Ford Powerstroke (Manual Transmissions)

6 November 2008 BD BrakeLoc (Ford Powerstroke Manual Transmission) P/N # 1030755 1 BD BrakeLoc EBP Valve Control Ford Powerstroke (Manual Transmissions) Part# 1030755 * Please read this instruction manual before starting installation * Installation Manual Part# I1030750 Printed in Canada

6 November 2008 BD BrakeLoc (Ford Powerstroke Manual Transmission) P/N # 1030755 2 TABLE OF CONTENTS Welcome...3 The BD BrakeLoc Advantage...3 Operating the BD BrakeLoc...3 Wiring...3 Cruise Control Disconnect Wiring...4 EBP Valve & Final Wiring...5 Wiring Diagram...8 DFIV Adjustment & Testing...9 Have any questions?...9 Ford Exhaust Brake RetroFit Kit (California Trucks)...10

6 November 2008 BD BrakeLoc (Ford Powerstroke Manual Transmission) P/N # 1030755 3 Welcome Thank you for purchasing the BD BrakeLoc Kit. This manual is to aid you with your installation and operation of the unit. We strongly suggest that you retain this manual for any future reference. The BD BrakeLoc Advantage Though not as efficient as a BD Exhaust Brake, the BrakeLoc offers a cost effective solution of engine retarding for towing with the Ford PowerStroke by utilizing the OEM Exhaust Back Pressure (EBP) valve. The BD BrakeLoc commands the EBP valve to activate. This allows the use of the Ford OEM stock Exhaust Back Pressure Valve to act as an engine brake. Operating the BD BrakeLoc The BrakeLoc is controlled by a manual toggle switch and works off of the power signal from the throttle position sensor to activate the EBP Valve circuit allowing it to close, and, will only operate when the toggle switch is on AND the throttle pedal is at idle. Once the toggle switch for the 1030755 BD BrakeLoc is turned on, the kit monitors the accelerator pedal position for the signal that it is at the idle position. When this occurs, the kit will begin to activate the EBP valve, which after an approximately 3 second delay, you will feel and hear the EBP Valve apply. When the accelerator pedal is applied or the toggle switch is turned off, the kit will disengage the EBP valve, allowing the EBP Valve to continue stock OEM operation. Wiring CAUTION: Before installing any wiring modifications or equipment ensure to disconnect the battery Ground (Negative) terminals on all vehicle batteries as damage to the vehicle s ECU and/or installed component may result. Remove lower section of dash, under the steering column, and mount the DFIV module to the cross member under the steering column. Connect the Black wire from the DFIV module to a good ground. Using a Posi-Tap connector, attach the fused wire from the toggle switch to either one of the two Red w/black tracer wires (ignition switched power) under the steering column.

6 November 2008 BD BrakeLoc (Ford Powerstroke Manual Transmission) P/N # 1030755 4 Mount Toggle Switch in a convenient spot on the dash. Locate the Throttle Position Sensor (TPS) at the throttle pedal and, using a Posi- Tap connector, attach the yellow wire attached to the APPS terminal on the DFIV module to the grey w/white tracer wire on the TPS. Ensure the green wire is connected to the COM terminal of the DFIV module and the blue wire is connected to the FORD terminal of the DFIV module. Connect the pink wire to the BRAKE terminal of the DFIV module. Run the other end of the pink, blue and green wires through a grommet on the firewall making sure all wires are secure and away from moving objects and heat sources. Reinstall the lower dash cover. Cruise Control Disconnect Wiring Consult the schematic on page 8 for proper connections and assistance in connecting wires. Locate the Brake Applied Switch on the front of the master cylinder. Expose the wiring approximately 3-6 from the switch. Cut the black wire, then strip both ends and attach a blue Posi-Lock connector. w/yellow tracer Run the blue and green wires that were brought through the firewall them to the connectors just attached to the Black wire w/yellow tracer. and connect For 1999-2003 Powerstrokes, Run the pink wire that was brought through the firewall and tap into the EBP valve wiring harness using a black (14-18ga) or grey (18-22ga) Posi-Tap. For 1994-1997 Powerstrokes, disconnect the EBP valve wiring harness connection (see page 8) and tee in the small harness supplied with this kit (1300742). Attach the female end of the EBP valve harness into the male end of the BrakeLoc harness, and attach the male end of the EBP valve harness into the female end of the BrakeLoc harness. Use the blue bullet connector supplied to attach the red wire coming off the tee harness to the pink wire attached to the BRAKE terminal of the DFIV module that was brought through the firewall.

6 November 2008 BD BrakeLoc (Ford Powerstroke Manual Transmission) P/N # 1030755 5 EBP Valve & Final Wiring To gain access to the EBP Valve and wiring, remove the top intercooler hose and then remove the sensor hose and wire connector from the MAP sensor.

6 November 2008 BD BrakeLoc (Ford Powerstroke Manual Transmission) P/N # 1030755 6 For ease of access and hook up, remove the connector from the EBP Valve and pull the wiring through and underneath to the front of the intake Y-plenum. This will allow access to install a Posi-Tap or Connector harness.

6 November 2008 BD BrakeLoc (Ford Powerstroke Manual Transmission) P/N # 1030755 7 FORD 1999-2003 (7.3L) FORD 1995-1997 (7.3L) Locate the wire harness at the EBP Valve and peel back the insulation to allow access to the wires. Locate and attach a Posi-Tap to the Grey w/red tracer wire. Install the Gray wire to this connection. Remove the wiring connector from the EBP Valve and install the Red wiring harness with a Posi-Tap connector. Then attach the other end of the Red wire to the end of the Gray wire. Reroute the EBP Valve electrical connector back underneath the intake Y-plenum and reinstall into the EBP Valve. NOTE: After installation, ensure to replace the intercooler hose and clamps. Reattach the MAP sensor hose and wiring connector. Check all connections for security and tightness and secure all wiring to ensure they are out of the way of moving and heated items. Reconnect and secure all battery connections removed at the beginning of this installation.

6 November 2008 BD BrakeLoc (Ford Powerstroke Manual Transmission) P/N # 1030755 8 Wiring Diagram NOTE: After installation ensure to replace the intercooler hose and clamps. Reattach the MAP sensor hose and wiring connector. Check all connections for security and tightness and secure all wiring to ensure they are out of the way of moving and heated items. Reconnect and secure all battery connections removed at the beginning of this installation.

6 November 2008 BD BrakeLoc (Ford Powerstroke Manual Transmission) P/N # 1030755 9 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. Connect a test light to the BRAKE terminal of the DFIV module. 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 test light JUST turns on. CAUTION: THE ADJUSTING SCREW IS A MICRO-SWITCH WHICH 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 test light should turn off just before the engine starts to rev, indicating proper calibration of the DFIV Module with the APPS. Then the test light 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), re- the flange torque bolts. Have any questions? Thank you for purchasing the BD BrakeLoc, please check out our web site at www.bd-power.com for other performance products such as BD PressureLoc, BD Performance Chip or for info on our Performance Transmissions and components please call, fax or E-mail our BD Technical Service or Sales Department, 8:30am to 4:30pm Pacific Time, Monday to Friday.

6 November 2008 BD BrakeLoc (Ford Powerstroke Manual Transmission) P/N # 1030755 10 Ford Exhaust Brake RetroFit Kit (California Trucks) The purpose of this kit is to cure the problematic Ford P-Code in regards to exhaust back pressure being too high. This code is normally set with California Powerstrokes when using an exhaust brake. This kit should only be used on California trucks that exhibit the problem. To install, locate the Exhaust Back Pressure sensor at the front of the engine, just behind the idler pulley and to the left of the water pump outlet hose. Install the supplied Posi- Tap connector on to the Violet with Light Blue wire (2000 03) or the Pink with Light Blue wire (1999). Connect the black wire pigtail to the Posi-Tap connector using the male blade connector. Run the remaining wire away from the belt and the pully and use the nearest engine bolt as a ground. Do not cut or shorten the supplied wire. There is a diode located inside of it.

6 November 2008 BD BrakeLoc (Ford Powerstroke Manual Transmission) P/N # 1030755 11 LIMITED WARRANTY STATEMENT, Valley Fuel Injection Ltd., BD Diesel Performance, Turbocharger.net (the Seller ) warrants the following product(s): All products manufactured or rebuilt by the Seller are to be free from defects in material or workmanship which includes but is not limited to Turbochargers, Exhaust and Intake manifolds, Exhaust brakes, Intercoolers, Flex Plates, Transmissions, Torque Converters, Oil pans, Fuel pumps and systems, Electronic monitors and control systems. The Seller warrants to the original buyer of the product (the Buyer ) that it will repair or replace, free of charge, any product which has a defect in material or workmanship within the warranty period described below. Copy of original invoice is required to qualify for warranty. A defect is defined as a condition within the product that would render the product inoperable under normal conditions of use and service. The Seller s responsibility under this Warranty is limited to the repair or replacement, at the Seller s option, of any warrantable product returned prepaid with a complete service history and proof of purchase. A valid proof of purchase is a dated bill of sale or receipt. A Return Material Authorization (RMA) number, obtained in advance from a customer service representative of the Seller and the dated bill of sale or receipt, must accompany any product returned by the Buyer for warranty determination. The Seller will be the final authority on the approval of all warranty claims hereunder. The issuance of a RMA number does not represent an approval of a warranty claim. All repaired or replaced products will be returned to the Buyer freight collect. Accepted warranty products, which have been replaced, will become the sole property of the Seller. Until the Seller has approved a warranty claim, the Buyer will be responsible for all costs. Replacement parts and the labor costs incurred by the removal and replacement of the product while performing warranty work will be the responsibility of the Buyer. In no case does the obligation of the Seller exceed the original purchase price of the product as indicated on the original bill of sale or receipt. Under no circumstances will the Seller be liable for any travel time incurred in diagnosis for defects, or any other contingent expenses. Once the claim is approved and with in a 1 year period of original purchase Labor costs incurred will be considered for the removal and replacement of an eligible part while performing warranty work, at a rate of 55.00 per hour at authorized centers with prior approval of the Seller. Freight is FOB Abbotsford, B.C. Canada. To the extent permitted by law, the Buyer hereby waives all rights other than those expressly set out herein and acknowledges that this warranty sets out the Buyer s exclusive remedies with respect to products covered by it. This warranty shall not be extended, amended or varied except by written instrument signed by the Seller and the Buyer. The Seller will administer warranty requests on products sold by the Seller and not manufactured by the Seller by forwarding claims made by a Buyer under the manufacturer s warranty to the manufacturer. The final disposition of such claims will be made by the manufacturer and ruled by the laws of British Columbia, Canada. Customer assumes risk in purchasing product with in 30 days may return the product for exchange of other BD products or services only. No cash refunds are available. Please refer to Warranty time limitation per product.

6 November 2008 BD BrakeLoc (Ford Powerstroke Manual Transmission) P/N # 1030755 12 NOT COVERED UNDER THIS WARRANTY This warranty is limited to the original purchaser of the product and is not transferable to subsequent owners. Specifically excluded from this warranty are failures of products caused by misuse, misapplication, negligence of the Buyer, accidents, modification, abuse, improper storage, installation, repair or operation, use of unauthorized parts or other mistreatment of the Buyer or his agent. Any competitive use, sled pulling, drag racing will void warranty on product. A sheared or twisted shaft, broken planetary gear sets, burned clutches, broken drive hubs, sun gear damage, cracked housings is not covered. Fluids and filters or damage caused from fuel or air contamination, BioDiesel, low fluid levels. This warranty does not cover deterioration of plating, paint or any other coating, linings or parts that are subject to normal wear and tear, such as light bulbs, fuses, bearing wear, seal wear, etc. If product is not installed by a trained and authorized BD dealer, installation facility must prove it is properly tooled and has certified training to have installed or to carry out repair of product. The Seller also disclaims any liability for incidental or consequential damages including but not limited to, repair labor, rental vehicles, hotel cost or any other inconvenience cost. To the extent permitted by law, this warranty is in lieu of all other warranties or guaranties, either expressed or implied, included the implied warranties of merchantability and fitness for a particular purpose and shall not extend to any Buyer or to any person other than the original purchaser residing within the boundaries of the continental U.S. or Canada. As well the seller is not responsible or obligated to update previously manufactured parts that are currently under the above warranty. NOTE THAT THIS GUARANTEE WILL BE VOID IF THE USER BREACHES THE CONDITIONS IN THE SECTION LABELED NOT COVERED UNDER THIS WARRANTY AND IS ONLY APPLICABLE ON THE PRODUCTS THE SELLER MANUFACTURES. DISCLAIMER OF LIABILITY Other than as expressly set forth herein, the Seller, together with its distributors, jobbers and dealers shall in no way be responsible for the product s proper use and service. In no event shall the Seller be liable for any special, incidental, indirect or consequential damages of any kind or nature, whether or not the Buyer was advised of the possibility of damage, arising or resulting from the use or performance of the product, and the Buyer hereby waives any and all such claims. The Buyer acknowledges that he/she/it is not relying on the Seller s skill or judgment to select or furnish goods suitable for any particular purpose and that the Seller has no liability that will extend beyond the scope of the limited warranty contained herein, and the Buyer hereby waives all remedies or liabilities, expressed or implied, arising by operation of law or otherwise, (including, without limitation, any obligations of the Seller with respect to fitness for any particular purpose; merchantability; and special, incidental, indirect or consequential damages) or whether or not occasioned by the Seller s negligence. The Seller disclaims any warranty and expressly disclaims any liability for personal injury or damages related to the Buyer s use of the product. 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 the Seller and hold the Seller harmless from any claim related to the product and its use or performance. Under no circumstances will the Seller be liable for any damages, liabilities, costs or expenses incurred as a result of by reason of the use, performance or sale of the product, including without limitation, any damages, liabilities, costs or expenses incurred by reason of the Buyer s negligence related to those uses of the product as a result of the removal of the speed limiter. The Seller assumes no liability regarding the improper installation or misapplication of the product. It is the installer s responsibility to check for proper installation, and, if in doubt, contact the manufacturer.

6 November 2008 BD BrakeLoc (Ford Powerstroke Manual Transmission) P/N # 1030755 13 Product Name Limited Warranty Details Parts Labour (Months/Miles) 1 (Months/Miles) 1, 2 Notes Torque Converters (Dodge) 36/ 150,000 12/12,000 Torque Converters (Ford & Allison) 36/ 150,000 12/ 12,000 Transmissions 36/ 150,000 12/ 24,000 Race Transmissions 12/ 24,000 Not Eligible Valve / Accumulators Bodies 12/ 24,000 12/ 24,000 Transmission Pans 36/ 150,000 Not Eligible Auto / Torq / Towloc s 12 / 24,000 Not Eligible Flex Plates 36/ 150,000 Not Eligible Injectors & Injection Pumps 12 / 24,000 12/ 24,000 Tuners and Chips Manufacturer 3 Not Eligible X-Monitor / Cool Down Timers 12/ 24,000 Not Eligible Intake / Exhaust Manifolds 36/ 75,000 Not Eligible Exhaust Kits 24 Months Not Eligible Turbo Guards / Boost Builders / Waste Gate Kits 12/ 24,000 Not Eligible Intercoolers / Hoses / Clamps 12/ 24,000 Not Eligible Transmission Coolers Manufacturer 3 Manufacturer 3 Manual Transmission Clutches Manufacturer 3 Manufacturer 3 Short Shifters 12/ 24,000 Not Eligible Engine / Head Stud kits Manufacturer 3 Manufacturer 3 Engine Brakes 24/ 24,000 12/ 24,000 Steering Stabilizers / Sway bars 12/ 24,000 Not Eligible Boost Coolers Manufacturer 3 Manufacturer 3 Gauges and Mounts Manufacturer 3 Manufacturer 3 Performance Turbos 12/ 12,000 Not Eligible FlowMAX Fuel Pumps 60/ 75,000 Not Eligible Auxiliary Fuel Pumps 12/ 12,000 Not Eligible No Race abuse covered No Race abuse covered No Race abuse covered Race Pumps 90 days parts/no labour Surface rust not eligible A Return Material Authorization (RMA) number, obtained in advance from a customer service representative of the Seller and the dated bill of sale or receipt, must accompany any product returned by the Buyer for warranty determination. 1 Warranty is based on whichever occurs first (Months or Mileage). 2 Prior approvals must be given to qualify for labour reimbursement. 3 As per Manufacturer s warranty