jacobs exhaust brake · cummins isb engine with a manual transmission. the jacobs exhaust brake kit...

InstallationManual

For 2003, 2004, and 2004.5 Dodge Ram TrucksEquipped with the Cummins ISB 5.9 Engine

And Manual Transmission

®

Jacobs Exhaust Brake®

Please see Web Site for latest instructions

www.jakebrake.com

2 CUMMINS E BRAKE BY JACOBS FOR DODGE RAM INSTALLATION MANUAL

Table of ContentsSection 1: Preparation .................................................... 3

Section 2: Installing the Exhaust Brake ........................... 6

Section 3: Installing the Pneumatic Group ...................... 7

Section 4: Installing the Vacuum System ........................ 9

Section 5: Installing the Wiring Harnesses .................... 11

Section 6: Installing the Vacuum Supply Hose ............. 17

Section 7: Installing the Brake Switch ........................... 18

Section 8: Installing the ECM Connection ..................... 19

Section 9: Completing the Installation .......................... 20

Section 10: Operational Check ..................................... 21

Section 11: Exhaust Brake Features ............................. 22

Section 12: Troubleshooting ......................................... 23

IntroductionThe procedures for installing the brake system areorganized into twelve main sections, with each sectiondetailing the installation of related components. Westrongly recommend that you perform the procedures inthe order in which they are presented. The last section liststroubleshooting procedures, in case you are experiencingproblems with the Jacobs Exhaust Brake®.

Safety PrecautionsThe following symbols in this manual signalconditions potentially dangerous to the mechanic orequipment. Read this manual carefully. Know whenthese conditions can exist. Then take necessarysteps to protect personnel as well as equipment.

THIS SYMBOL WARNS OF POSSIBLEPERSONAL INJURY.

THIS SYMBOL REFERS TO POSSIBLEEQUIPMENT DAMAGE.

NOTE: INDICATES AN OPERATION, PROCEDURE ORINSTRUCTION THAT IS IMPORTANT FOR CORRECTSERVICE.

Fuels, electrical equipment, exhaust gases andmoving engine parts present potential hazards thatcould result in personal injury. Take care wheninstalling equipment or parts. Always wear safetyglasses. Always use correct tools and follow properprocedures as outlined in this manual.

For additional information or technical support, contactCummins Customer Assistance Center by calling 1-800-DIESELS (1-800-343-7357).

Application NotesThe Jacobs Exhaust Brake kit (Cummins P/N 4089427 orMopar P/N 82208277), has been specifically engineered tofit your 2003 or 2004 Dodge Ram truck equipped with theCummins ISB engine with a manual transmission. TheJacobs Exhaust Brake kit (Cummins P/N 4089598 orMopar P/N 8220828835), has been specifically engineeredto fit your 2004.5 Dodge Ram truck equipped with theCummins ISB engine with a manual transmission. All partsare included in the kit, allowing installation without requiringany fabrication.

Special Tools andMaterials RequiredYou should have the following tools and materials beforeyou begin this installation:

• Rust penetrant, such as Liquid Wrench®

• Battery terminal puller

• Common hand tools such as metric wrenches,screwdrivers and pliers.

• Torque wrenches

• Drill with a ¼” bit

• #56 (3/64") Drill bit or back probe tool (mopar), orpaper clip to remove ECM sealing plugs

• Knife or other tool for cutting the rubber vacuum hose

• Clean shop towels

• Teflon® pipe sealant

• Loctite® 242 or equivalent

• Volt/Ohm Meter or test light

• 4 mm Ball End Hex Driver or Hex Wrench

• Electrical Tape

• Heat Gun

• Dielectric Grease

• Miller Connectocr Tool #6680 (or very small thinbladed screwdriver)

For Manual Transmission Vehicles Only!

NOTE: IF YOU HAVE A VEHICLE WITHOUT AIRCONDITIONING, YOU WILL NEED TO PURCHASE ADIFFERENT ACCESSORY DRIVE BELT CUMMINSPART NUMBER 4025090 (LENGTH WILL BE 2,892MM/113.9 IN).

CUMMINS E BRAKE BY JACOBS FOR DODGE RAM INSTALLATION MANUAL 3

Section 1: Preparation

Fig. 1

Fig. 2

Fig. 3

NOTE: WITH THE BATTERIES CONNECTED,DISCONNECTING THE VEHICLE POWERCONNECTOR CONTAINING KEY SWITCHED POWERWILL RESULT IN FAULT CODES BEING RECORDEDIN THE VEHICLE ECM AND ABS MODULE. TOPREVENT THIS, SWITCHED 12 VOLT POWER NEEDSTO BE FOUND WITHOUT DISCONNECTING THEVISTRONIC FAN CONNECTORS.

1. Locating key switched power.

For MY2003 vehiclesFor MY2003 vehiclesFor MY2003 vehiclesFor MY2003 vehiclesFor MY2003 vehicles

a. Locate the Vistronic fan connector, located on the topside of the dash panel in the passenger side corner.(see figure 1)

b. Locate the Solid Dark Blue wire in the right sideconnector pin 13. This should be 12 volt key switchedpower. Check this pin with a volt/ohm meter or testlight with a hard point test lead, back probe tool orpaper clip. (see figure 2)

c. It should read 12 Volts with the key in the on positionand no voltage when the key is off. If pin 13 does nothave key switched power, test the other pins. Whenyou have found the key switch power use this pin andwire in place of the Solid Dark Blue wire. (see figure 3)

d. Record the color of the wire and the pin number thatyou have found to have 12 volt switched power.

Wire Color: ______________________________________

Pin Number: _____________________________________

Fig. 1


A B C1

8

For My2004 and 2004.5 vehiclesFor My2004 and 2004.5 vehiclesFor My2004 and 2004.5 vehiclesFor My2004 and 2004.5 vehiclesFor My2004 and 2004.5 vehicles

a. Locate the two 24-pin connectors located on the topside of the dash panel on the driver's side. The leftconnector is gray, the right connector black. Keyswitched power is in the black connector (see figure 4)

b. Locate the Pink w/Gray Stripe wire in the blackconnector, pin location B4. This should be 12 volt keyswitched power. Check this pin with a volt/ohm meteror test light with a hard point test lead, back probetool or paper clip. (see figure 5)

c. It should read 12 Volts with the key in the on positionand no voltage when the key is off. If pin B4 does nothave key switched power, test the other pins. Whenyou have found the key switch power use this pin andwire in place of the Pink with gray stripe wire. (seefigure 6)

d. Record the color of the wire and the pin number thatyou have found to have 12 volt switched power.

Wire Color: ______________________________________

Pin Number: _____________________________________

Fig. 4

Fig. 5

Fig. 6


2. Disconnecting Batteries.

NOTE: WHEN YOU DISCONNECT THE BATTERIES, THEMEMORY OF THE CLOCK WILL BE LOST.

a. Use a battery terminal puller to disconnect thenegative (-) leads from both batteries. (see figure 7)

b. Use a battery terminal puller to disconnect the positive(+) leads from both batteries. (see figure 7)

c. Loosen and remove the clamps that hold the batteriesfirmly in the battery trays. (see figure 7)

d. Remove the batteries from both sides of the vehicle.

3. Removing front wheel wells.

NOTE: To allow for ease in installation of the exhaustbrake assembly and gain access to ECM it isrecommended that both front wheel wells be removedto gain access.

a. To facilitate removal of the front tires and wheel wells,use a floor jack or lift to elevate the front axle.

MAKE SURE TO SUPPORT THE VEHICLEPROPERLY (JACK STANDS) AS YOU WILLBE WORKING UNDER IT.

b. Remove both front tires. (see figure 8)

c. Remove the front wheel wells by loosening andremoving the eight (8) capscrews attaching the wellto the truck fender. Pull the wheel well down toexpose the ABS cable. Remove the ABS cable fromthe wheel wells and set the wheel wells aside. (seefigure 9 and 10)

Fig. 8

Fig. 9

Fig. 10

Fig. 7


1. Remove the existing Exhaust Elbow that mounts tothe rear of the Turbocharger. (see figure 11 and 12)

a. Loosen (11 mm socket) the “V” clamp that attachesthe exhaust pipe to the exit side of the elbow. Slidethe “V” clamp over the exhaust pipe away from theelbow. Retain this clamp for use in installation of thebrake. (See figure 12)

b. Loosen (10 mm socket) and remove the “V” clampthat attaches the elbow to the exhaust side of theturbocharger. Retain this clamp for use in installationof the brake. (See figure 12)

c. Remove the elbow from the vehicle. This elbow can bereused if the exhaust brake is removed.

2. Attach the Exhaust Brake Assembly to theTurbocharger.

a. The gasket supplied in the kit is for use between theturbocharger and the exhaust brake housing. Thisgasket is adhesive-backed to ease installation. Cleanthe gasket surfaces of the turbo outlet and the exhaustbrake assembly, making sure the surfaces are free ofdirt, grease and oil. Remove the paper backing fromthe gasket and adhere the gasket to the exhaust inlet(turbocharger) side of the exhaust brake assembly. Ifthe surface is not clean or dry the gasket will notadhere. If the gasket does not adhere, the 'V" clampwill hold it in place.

b. Place the “V” clamp previously removed from theexhaust side of the turbocharger on the brake’sexhaust inlet flange. This will help hold the gasket inplace when installing the exhaust brake.

c. Align the exhaust brake, with gasket and clamp,between the turbocharger outlet and exhaust pipe.Install the brake to the turbocharger using the “V”clamp. (see figure 13)

d. Tighten the clamp enough to hold the brake flush withthe turbocharger outlet. DO NOT torque the clamp atthis time.

3. Attach the Exhaust Pipe to the Exhaust BrakeAssembly. (see figure 13)

BE CAREFUL NOT TO DAMAGE THEGASKET BY HITTING IT WHENINSTALLING THE EXHAUST BRAKE OR

WHEN ROTATING THE BRAKE INTO POSITION.

a. Check the alignment of the exhaust pipe to theexhaust brake outlet. If necessary, carefully rotate thebrake until alignment is achieved. (Loosen theturbocharger/brake clamp if necessary)

b. Install the exhaust pipe to the brake using the exhaustpipe “V” clamp.

c. Tighten the clamp enough to hold the exhaust pipeflush with the brake outlet.

Section 2: Installing the Exhaust Brake

Fig. 11

Fig. 12

Fig. 13

4. Complete Brake Assembly Installation. (see figure 13)

a. Torque (10mm socket) the “V” clamp between theturbocharger and exhaust brake.

Torque Value: 8.5 N∙m (75 in-lb)

b. Torque (11 mm socket) the “V” clamp between thebrake and exhaust pipe.

Torque Value: 11.3 N∙m (100 in-lb)


1. Drill Vacuum Solenoid Mounting Holes.

NOTE: THE VACUUM SOLENOID WILL MOUNT ON THEBACK (REAR FACE) OF THE PASSENGER SIDEBATTERY TRAY.

a. Take the brass inserts out of the isolators. Install theisolators into the bracket as shown in figure 14.

b. Reinstall the inserts as shown in figure 14.

c. Using the solenoid mounting bracket as a template, laythe bracket on the inside rear face of the battery trayand mark the two (2) drill holes. For location seefigure's 15 & 16.

d. Using a ¼” drill bit, drill the two mounting holesthrough the battery tray.

2. Using the ¼” drill bit, drill the hole to be used formounting the P-clip. For location see figures 12and 16.

3. Prepare the Solenoid/Bracket for Mounting.

NOTE: USE PIPE SEALANT ON ALL NPT (PIPE THREAD)CONNECTIONS.

a. Attach the 90o hose fitting to the solenoid’s #1 port.Be sure to orient the outlet of the 90o fitting pointingaway from the solenoid’s coil.

b. Attach the straight hose fitting to the solenoid’s #2port.

c. Using Loctite® on the screw threads, attach thesolenoid to the mounting bracket with the two #8-20screws and lock washers supplied in the kit.

4. Mount the Solenoid/Bracket Assembly.

a. Place a flat washer on each of the two M6 x 32 mmcapscrews. Slide the capscrews through the holes inthe battery box so the threads are outside the batterybox.

NOTE: THE HEADS OF THE CAPSCREWS SHOULD BEINSIDE THE BATTERY BOX TO PREVENT DAMAGETO THE BATTERY AND/OR BATTERY BLANKET.

b. Place the solenoid and bracket onto the capscrews sothat the black coil is down. (See figure 17)

c. Place two additional flat washers on the capscrewsand install locking nuts.

Section 3: Installing the Pneumatic Group

Fig. 14

Fig. 15

Fig. 16

Fig. 17


5. Connect the Exhaust Brake Vacuum Actuator to theSolenoid

a. Using a hose clamp and ¼ inch I.D. hose supplied inthe kit, connect one end of the hose to the vacuumtube on the exhaust brake’s vacuum actuator.Tighten the hose clamp.

b. Install p-clip supplied in the kit onto the hose. Routethe end of the hose from the actuator to the end of thebattery tray. Loosely mount the p-clip to the batterytray using the M6 X 19 mm capscrew, flat washer andlock nut provided in the kit. (see figures 18 and 19).The head of the capscrew should be inside batterytray as shown in figure 19.

c. Route the end of the hose to the solenoid’s #2 port(straight fitting) as shown in figure 19.

d. Trim the hose to length and attach the hose to thesolenoid’s #2 port fitting. No clamp is required for thisend. (see figure 19)

e. Tighten p-clip capscrew and nut.

Fig. 18

Fig. 19


THE VACUUM PUMP MUST NEVER BERUN WITHOUT A VACUUM LOAD (I.E.OPEN TO ATMOSPHERE). IF THE PUMP

IS RUN WITH NO LOAD, THE PUMP DIAPHRAGMWILL FAIL. IF THE VEHICLE MUST BE DRIVEN AFTERINSTALLING THE VACUUM PUMP BUT BEFOREINSTALLING THE EXHAUST BRAKE ASSEMBLY,CONNECT THE PUMP TO THE VACUUM SOLENOIDBEFORE RUNNING THE ENGINE (AS SHOWN IN THEINSTALLATION MANUAL). THE SOLENOID MUSTREMAIN OFF (DE-ENERGIZED) UNTIL THE SOLENOIDIS CONNECTED TO THE EXHAUST BRAKE. ANALTERNATIVE METHOD IS TO SECURELY(RE)INSTALL THE RED PLASTIC VACUUM OUTLETCAP SHIPPED ON THE PUMP. THIS CAP ISDESIGNED TO PROVIDE SUFFICIENT VACUUMLOAD.

VACUUM PUMP FAILURE DUE TO PARTIAL SYSTEMINSTALLS AND RUNNING THE PUMP WITHOUTVACUUM LOAD IS NOT COVERED BY BRAKEWARRANTY.

1. Gaining access to gear housing.

For 2003 model vehicles, unfasten the threecapscrews on top of the Throttle Position Sensorassembly. Relocate the Throttle Position Sensorassembly to gain access to the top of the gearhousing. (see figure 20)

2. Prepare the Vacuum Pump/Bracket for mounting.

a. Attach the vacuum pump to the mounting bracketusing the three M8 x 30 mm capscrews supplied inthe vacuum kit. (See figure 21)

Torque to 25 N.m (18 ft-lb).

b. Install 3/8” I.D. hose onto the vacuum pump andsecure with the hose clamp provided.

3. Mount the Vacuum Pump/Bracket Assembly.

a. Attach the vacuum pump/bracket assembly to the rearof the gear housing using the four M8 x 45mmcapscrews supplied in the vacuum kit. Reference gearhousing holes in figure 22 and installed vacuum pumpin figure 23.

Torque to 25 N.m (18 ft-lb).

b. Insure no wiring harnesses are taut against thevacuum pump bracket. This is to avoid harnesschafing.

NOTE: IT MAY BE NECESSARY TO REMOVE THEACCESSORY DRIVE BELT TO EASE INSTALLATION

Fig. 20

Fig. 21

Fig. 22

Fig. 23

Section 4: Installing the Vacuum System


Fig. 24

Fig. 25

4. Change the Alternator/Fan/Vacuum Pump Drive Belt.

a. Remove the current drive belt. Use a 1/2 socketwrench on the tensioner pulley to create slack in thebelt. This belt can be reused if either the exhaustbrake is removed or should there be a problem withthe vacuum pump. The vacuum pump does not needto be removed if installing the original belt for anyreason.

b. To install the new drive belt supplied in the vacuum kit,route the new belt as shown in figure 24. Create slackin the belt by using a 1/2 socket wrench on thetensioner pulley and slide belt into place.

NOTE: IF YOU HAVE A VEHICLE WITHOUT AIRCONDITIONING, YOU WILL NEED TO PURCHASE ADIFFERENT ACCESSORY DRIVE BELT CUMMINSPART NUMBER 4025090 (LENGTH WILL BE 2,892MM/113.9 IN).

5. Reinstall the throttle position sensor assembly

a. Reinstall the Throttle Position Sensor assembly. Seefigure 25.

b. Torque the three (3) cap screws to 48 N.m (35 ft lbs).

NOTE: THE 3/8" VACUUM PUMP HOSE INSTALLATION WILLBE COMPLETED IN SECTION 5 AFTER THEINSTALLATION OF THE WIRE HARNESS IN SECTION 4.


Harness Installation for MY2004 and 2004.5Vehicles. (For MY2003 vehicles, see addendumprovided in the kit)

1. Route the Harness.

a. Lay the exhaust brake harness near the top of thedash panel in the engine compartment over theengine. The harness should be oriented so that theend with the relay is located on the passenger side ofthe engine compartment and the end with the fuse-holder is located on the driver side of the enginecompartment. (See figure 26)

b. If needed, reroute the brake harness under the vehicleharness running along the top of the dash panel. It isrecommended that the driver’s end of the harness berouted behind the two 24-pin connectors and themaster brake cylinder. (see figure 27)

c. Using provided tie-wraps, secure the harness underthe vehicle harness running along the top of the dashpanel. To allow for minor adjustments to the locationof the harness, it is recommended the tie-wrapsloosely secure the brake harness until all hookups arecompleted.

2. Mount the Harness Relay.

Remove the nut from the dash panel stud (see figure28). Put the relay bracket over the stud. Put theharness black and green/yellow ground wire eyeletonto the stud and replace the nut on the dash panelstud. Tighten nut.

3. Attach the Solenoid Connector.

Attach the male connector with the purple and blackwires from the harness to the female connector withthe two black wires on the exhaust brake solenoid.

Section 5: Installing the Wiring Harness

Fig. 26

Fig. 28

Fig. 27


Fig. 30

Fig. 31

Fig. 29

Fig. 32

4. Connect the Harness to the Switched 12 volt powersupply.

a. Route the exposed solid grey wire on the driver’s sidefrom behind the 24-pin connectors to the blackconnector on the right. (see figure 29)

b. Disconnect the black 24-pin connector.

c. Locate the switched 12 volt power wire called out onpage 4, step 1d.

d. By placing the blade of a small screwdriver betweenthe yellow locking mechanism and the blackconnector, pry the locking mechanism upward andremove from the connector. (see figure 30)

e. Using a Miller Connector Tool #6680 (or very smallthin bladed screwdriver), slip the tool’s blade betweenthe connector and the wire’s silver pin to release thepin’s locking mechanism and remove the 12 volt wireand pin from the back of the connector. (see figure 31)

NOTE: IT IS RECOMMENDED THAT THE SWITCHED POWERLEAD NOT BE CUT. THE SPLICE SHOULD BESOLDERED TO THE EXISTING UNCUT WIRE.

f. Strip electrical tape from the connector’s harness asneeded. Approximately 3 inches from the end of thepin, strip ½ inch of insulation from the switched 12 voltwire to prepare the wire for splicing. Take care to notdamage the wire strands. (see figure 32)

g. Splice the solid grey wire from the exhaust brakeharness to the switched 12 volt connector wire bysoldering the splice and wires together.

h. Locate a heat shrink tube provided in the kit and slidethe heat shrink over the splice. Using a heat gun,shrink the tubing to seal the connection.

i. Place a small amount of dielectric grease to theweather seal in the connector cavity that contained theswitched power wire (dielectric grease will helpprevent cutting of the weather seal while reinsertingthe pin). Reinstall the pin into the 24-pin connector.Pull gently on the wire to ensure the pin’s lockingmechanism has locked the pin in place.

j. Reinstall the connector’s yellow locking mechanismand connect both sides of the connector.


6. Secure the Brake Harness

a. Ensure that the brake harness is properly aligned withthe vehicle harness and that the 90 degree end of thepolytube is to the right of the master brake cylinder(see figures 33, 34, and 35). Secure the harness bytightening the harness tie-wraps. Do not over-tightenthe wraps thereby crushing the vehicle or brakeharness convolute.

b. Using a provided tie-wrap, secure the brake harness’switched 12 volt grey wire to the wire bundle of the24-pin black connector.

7. Install Vacuum Supply Hose to the Straight End ofthe Polytube.

Connect one end of the ¼ inch I.D. hose provided inthe kit to the straight end of the polytube then proceedto Section 6: Installing the Vacuum Supply Hose.

Fig. 33

Fig. 34

Fig. 35


1. Install vacuum tube to exhaust brake solenoid

a. Route the ¼ inch I.D hose to the 90o elbow onsolenoid port #1. (see figure 36)

b. Trim the hose to size and attach the hose to thesolenoid’s #1 port fitting. No hose clamp is required.

c. Using provided tie-wraps, secure the hose fromchafing and heat sources taking care to not crimp orpinch the hose closed.

2. Attach the Vacuum Pump to the poly tubing.

a. Route the 3/8 inch I.D. hose from the vacuum pumpto the 90o polytube fitting on the drivers side. (seefigure 37)

b. Cut the hose to length and connect the 3/8 inch I.D.hose to the 90o polytube fitting.

c. Using provided tie-wraps, secure the hose fromchafing and heat sources taking care to not crimp orpinch the hose closed.

Section 6: Installing the Vacuum Supply Hose

Fig. 36

Fig. 37


Fig. 38

Fig. 39

Fig. 40

Fig. 41Fig. 42

Section 7: Installing the Brake Switch1. Run the wires under the dash panel then towards the

driver side as shown in figure 38.

2. Locate the grommet in the floor panel behind thepedals as shown in figure 39. With a small screwdrivermake a hole in the grommet to slide the wiring harnessthrough.

3. Slide the wires through the grommet. Pull back thecarpet on the drivers side and route the harness justunder the top of the carpet. Restore the carpet to itsoriginal position. (see figure 40)

4. Attach the stalk switch to the shifter stalk and installthe four (4) clamping screws through the attachmentpiece. Two bushings provided with the switch will notbe used in this installation and may be discarded. (seefigure 41)

5. Using tie wraps provided in the kit, secure the switchwires to the shifter stalk.

6. In the engine compartment route the three wires alongthe vehicle harness, from the grommet to the brakeharness on the drivers side. (see figure 42)


Section 8: Installing the ECM Connections

Fig. 43

Fig. 44

Fig. 45

Fig. 46

1. Connecting to the ECM.

a. Insert the light green wire from the Exhaust BrakeHarness and yellow wire from the Stalk Switch into the¼ inch convolute supplied in the kit. Tape asnecessary to secure the convolute to the wires.

b. Route the convolute containing the light green andyellow wires along existing vehicle wiring to the 50 pin"B" connector of Engine Control Module (ECM). (seefigures 43 and 51)

c. Route the two remaining brake switch wires (red andgreen) toward the wire trough. They will connect withthe similar color wires of the brake harness (red to red,green to green). Trim the switch wires to meet with thebutt splices in the brake harness. Strip the ends andcrimp to the similar color wires on the brake harness.(See figures 45 and 46)

d. Using a 4 mm hex wrench, loosen and remove theECM’s 50 pin “B” connector (rear connector).

e. Locate the #39 terminal sealing plug on the connector.Insert a #56 (3/64") drill bit, back probe tool or similarsmall diameter rod into cavity #39 to push out thesealing plug. Pull the sealing plug out of the cavity withneedle nose pliers. (see figure 44)

f. Locate the #42 terminal sealing plug on the connector.Insert a #56 (3/64") drill bit, back probe tool or similarsmall diameter rod into cavity #42 to push out thesealing plug. Pull the sealing plug out of the cavity with

needle nose pliers. (see figure 44)

Make sure the driver side battery isremoved from the vehicle. sparks, flamesor smoking near The battery can cause an

explosion or fire leading to personal injury.

g. Using a heat gun, heat shrink the butt spliceconnectors to seal the wires.

NOTE: BE SURE TO FOLLOW INSTALLATION PROCEDURESAS WRITTEN. ONCE THE TERMINALS ARE SEATEDIN THE CAVTIES, THEY CAN ONLY BE REMOVEDWITH A SPECIAL TOOL.

h. Insert the terminal on the yellow wire from the switchharness into the #39 cavity of the ECM 50 pin "B"connector. Push the terminal straight into the cavityuntil a positive stop is felt. Lightly pull on the terminalto ensure that it is properly locked in place.

i. Insert the terminal on the light green wire from thebrake harness into the #42 cavity of the ECM 50 pin"B" connector. Push the terminal straight into thecavity until a positive stop is felt. Lightly pull on theterminal to ensure that it is properly locked in place.

j. Reinstall the 50 pin "B" connector to the ECM using a 4mm hex wrench.


Section 9: Completing the Installation

Fig. 47

Fig. 48

Fig. 49

Fig. 50

1. Reinstall the driver side battery

a. Reinstall the driver side battery into the tray andsecure with the battery clamp. (see figure 47)

b. Make sure the negative leads for both batteries are notgrounded and place the positive lead onto the positivebattery post.

c. Remove nut from the clamp and install the fused blackbrake harness wire with eyelet onto the bolt. Replacethe nut and tighten onto the positive battery post. (seefigure 48)

d. Install the negative battery lead onto the negativebattery post and tighten.

2. Secure the Wiring Harness.

a. Using remaining ¼ inch convolute, tape and securewith tie-wraps to protect the brake wiring harness fromsources of heat and chafing.

b.Tighten the tie wraps holding the wire harness. (seefigure 49)

3. Reinstall the wheel wells.

Attach the ABS cable to the wheel well. Slide the wheelwell into place. Install Eight (8) cap screws to securethe wheel well to the fender. Repeat for othersidewheel well. (see figure 50)

4. Reinstall both front tires.

a. Follow proper procedure from your owners manual toinstall the front tires.

b. Lower vehicle.

5. Reinstall the passenger side battery.

a. Reinstall the passenger side battery into the tray andsecure with the battery clamp. (see figure 47)

b. Install positive lead onto the positive battery post andtighten.

c. Install negative lead onto the negative battery post andtighten.


Section 10: Operational Check6. Reprogram Clock.Once you have completed the installation, the final stepbefore the test drive is to check the operation of the brake.

KEEP HANDS, TOOLS AND ELECTRICALCORDS AWAY FROM THE COOLINGFAN AND OTHER MOVING PARTS.INJURY COULD RESULT.

1. Open the vehicle hood so that you can observe themovement of the vacuum actuator. Make sure thebrake is operating correctly with the enginerunning at idle.

a. Verify that the accessory drive belt is tracking properly.

NOTE: THE BRAKE WILL TURN ITSELF OFF AT IDLECONDITIONS WHENEVER COOLANT TEMPERATUREIS GREATER THAN 170-175 DEGREES F.

b. Turn the brake switch to the on position (pull theswitch up). The red light on the switch shouldilluminate and the brake will activate. You can tell thebrake is activated by a change in the engine sound orby observing the actuator arm moving the brake to theclosed position.

2. Carefully operate the throttle pedal to bring theengine off idle. The brake should shut off. Watchthe movement of the brake to tell if the brakemoved to the open position.

3. Close the hood and proceed to road test.

If the brake does not operate as described above, turnthe switch to the "OFF" position and check thetroubleshooting section for details on how to proceed.


Section 11: Exhaust Brake FeaturesCruise Control

Your exhaust brake will function during cruise control whenthe cruise is set and the exhaust switch is in the onposition. When coasting and gaining speed, the cruisecontrol will turn the brake on and off to maintain the setspeed.

Warm up device

You can use your exhaust brake to help warm up yourengine. Start your vehicle and turn the stalk switch to theon position. The brake will come on and reduce the time ittakes to get your engine to operating temperature. Whencoolant temperature reaches 170-175 degrees F, thebrake will be automatically turned-off by the Engine ControlModule at idle conditions.

IT IS NOT RECOMMENDED TO IDLEYOUR VEHICLE FOR LONG PERIODS OFTIME.


Section 12: TroubleshootingBrake will not turn on

NOTE: THE BRAKE WILL TURN ITSELF OFF AT IDLECONDITIONS WHENEVER COOLANT TEMPERATUREIS GREATER THAT 170-175 DEGREES F.

1. With the truck running, check to see if the stalk switchis in the on position and the switch light is illuminated.If the switch is in the on position and the light is notilluminated then go to the electrical troubleshootingsection.

2. Make sure the throttle cable to the TPS is not kinkedor out of position. A kink or out-of-position cable couldgive the TPS an incorrect throttle position reading. TheECM needs to read that the throttle is in the idlepositon for the brake to function.

3. Next step is to go to the Vacuum Troubleshootingsection. If this does not resolve the problem, go to theElectrical Troubleshooting section.

Brake will not shut off1. Hose connections on the solenoid may be reversed.

Hose from vacuum pump should be in solenoidconnection 1. Hose to the brake should be in position2. Numbers will be marked on the solenoid itself.

2. At the solenoid, remove the vacuum hose coming fromthe brake. If the brake does not shut off, the brakemay need to be replaced. Go to BrakeTroubleshooting section.

3. If the brake does shut off in step 2, reconnect thebrake hose and disconnect the solenoid harness. If thebrake shuts off then go to the ElectricalTroubleshooting section. If the brake stays on, replacethe solenoid.

Brake is slow to shut off The filter on solenoid may be clogged. Remove the

filter and clean with solvent and compressed air fromthe back side. If this does not fix the problem, go tothe Brake Troubleshooting section.

Whistling sound from brakeNOTE: SOME SOUND IS NORMAL DURING THE OPERATION

OF THE BRAKE. THE SOUND WILL BE MORE OF AWOOSHING SOUND THEN A WHISTLE.

1. Whistling sound is usually caused by an exhaust leak.Look at and around the brake for carbon tracks.Visible carbon will indicate where the exhaust isleaking.

2. Check the torque of the exhaust brake clamps.

a. Torque the “V” clamp between the turbochargerand exhaust brake. Torque Value: 8.5 N∙m [75 in-lb]

b. Torque the “V” clamp between the brake andexhaust pipe. Torque Value: 11.3 N∙m [100 in-lb]

3. If the clamps are tight, the gasket might be damagedor missing. Follow the instructions for installing thebrake and replace the gasket.

Vacuum troubleshooting:

1. Check all vacuum hoses for kinks, leaks or damage.

2. With the engine running, disconnect the vacuum hosefrom both sides of the vacuum solenoid and hold thehoses together. The brake should come on and moveto the closed position. If it does, reconnect the hosesand go to the Electrical Troubleshooting section. Iftesting the vacuum with a vacuum gage, your readingshould be between 15 and 29 inches of mercury.

3. Check to see that the vacuum pump belt is in positionand the vacuum pump pulley and shaft are rotating,spinning with the belt.

4. With the engine shut off, disconnect the vacuum hosefrom the vacuum pump. With the engine running, testfor suction at the vacuum pump with your finger. Ifthere is no suction, replace the vacuum pump.

Electrical troubleshooting:

1. Check 10 amp fuse in wiring harness (driver sidebattery, near positive terminal). If fuse is blown ordamaged, replace the fuse.

2. Disconnect the solenoid connector from the brakeharness. With a Volt/Ohm meter, check the resistancebetween the pins of the solenoid connector. If readingis zero (0) then the solenoid is shorted and should bereplaced. If the reading is over 20 ohms then thesolenoid has an open condition and should bereplaced. The normal resistance reading should bebetween 10 ohms and 20 ohms.

3. With the solenoid connector disconnected and thebrake switch on, turn the key to the on position andcheck the solenoid supply voltage with a Volt/Ohmmeter. 12 Volts should be read between the pins ofthe connector on the brake harness. If there is 12 voltsreplace the solenoid.

4. Shut the key off and remove the relay base from therelay. Turn the key back on and check the pins in therelay base as follows:

Pin 30 - Battery 12 volts (12 volts)

Pin 85 - Key Switched 12 volts (12 Volts when the key is on)

Pin 86 - To Pin 42 ECM (check continuity between thispin and pin 42 on the ECM connector)

Pin 87 - to Solenoid (check continuity between this pinand solenoid connector)

5. Check wiring against figure 51.


Brake troubleshooting:

NOTE: THE BRAKE IS NOT SERVICEABLE. THE BUTTERFLYAND SHAFTS ARE PRESSED TOGETHER AND CANNOT BE DISASSEMBLED. THIS SECTION IS TODETERMINE IF THE BRAKE IS FAULTY AND SHOULDBE REPLACED.

1. Disconnect the vacuum cylinder from the brake asfollows:

a. On ball socket end remove the safety clip.

b. Using a screwdriver pry the socket off the ball.

2. Move the ball end to the closed position. Noresistance should be felt. Be careful not to remove thehigh temperature grease on the ball. If it is difficult tomove the brake, then the brake should be replaced.

3. Connect a vacuum source to the vacuum cylinder. Thecylinder should open quickly and when vacuum isremoved it should snap closed.

ECM troubleshooting:

NOTE: TROUBLESHOOTING THE ECM REQUIRES SPECIALDIAGNOSTIC EQUIPMENT AND SHOULD ONLY BEATTEMPTED BY QUALIFIED PERSONNEL.

The following are conditions or codes used by the ECM:

1. The brake will function only when the ECM reads thethrottle as being in the idle position.

2. The brake will shut off when the engine's coolanttemperature sensor reads above 170o - 175o and withzero vehicle speed. The brake will shut off to preventexcessive increase in engine water temperature.

3. Fault code 0477 (Low voltage - ECM pin B42). Withthe exhaust brake switch in the off position, no voltageis detected on Pin B42 (12 Volts is expected). InspectLight Green wire on the brake harness.

4. Fault Code 0478 (High voltage engine brake driver -ECM pin B42). The ECM has detected greater than 12volts at ECM pin B42. Troubleshoot the ECM. Refer toChrysler service literature.

Fig. 51

Fig. 52

Cummins Engine Company, Inc.Box 3005Columbus, IN 47202-3005U.S.A.

Bulletin 4081384Printed in U.S.A. 11/03©2003 Cummins Engine Company, Inc. andJacobs Vehicle Systems, Inc. P/N 032414 Rev C

jacobs exhaust brake · cummins isb engine with a manual transmission. the jacobs exhaust brake kit...

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