BD Diesel Performance 1036700 User manual

4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 1
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: [phone] Fax: [phone] Internet: www.bd-power.com
1999.5-2003 Ford 7.3L Powerstroke
Positive Air Shutoff
P/N#
1036700
P/N#
1036700-M
PLEASE READ ALL INSTRUCTIONS BEFORE INSTALLATION

4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 2
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: [phone] Fax: [phone] Internet: www.bd-power.com
KIT CONTENTS:
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
Air Shutoff Valve
3”-3” Upper Silicone
Boot
Wiring Harness 3”-3 ¼” Silicone Boot
Qty: 1
Qty: 1
Qty: 1
Qty: 2
1302268P
1302269P
1405212
1407030
Lower CAC Pipe
Upper CAC Pipe
3.78” HD Clamps
3.50” Clamps
Qty: 1
Qty: 1
Qty: 2
Qty: 2
1800060
1301381
1306700
1302285
Velcro strips Heat Shrink
Ford Electronic
Module
Solder
Qty: 2 x 4”
Qty: 3”
Qty: 1
Qty: 5”

4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 3
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: [phone] Fax: [phone] Internet: www.bd-power.com
1036700-M kit Contents
1302300
1407001
1302253
1405404
Air Shutoff Valve
3”-3” Upper
Silicone Boot
Wiring Harness
3”-3 ¼” Silicone
Boot
Qty: 1
Qty: 1
Qty: 1
Qty: 2
1302268P
1302269P
1405212
1407030
Lower CAC Pipe
Upper CAC Pipe
3.78” HD Clamps
3.50” Clamps
Qty: 1
Qty: 1
Qty: 2
Qty: 2

4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 4
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: [phone] Fax: [phone] Internet: www.bd-power.com
WELCOME
Thank you for purchasing a BD positive air shutoff. This manual is divided into different
areas to assist you with your installation and operation of your positive Air shutoff.
This product is a safety product and should be tested often.
Installation should occur on a vehicle properly secured to prevent rolling.
TABLE OF CONTENTS
1036700 Kit Contents.......................................................................................................2
1036700-M kit Contents....................................................................................................3
REQUIRED TOOLS..........................................................................................................4
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...............24
Automatic Mode (Pre Configured RPM)......................................................................24
Manual Mode (User Configured RPM) ........................................................................26
TESTING FLOW CHART with OVER SPEED ELECTRONICS......................................29
TESTING FLOW CHART without OVER SPEED ELECTRONICS.................................30
LED OPERATION...........................................................................................................31
REQUIRED TOOLS
•Frequency/Voltmeter (Optional)
•Drill
•1/8” Drill Bit
•½” Unibit
•7/16”, ½” Sockets
•Wire Strippers
•Electrical Tape
•Soldering Iron
•Air or Manual Ratchet
•Wire Cutters
•Heat Gun

4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 5
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: [phone] Fax: [phone] Internet: www.bd-power.com
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 SHO
ULD BE SAFELY SECURED BEFORE
INSTALLATION.
1. Block the wheels of the vehicle to prevent the vehicle from rolling.
Open the hood.
2. Remove passenger’s
side
charge air cooler
(CAC) pipe and upper
silicone boot
using a
7/16” socket and
ratchet.
Keep all spring clamps
as you will be reusing
them.

4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 6
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: [phone] Fax: [phone] Internet: www.bd-power.com
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. Next, insert the two 3-3¼”
boots (#1405404) over each end of the PAS valve.
Tighten this connection with 2 of the 3.78” (#1405212) spring clamps. Tighten
until spring bound.
5. Then install t
he PAS/Boot assembly to the lower CAC pipe you installed earlier.
Rotate the assembly as the valve our pipe do not contact any other components.
Secure this connection with the 3.5” (#1407030) spring clamp.
6. Finally install the upper CAC pipe (1302269P) to the PAS/Boot assembly. Again
secure this connection with 3.5” (#1407030) spring clamp.
7.
Lastly, install the 3” boot (#1407001) to the upper CAC pipe and the stock
aluminum compressor manifold. You will utilize the factory clamps for this
location.
8. Ensure the assembly does not contact anything.
1302268P
1302269
1405404
1302300
AIRFLOW
1407001

4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 7
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: [phone] Fax: [phone] Internet: www.bd-power.com
9. L
ay 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
driver’s side (note
you will
need to remove the switch
from the harness to
accomplish this).
Choose a highly visible
location for the switch and
mount it to the dash.
Recommended location
Switch end of wiring harness & yellow
wire should be routed through the kick
panel.

4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 8
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: [phone] Fax: [phone] Internet: www.bd-power.com
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.
12.
Once you have the
mounting hole drilled,
insert the switch from the
backside.
Reinstall the correct wires to
the correct switch terminals.

4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 9
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: [phone] Fax: [phone] Internet: www.bd-power.com
13. 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.
14. Now underneath the
hood l
ocate and connect
the weather pack
connector on the wiring
harness
to the solenoid
on the PAS valve.

4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 10
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: [phone] Fax: [phone] Internet: www.bd-power.com
15.
On the front of the
engine locate the
Camshaft Position
Sensor (#14 in diagram).
Once you have located the
sensor,
trace back the
wiring harness and locate a
long section that will be
easy to splice into. Locate
the correct wire color and
pull back loom and expose
wire.
Year
Wire Color
1999-2003
Dark Green
16.
As an alternate you can
a
lso connect to the CAM
position sensor wire at the
ECM. The ECM is located
at the rear of the fire wall
driver’s side. It is below the
master cylinder.

4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 11
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: [phone] Fax: [phone] Internet: www.bd-power.com
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.

4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 12
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: [phone] Fax: [phone] Internet: www.bd-power.com
17. Being that the RPM signal is
critical you will need to
solder the connection.
Using wire strippers create
a 1” window/gap in
insulation of the wire.
Then
strip about 1” of
insulation of the RPM signal
wire of the BLUE wire from
the PAS wiring harness.
Wrap the copper wire
around the factory RPM
signal
wire and solder this
connection.
Then use electrical tape to
wrap this connection so that
it is water tight.
You can also cut the factory
crank signal wire and use
heat shrink tubing if you
would like.
Solder the connection and then wrap
and seal with electrical tape

4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 13
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: [phone] Fax: [phone] Internet: www.bd-power.com
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. This will power the
automatic over speed
control box LED switc
h.
Note that they unit can still
be activated manually with
the switch at any time.
Locate the kick panel
underneath the steering
wheel. Remove the kick
panel and then the junction
box cover.
Locate appropriate fused
ignition power circuit (see
table
below). Install fuse
tapper on to fuse, reinstall
fuse. Connect yellow lead
wire with flag connector to
this new connection. Route
wire out of the box and
Fuse #29 (10 AMP)

4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 14
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: [phone] Fax: [phone] Internet: www.bd-power.com
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.
20.
Double check all wiring connections and ensure wires are routed away from any
heat sources and moving parts.

4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 15
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: [phone] Fax: [phone] Internet: www.bd-power.com
INSTALLATION without OVER SPEED ELECTRONICS
INSTALLATION without OVER SPEED ELECTRONICS (1036700-M)
VEHCILE SHOULD BE SAFELY SECURED BEFORE
INSTALLATION.
1. Block the wheels of the vehicle to prevent the vehicle from rolling.
Open the hood.
2.
Remove passenger’s
side charge air cooler
(CAC) pipe and upper
silicone boot using a
7/16” socket and
ratchet.
Keep all spring clamps
as you will be reusing
them.

4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 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: [phone] Fax: [phone] Internet: www.bd-power.com
INSTALLATION without OVER SPEED ELECTRONICS
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. Next, insert the two 3-
3¼” boots (#1405404) over each end of the PAS valve.
Tighten this connection with 2 of the 3.78” (#1405212) spring clamps. Tighten until
spring bound.
5. Then install the PAS/Boot assembly to the lower CAC pipe you installed
earlier.
Rotate the assembly as the valve our pipe do not contact any other components.
Secure this connection with the 3.5” (#1407030) spring clamp.
6. Finally install the upper CAC pipe (1302269P) to the PAS/Boot assembly. Again
secure this connection with 3.5” (#1407030) spring clamp.
7. Lastly, install the 3” boot (#1407001) to the upper CAC pipe and the stock aluminum
compressor manifold. You will utilize the factory clamps for this location.
8. Ensure the assembly does not contact anything.
1302268P
1302269
1405404
1302300
AIRFLOW
1407001

4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 17
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: [phone] Fax: [phone] Internet: www.bd-power.com
INSTALLATION without OVER SPEED ELECTRONICS
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.
You will then need to route
the switch wires as well as
the pink igni
tion power
through the firewall on the
driver’s side (note you will
need to remove the switch
from the harness to
accomplish this).
Choose a highly visible
location for the switch and
mount it to the dash.
NOTE: you may need to
trim the switch wires to
l
ength once you have
located where the switch is
to be mounted.
Switch end of wiring harness & pink
wire should be routed through the kick
panel.

4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 18
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: [phone] Fax: [phone] Internet: www.bd-power.com
INSTALLATION without OVER SPEED ELECTRONICS
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.
11. Once you have the
mounting hole drilled, crimp
the switch connectors to the
switch wires and install the
correct wires to the correct
switch terminals. Then
insert the switch into the
dash from the backside.
Recommended location

4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 19
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: [phone] Fax: [phone] Internet: www.bd-power.com
INSTALLATION without OVER SPEED ELECTRONICS
12.
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.
13. Next trim the wires to length
and crimp the ring terminals
to the BLACK and RED
wires to connect to the
respective battery
connections.
(Drivers Side Battery).

4 February 2010 Ford 7.3L 1999.5-2003 Positive Air Shutoff 20
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: [phone] Fax: [phone] Internet: www.bd-power.com
INSTALLATION without OVER SPEED ELECTRONICS
14.
For the last connection you
will
need to locate ignition
power.
Locate the kick panel
underneath the steering
wheel. Remove the kick
panel and then the junction
box cover.
Locate appropriate fused
ignition power circuit (see
table below). Install fuse
tapper on to fuse, reinstall
fuse.
Trim the pink wire to
l
ength and crimp the flag
connector to the wire and
connect the pink
lead wire
with flag connector to this
new connection. Route wire
out of the box and close lid
and kick panel.
Fuse #29 (10 AMP)
15. Double check all wiring connections and ensure wires are routed away from any
heat sources and moving parts.
Then install the loom with the supplied tee
connector and clips for the loom ends and continue to the testing flow chart without
engine over speed electronics in this manual.