How to Install a BD Diesel EZ Amp and Increase Horsepower Part 1/3

Dave: Alright folks, here is what's going on. Sam just got himself a brand new toy, brand new pickup truck, show what it's all about Sam. Sam Ness: Well it's a new 3500 series Chevrolet, the Silverado. 2002 model with a 6.6 turbo diesel, allison, 5-speed, plenty of power, great for hauling. Dave: Yeah, well guess what he did? The first thing he did, he brought it into the shop, put it on the dyno, wanted to check it out see what kind of horsepower it got. Sam Ness: Numbers were pretty good. Dave: They were very good, but not enough for Sam. Sam Ness: Right. So we are going to have to hop it up a little bit because whenever you increase the performance you got to do a couple of other things. One, you got to be able to stop it. If you want to take advantage of the high compression of a diesel engine, what we've got here is an exhaust brake, we'll show you all about this we're going to install our exhaust brake, which will really slow the truck down. Dave: Yeah and you know what's interesting about it, when you got a truck like this, you can pull and haul a lot more than you really think you can't, of course, then you don't have anyway to stop it, that's where you got to have that brake on there. Sam Ness: Absolutely! Dave: Well the other part about it though is it's easy to hop up the engine that really make it perform, because it's got a computer on it and all we have to do here is just plug-in our ECM and TCM or this is Engine Control Management system, Transmission Control Management; all here in this little computer. Sam Ness: So we're going to size the fuel timing, the fuel injection duration all that kind of stuff, monitor the transmission. First, that we got to do though is disconnect batteries and put this thing up in the air. Dave: Let's keep going. Sam Ness: Alright, like any other kit you want to think safety, read the instructions, this can size and take you through step-by-step. First step in the BD diesel is to mount it, we find the intermediate exhaust pipe, which is from the flange back to the muffler not the down pipe, this 4 bolts, this is where our exhaust brake is going to mount. You can see, it's got a nice flange in a same way; we'll go ahead and put this up here. Now to adapt it, we're going to need to cut this pipe so you want to read the instructions carefully, know exactly where you're going to cut it. Now of course, this one here is a 3-and-a-half inch exhaust that came from the factory, that's a stand exhaust. BD has a high performance 4 inch exhaust system, if you buy that system, the brake would still work, if they got the adapter, they got you covered. First thing I do is, I like to take and put a little bit of solvent on these bolts because this is a new truck but still you never know, you want to go all the thread. I take a little silicon and I put it on these rubber bumpers, okay, the exhaust tank as when you pop them off, they'll come off really will drop this down, we're ready to mount our brake. Perfectly square the line was crooked. Alright now what I do with that I cleaned up my cut and I've driven in the flange adapter that comes in the kit, really nothing to it. They of course have a clamp around here, and then there is this special clamp -- always clamp come in the kit. Right up here I put the gasket that comes in it on the flange. Here we'll be ready to mount our exhaust brake and you can see, we put it right up here; you want to make sure you put the new gasket, the flange is clean, so that way you'll have a nice good seal right there, that will go like that. Dave: And about we get started on that. Let me give you a hand, I want to get this pipe out right here, okay? Sam Ness: Alright. Dave: So what I want to do is I'm going to mark it, so I can put that weld in that fitting, drill it in, weld it, so we can put that sensor in there, okay. Sam Ness: I was wondering why you took that lose. Dave: Aright. Sam Ness: Alright well Dave's taking that and putting our adapter in for a sensor, I am going to take this solenoid right here, this revert here, over to the brake to operate the brake, passing a hole in the frame that's already drilled so to go right up here. Dave: Well I got back in after a fashion Sam, watch your head there. Sam Ness: Aright, well there is rustling in the downpipe, shows you the exhaust brake is going to mount right onto the end of that flange. We also have a little stainless steel tubing arrangement with some fittings, it's going to go on here, this will allow us to run a tube up and we can mount it at the back pressure of this exhaust brake. Dave: Brake? Sam Ness: Yeah. Dave: Did I hear brake? Sam Ness: Yeah you heard brake. Dave: I think it's a good idea. we're going to take when we come back; we're going to continue working on Sam's diesel, so stay with us.