19 November 2008
BD X-Monitor 2 #
1080500
8
BD Engine Brake Inc
A10 – 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
Ship: #88 – 446 Harrison St, Sumas, WA 98295 Mail: PO Box 231, Sumas, WA 98295
Ph: 604.853.6096 Fax: 604.853.8749 Internet: www.bd-power.com
Post-Turbo Installation
Drill a 21/64 hole into your turbo down pipe. There is no need for the engine to idle or to
remove the exhaust piece from the truck. The metal shavings will simply exit the exhaust
system when you run the engine.
Use a 1/8-27 or 1/8NPT tap to make threads in the hole you just drilled. You will not want
to run the tap all the way into the manifold. This is a tapered tap, meaning that the
threads at the top are larger than the ones on the bottom. You need to tap it far enough
to screw the thermocouple bushing into the exhaust pipe.
Screw the thermocouple bushing into the pipe. Be careful not to over tighten because it is
easy to strip the threads in the thin exhaust pipe.
Insert the supplied thermocouple into the bushing and tighten the locking nut.
Wiring Installation
Dodge 1998-2002 5.9L
1. Find the lead wire. This is a 2-wire harness with an orange and black wire. The
larger connector needs to be connected to the thermocouple.
2. Route the lead wire across the engine bay to the driver’s side. Tie the lead wire out
of the way of any moving or hot parts to avoid damage to the wires.
3. On the driver’s side firewall there is a rubber plug. Cut a slit in the outer portion of
the plug to route the small connector and wire into the cab.
4. Plug the small 2-wire plug into the corresponding plug on the cable harness.
5. Lay wiring harness #1 out on your engine. The green plug will go inside the cabin
using the same location you routed the lead wire through.
6. Locate the engine’s MAP sensor. This is on the driver’s side of the engine and
behind the fuel filter canister. The year model determines the shape of the
connector.
a. For 1998-2000 trucks, the MAP sensor is round (triangle). There are 2 wires
in the top of the plug and 1 wire in the bottom of the plug. Connect the
supplied T-Tap to the wire that is on the bottom of the plug. This should also
be labeled pin “C” on the connector.
