engine and
locate the engine-lifting eye
by the turbo outlet and
remove. Remove and retain
the turbo exhaust clamp
between the turbo and
exhaust pipe.     Loosen the
17mm nuts of the turbo down
pipe (under cab) and push the
pipe out of the way.

Remove the three mounting
bolts of the outlet housing on
the turbo.        NOTE: The
bottom-rear      bolt,    which
cannot be seen, will require a
5/16" 12pt. half-moon wrench
to loosen it, then taken out with the use of a swivel socket.

Disconnect the actuation rod from the bottom of the outlet housing by sliding back
the ball joint cover and remove the turbo outlet housing. NOTE: The clip that holds
the rod to the outlet housing is similar to that found on carburetors.
To prevent the rod from hanging, which can cause the rod seal to leak due to
vibration, install the supplied rod support fitting.

This is a brass fitting that has a cut in it, which fits around the rod and holds the rod
securely.

The EBP Valve will not be required with the installation of the BD Exhaust Brake. It
is recommended that the EBP Valve wiring harness be disconnected to prevent the
actuator rod from moving to protect the seal.




                                                     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
November 09      Ford 7.3L 1994-1997 Powerstroke Vacuum Exhaust Brake (Turbo Mount) #2033143                         5




NOTE: ON CALIFORNIA MODEL VEHICLES THE EBP VALVE WIRING MUST
BE CONNECTED TO ENSURE THE ECM DOES NOT SET AN ENGINE
TROUBLE CODE.

Install the BD Brake Valve Assembly on the turbo using the original mounting bolts,
first threading in the front bolt, then the top bolt and the bottom rear bolt last, and
tightening all bolts.

Using the turbo exhaust clamp, secure the exhaust pipe to the Brake Valve and
tighten the lower 17mm nuts of the down pipe, and then re-connect the sensor hose
and wire connector from the MAP sensor.




                                                     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
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