BD Diesel Performance 1036700 Installation Instructions Manual
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BD Diesel Performance 1036700 Installation Instructions Manual

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4 February 2010
Ford 7.3L 1999.5-2003 Positive Air Shutoff
1999.5-2003 Ford 7.3L Powerstroke
Positive Air Shutoff
1036700
P/N#
1036700-M
P/N#
PLEASE READ ALL INSTRUCTIONS BEFORE INSTALLATION
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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  • Page 1 4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 1999.5-2003 Ford 7.3L Powerstroke Positive Air Shutoff 1036700 P/N# 1036700-M P/N# PLEASE READ ALL INSTRUCTIONS BEFORE INSTALLATION 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...

  • Page 2: 1036700 Kit Contents

    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 your truck. 1036700 Kit Contents 1302300 1407001 1302253 1405404 3”-3”...

  • Page 3: 1036700-M Kit Contents

    4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 1036700-M kit Contents 1302300 1407001 1302253 1405404 3”-3” Upper 3”-3 ¼” Silicone Air Shutoff Valve Wiring Harness Silicone Boot Boot Qty: 1 Qty: 1 Qty: 1 Qty: 2 1302268P 1302269P 1405212...

  • Page 4: Table Of Contents

    MAINTENANCE........................ 5 INSTALLATION with OVER SPEED ELECTRONICS (1036700) ........5 INSTALLATION without OVER SPEED ELECTRONICS (1036700-M) ......15 WIRING DIAGRAM with OVER SPEED ELECTRONICS (1036700) ......21 WIRING DIAGRAM without OVER SPEED ELECTRONICS (1036700-M) ..... 22 RESETTING THE VALVE ....................23 SETUP, TESTING AND VERIFICATION with OVER SPEED ELECTRONICS ....

  • Page 5: Maintenance

    Ford 7.3L 1999.5-2003 Positive Air Shutoff MAINTENANCE No maintenance is needed other then check to make sure the valve is acting correctly. Please see the testing section later in the manual for the correct procedure. INSTALLATION with OVER SPEED ELECTRONICS (1036700) VEHCILE SHOULD SAFELY...
  • Page 6 4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff AIRFLOW 1405404 1302268P 1302300 1302269 1407001 All springs should be tightened until springs binds. 3. First install the new BD lower Charge Air Cooler (CAC) tube (#1302268P) to the CAC. You will utilize the stock clamps and silicone boot for the lower connection. 4.
  • Page 7 4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff Switch end of wiring harness & yellow wire should be routed through the kick panel. 9. Lay out supplied harness over top of the passenger’s side of the engine. 10. You will then need to route the switch wires as well as the yellow ignition power through the firewall on the...
  • Page 8 4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 11. Using a 1/8” drill, drill a pilot hole in the location you have selected for the switch to be mounted. Finally using a ½” UNIBIT drill bit, drill an exact ½” round hole.
  • Page 9 4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff Mount the switch so that the groove on thread boss is facing down. Adjust the HEX washer/nut so that the switch threads do not protrude an unsightly amount. Then apply the supplied sticker and finally install the round plastic nut.
  • Page 10 4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff On the front of the engine locate Camshaft Position Sensor (#14 in diagram). Once you have located the sensor, trace back wiring harness and locate a long section that will be easy to splice into.
  • Page 11 4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff Pin 21 Dark Green Please note that this view is with the plug disconnected look into the plug. You will need to mirror this view. 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...
  • Page 12 4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 17. Being that the RPM signal is critical you will need to solder the connection. Using wire strippers create 1” window/gap insulation of the wire. Then strip about 1” insulation of the RPM signal wire of the BLUE wire from the PAS wiring harness.
  • Page 13 4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 18. Next on the wiring harness connection the BLACK and RED wires to the respective battery connections (Driver’s Side Battery). 19. For the last connection you will need to locate ignition power.
  • Page 14 4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff close lid and kick panel. Mount the electronic control unit on the driver’s side, to the rear of the battery. Be sure to clean the mounting surface with alcohol before applying Velcro. Connect the wiring harness to the electronic control unit.

  • Page 15: Installation Without Over Speed Electronics (1036700-M)

    4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff INSTALLATION without OVER SPEED ELECTRONICS (1036700-M) VEHCILE SHOULD SAFELY SECURED BEFORE INSTALLATION. 1. Block the wheels of the vehicle to prevent the vehicle from rolling. Open the hood. 2. Remove passenger’s...
  • Page 16 4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff AIRFLOW 1405404 1302268P 1302300 1302269 1407001 All springs should be tightened until springs binds. 3. First install the new BD lower Charge Air Cooler (CAC) tube (#1302268P) to the CAC. You will utilize the stock clamps and silicone boot for the lower connection. 4.
  • Page 17 4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 9. Lay out supplied harness over top of the passenger’s side of the engine. And locate and connect the weather pack connector on the wiring harness to the solenoid on the PAS valve. 10.
  • Page 18 4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff Using a 1/8” drill, drill a pilot hole in the location you have selected for the switch to be mounted. Recommended location Finally using a ½” UNIBIT drill bit, drill an exact ½” round hole.
  • Page 19 4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff Mount the switch so that the groove on thread boss is facing down. Adjust the HEX washer/nut so that the switch threads do not protrude an unsightly amount. Then apply the supplied sticker and finally install the round plastic nut.
  • Page 20 4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 14. For the last connection you will need to locate ignition power. Locate kick panel underneath steering wheel. Remove the kick panel and then the junction box cover. Locate appropriate fused ignition power circuit (see Fuse #29 (10 AMP) table below).

  • Page 21: Wiring Diagram With Over Speed Electronics (1036700)

    4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff WIRING DIAGRAM with OVER SPEED ELECTRONICS (1036700) 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...

  • Page 22: Wiring Diagram Without Over Speed Electronics (1036700-M)

    4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff WIRING DIAGRAM without OVER SPEED ELECTRONICS (1036700-M) 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...

  • Page 23: Resetting The Valve

    4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff RESETTING THE VALVE Valve Activated (Closed) Valve Reset (Open) Rotate lever and lock in position to reset 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...

  • Page 24: Setup, Testing And Verification With Over Speed Electronics

    4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff SETUP, TESTING AND VERIFICATION with OVER SPEED ELECTRONICS Engine Idle Speed Frequency Each unit is specifically configured for each model of 1999.5-03 Ford 7.3 truck. As in the case of different model years and 140-160 Hz makes the engine RPM frequency is different.
  • Page 25 4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 5. With the valve reset, remove the outer enclosure from the control module. There are two locking tabs on the sides of the enclosure. 6. Change the position selection switch to position #2 (Auto Test). Slide enclosure cover over circuit board.

  • Page 26: Manual Mode (User Configured Rpm)

    4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff toggle switch should flash. board, it should flash proportionally to the engine RPM. 8. Reset the valve and reset the mode position switch to position #1 You are now complete and the unit should function correctly. This test cycle should be completed once a year.
  • Page 27 4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff PRESS & 3. Start the engine. HOLD Button 4. Press and hold the RPM SET button. When you push the SET RPM button will see the “RPM Set” LED illuminate. RPM Set 5.
  • Page 28 4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff them step on the accelerator with the PRESS & HOLD vehicle in park. Raise the engine RPM Button to MAXIMUM engine RPM. 11. Release the SET RPM button. RPM Set Upon releasing the button the unit will RELEASE TO store the RPM + 25%.

  • Page 29: Testing Flow Chart With Over Speed Electronics

    4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff TESTING FLOW CHART with OVER SPEED ELECTRONICS Manual Mode Automatic Mode Start Vehicle Start Vehicle Activate PAS valve using manual switch Activate PAS valve using manual switch Did Valve Activate Check Wiring Check Did Valve Activate Wiring...

  • Page 30: Testing Flow Chart Without Over Speed Electronics

    4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff TESTING FLOW CHART without OVER SPEED ELECTRONICS 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...

  • Page 31: Led Operation

    4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff LED OPERATION Description POWER Illuminates when unit is POWERED RPM SET Illuminates when SET Button is Pressed RPM Signal Flashes proportional to Engine RPM Ground Sense Illuminates when a GROUND signal is sensed on the activation line or when the solenoid is disconnected.

This manual is also suitable for:

1036700-m

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