BD Turbo Guard / Blow-Off Valve Installation Manual - BD Power

31 August 2012 Part #’s 1047250AR / 1047250AS / 1047250SR / 1047250SS / 1047251SR / 1047251SS 1 

BD Turbo Guard / Blow-Off Valve 

Installation Manual 

Part Number 

Application 

1047250AR General Application Kit, Aluminum Adaptor, Red Valve 

1047250AS General Application Kit, Aluminum Adaptor, Silver Valve 

1047250SR General Application Kit, Steel Adaptor, Red Valve 

1047250SS General Application Kit, Steel Adaptor, Silver Valve 

1047251SR 12 Valve Application Kit, Steel Adaptor, Red Valve 

1047251SS 12 Valve Application Kit, Steel Adaptor, Silver Valve 

* Read all instructions before beginning installation of this kit! * 

OWNER’S MANUAL – LEAVE IN GLOVE BOX 

Installation Manual Part # I1047250-251 

BD Engine Brake Inc. 

Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2 

U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295 

Phone: 604-853-6096 | Fax: 604-853-8749 | Internet: www.bd-power.com


TABLE OF CONTENTS 

Welcome ................................................................................................................... 3 

Special Tools Required ............................................................................................. 3 

Pre-Installation .......................................................................................................... 4 

Dodge 12/24V Auto Trans Install .............................................................................. 4 

Intercooler Tube Removal ......................................................................................... 6 

Intercooler Tube Installation ...................................................................................... 8 

Spool Valve Installation ............................................................................................. 9 

Dodge 12V Manual Trans Install ............................................................................. 11 

Throttle Switch ............................................................................................... 11 

Wiring & Plumbing Diagram ........................................................................... 14 

Wiring & Plumbing Diagram ........................................................................... 15 

Duramax Install (2001- 2004).................................................................................. 16 

Wiring And Plumbing Diagram ....................................................................... 18 

Duramax Install LLY,LBZ,LMM (2004.5- ................................................................. 19 


Ford 7.3/ 6.0L (R/S) Installation .............................................................................. 21 


Ford Powerstroke 6.4.............................................................................................. 24 


TGE Adjustment & Testing ..................................................................................... 27 

Troubleshooting ...................................................................................................... 30 

OPERATING GUIDELINES .................................................................................... 30 






Welcome 

Thank you for purchasing a BD Turbo Guard kit. This manual is divided into 

different areas to assist you with your installation of the different kits and operation 

of the Turbo Guard. 

The BD Turbo Guard is one of the nicest units on the market. The body and all 

internal components are CNC machined from 6061 aluminum alloys. It features the 

one of the largest dump valves at a whopping 1.98” (50.5 mm), which gives you the 

highest flow in the industry. A V-Band clamping system allows easy installation and 

removal. 

The valve seal utilizes a Viton O-ring that is clamped in place to prevent the 

possibility of sticking to the seat and pulling out. The valve stem and guide are 

Teflon lubricated and hard anodize coated for wear resistance. 

Special Tools Required 

Drill with 1 7/8” hole saw 

Crimping Pliers 

Test light 

¼” Drive Socket set 

Small Blade tip screwdriver 

MIG or TIG Welder (Aluminum feed for the Duramax kit) 

Teflon tape or putty 

5/32” Allen key 






Pre-Installation 

** PLEASE READ THIS MANUAL COMPLETELY BEFORE 

INSTALLING THE BLOW-OFF VALVE ** 

To prevent damage to electronic components, it is recommended that you 

disconnect both negative battery terminals before starting. 

Dodge 12/24V Auto Trans Install 

This kit is designed for the Dodge Cummins 12 or 24 Valve with an APPS/TPS 

voltage source. You will be using the new Turbo Guard Electronics (TGE) module 

to determine when to activate the valve. It is recommended that you mount this 

module underneath the steering column inside the cab to keep out any moisture or 

dirt from under the hood. 

Locate a switched 12 Volt power source in the fuse panel with a test light. You can 

also use the supplied fuse tap and flag connector for another power source as well. 






This 12 volt switched power should go to the “Switched Power” input on the TGE 

module using the supplied red wire. 

You will need to use a set of crimping pliers to connect the connectors on the power 

side of the red wire. 

When connecting the power wire to the TGE, there are special quick 

connectors that allow an easy installation. Trim the proper amount of 

insulation off of the wire and be sure to tighten the locking screw on the green 

quick connector. Be careful that there are no cross shorts between cables. 

Also check to make sure that the green connection block is firmly inserted 

into the TGE case. 

You also need to locate a clean ground location which should be wired into the 

“Ground” input on the TGE module using the supplied black wire and ring 

connector. Usually a bolt will protrude from the firewall, which makes a good 

ground. Please again trim excess wire. 

Route the gray and violet wires through the firewall and into the engine 

compartment. The violet wire should be connected to the TGE input labeled 

“APPS” and the grey wire should be wired into the TGE output labeled “Output”. 

Location Year Wire Color 

2004-05 Brown w/ White Tracer 

APPS/TPS Sensor 

2003 Yellow 

Or at ECM 

1994-2002 Light Blue w/ Black Tracer 

PCM 1994-2003+ Orange w/ Dark Blue Tracer 

The violet wire from the Turbo Guard kit should be connected to the APPS signal. 

Reference to the chart above for which wire to tap onto. This signal is located at the 

driver’s side front of the Cummins 24 valve engine above the injection pump on 

vehicles 98-03. On the 2004+ vehicles this wire will be located at APPS sensor on 

the throttle pedal. 

Use the supplied Posi-Tap to tap into the wire. Note that you may also tap into 

this wire at the PCM and as well at the Cummins ECM. This wire should range from 

approximately 0.5 volts to 5 volts depending on how far the pedal is depressed. At 

idle the voltage should be near the 0.5 to 1.0 volt scale and at full throttle it should 

read close to 3-5 volts. 

On 12 Valve engines the APPS/TPS is at the rear of the P7100 injection pump. 

Use the supplied Posi-Tap to tap into this wire and connect it to the violet wire. You 

may have to trim the excess wire. 






Once the Violet APPS wire has been routed connect the Grey wire to the bullet 

connector on the spool valve that you mounted to the intake horn earlier. You will 

need crimping pliers to attach the opposite gender bullet connector to the grey wire. 

Route the wire inside of the supplied loom. Please be careful of routing the wires 

away from any heat sources or any moving parts. 

Intercooler Tube Removal 

Before welding the Blow-Off Valve 

adapter onto the cool side of the 

intercooler tube (driver side), you 

must remove it. 

Remove the two clamps located 

on the intercooler boots. Use a 

7/16” deep socket to remove the 

top and bottom boot clamp. 

The adapter will be installed on 

the upper portion of the tube 

furthest away from the intercooler. 

Using a tape measure, measure 

about 2½ - 3” from the upper edge 

of the tube and mark a drill spot. This mark should be the center of the adapter. 

As you can see from the picture above, the edge of the adapter should be within a 

½ inch from the second raised lip. Once you have marked your drill location, use a 

center punch and drill a pilot hole. Use a 1-7/8” hole saw and drill out the remainder 

of the hole. 

Place the adapter and the tube in 

a vice in order to hold the adapter 

tight against the tube while 

welding. You can tack-weld the 

adapter if you are unsure of its 

proper location. After the weld is 

complete, be absolutely certain 

that the weld is strong and there 

are no air leaks. 

Warning: Ensure the weld is 

clean on the inside of the tube. 

If any slag is left there is a 

chance of engine damage. 






After the weld has been cleaned, a nice coat of black paint is recommended to 

eliminate any tarnishing. 






Intercooler Tube Installation 

Use the supplied aluminum V band clamp to attach the 

Blow-Off Valve to the newly welded adapter. Do not forget 

to use the supplied Viton O-ring to seal the valve to the 

adapter. 

Be very careful not to over-extend the V band clamp, as 

damage will result. 

Tighten the Allen bolt with a 5/32” Allen key so that the 

valve is securely fastened to 

the adapter. 

Re-install the intercooler tube 

in the reverse order that it 

was removed. 

Be sure that all the 

intercooler boot clamps are 

securely tightened. Rotate 

the tube so that the Blow-Off 

Valve is facing towards the 

front the truck. 






Turbo Blow-off Valve installed in intercooler tube 

Spool Valve Installation 

Remove the bolt holding the intake horn using a 10mm socket. Install the spool 

valve assembly ensuring the valve connections are the same as in the picture. 

Diode Assembly 

Ground 

Hollow Manifold 

Bolt 






When securing the spool valve assembly with the long 10mm bolt, connect the 

spool valve ground (ring connector) between the intake horn and the spool valve 

assembly. Be sure to re-torque the 10mm bolt, or a boost leak may occur. Install 

the “Free Wheeling” Diode pigtail assembly. Route the power through the red wire 

and then into the spool valve. The black wire of the assembly should be mounted to 

ground using the ring connector. 

Use the rubber hose to connect the Blow-Off Valve to the brass push-on connector 

on the spool valve. Secure the connection using the supplied hose clamps at each 

connection point. Keep the hoses as short as possible. 

Remove the 10mm bolt that holds the intake manifold plate in place. Install the 

supplied hollow manifold bolt with the blue or green “quick-connect” connector in 

place. 

It is recommended that a small amount of sealing putty be used on the manifold 

bolt. Route the hard plastic tube from the manifold connector to the blue or green 

“quick-connect” connector in the spool valve. 

Please verify the following connection points as each connection is numbered in the 

picture. 

Conn. Description 

1 

Engine Boost 

Pressure via 

“quick-connect” 

connector. 

2 N/C 

3 N/C 

4 

Blow-Off Valve 

via rubber air 

hose 

5 N/C 






If you are unsure about any connection, look through the next couple of pages and 

find your kit number. In your kit’s section you will find a wiring schematic that will 

assist your installation. 

Tighten the banjo bolt on top of the Blow-Off Valve securing the hose connection. 

You may also notice some pre-wired circuits connecting the ground to the power 

side of the spool valve. There should be a short diode harness wired as well. This 

is to remove any inductive spikes caused by the spool valve. 

Please trim any excess tubing or hose, trying to make the installation clean as 

possible. 

You will also notice that you received 4 shims in the kit as well. These shims are 

used to adjust the valve opening and closing pressure. The more shims you use, 

the higher the opening pressure. 

Dodge 12V Manual Trans Install 

This kit is designed for the Dodge Cummins 12 Valve with a standard transmission. 

A throttle pedal micro-switch is required for this application due to the fact that there 

is no TPS voltage. The purpose of this throttle switch is to indicate when then 

throttle is at the idle position. 

Throttle Switch 

At the throttle pedal, locate the nuts on the large aluminum bracket, just up from 

and to the left of the pedal. These nuts secure the aluminum bracket to the firewall 

and are the mount for the throttle and brake pedal. Remove the lower nut and 

loosen off the top nut. In the kit you will find the long throttle switch bracket, which 

has two long slots for the throttle switch. 

Slide the top end of the bracket (with the cut out slot) under the loosened upper nut 

and lay against the aluminum bracket so the stud that was exposed when you 






removed the lower nut protrudes through the other slot on the Throttle Switch 

Bracket. 

Screw the lower nut 

back onto the stud, but 

do not tighten the nuts 

yet. In the kit, find the 

small 2-3/8” long 

bracket with two holes. 

The arm of the throttle 

pedal starts off wide, 

then angles off into a 

thinner section further 

up the pedal. 

Just before the pedals 

arm angles to the 

thinner section, place 

the middle hole of the 

bracket on the still wide 

section, close to the 

edge and angle the 

bracket towards the throttle switch on the other bracket you installed above. 

Ensure sufficient clearance between the long throttle switch bracket and throttle 

pedal by sliding the bracket as far to the left as possible, to eliminate any possibility 

of the pedal catching on the bracket. 

Adjust both brackets so that the small bracket you are holding on the pedal arm is 

going to make good contact with the throttle switch when the pedal is in its 

resting/idle position. 

Mark and drill the two holes on the pedal arm and screw or pop rivet the small 

bracket to the arm. Tighten the nuts for the aluminum bracket and make any 

necessary final adjustments to the throttle switch bracket on the aluminum bracket. 

Make sure the screws supporting the throttle switch and screws for the electrical 

wires on the switch are tight. Periodic adjustment of the throttle switch might be 

required to maintain proper contact with the bracket on the throttle pedal. 

Use the supplied line tapper or fuse tapper and find a 12v fused ignition switch 

power source and attach one side of the throttle pedal micro switch to the power 

source using the supplied red wire. 

Attach the long grey wire to the last connection on the throttle pedal micro switch 

and route the wire through the firewall. Continue to route the wire in a discrete 






fashion to the bullet connector on the spool valve that you installed earlier on the 

intake horn of the engine. 

You will have to use a crimping tool to connect the bullet connector to the grey wire. 

Be conscious of moving or hot engine parts when routing the wire. Once all of the 

connections have been finalized and you are confident that everything is correct you 

may test all the connections. Turn the key to the “ON” position (KOEO). 

Press the throttle pedal up and down. As the accelerator pedal is applied, the spool 

valve should deactivate. A small click should be heard as the pedal is released and 

the spool valve should activate once again. 

You can test the circuit with a voltmeter or a test light. You must remember that 

when the key is “ON” and the throttle pedal is at an idle state the spool valve will be 

energized. As soon as the throttle is slightly pressed past idle position, the spool 

valve will deactivate. Refer to the diagram on the next page. 






Wiring & Plumbing Diagram 

Turn to page 20 to continue with the Turbo Guard installation. 






Wiring & Plumbing Diagram 

Turn to page 20 to continue with the Turbo Guard installation. 






Duramax Install (2001- 2004) 

The installation of the turbo guard for the Duramax is slightly different as the other 

applications although the concept is still the same. It is highly recommended that 

you read over the Dodge installation portion of this manual. 

The intercooler tubes that you will be mounting the blow-off valve adapter to are 

made of aluminum; hence you will need an aluminum welder to mount the aluminum 

adapter. The intercooler tube of choice is the turbocharger compressor outlet tube, 

which is located on the driver side. If you cannot mount it there, then the passenger 

side engine inlet will do, although you may suffer some response time. 

You will need to use the brass three-way adapter to tap into the wastegate line as a 

boost source. The APPS/TPS wire that you are looking for is Dark Blue - it can be 

found on the accelerator pedal assembly inside the truck. 

A suggested location for the spool valve is on the trucks firewall over top of the 

engine ground strap. Remember to keep the plastic & rubber hoses as short as 

possible. 

Use a ground strap 

bolt to mount the 

spool valve. 

Use a wastegate 

line as a boost 

source. 

Mount the valve on the 

compressor outlet of 

the intercooler tube 

(before the 

intercooler) 






Secondary mounting 

location. When using 

this location you will 

need to find a 

mounting bolt for the 

spool valve. 


used to adjust the valve opening pressure. The more shims you use the higher the 

opening pressure. 






Wiring And Plumbing Diagram 






Duramax Install LLY,LBZ,LMM (2004.5- 

Being that you have a VGT turbocharger you will not be able to pull boost pressure 

from the turbocharger waste gate line. Ideally it is best to install the unit on the 

turbocharger outlet tube (driver’s side). For the LLY you may have no choice but to 

install the unit into engine inlet pipe (passenger’s side). In the case of the LBZ and 

LMM you don’t have a choice and must install the unit on the turbocharger outlet 

pipe (driver’s side). 

Also it is very important that the boost pressure source for the top of the BOV be 

from the turbocharger outlet side. 

To install the boost pressure source there should be a nutsert included with the kit. 

You will need to remove the turbocharger outlet pipe and install the nutsert in it. 

Once this pipe is removed, drill a 3/8” hole on the top of the pipe closest to the 

turbo. Use a file or de-burring wheel to clean to hole. Coat the nutsert with a 

moderate temperature silicon or gasket maker. Insert the coated nutsert into the 

3/8” hole in the pipe. Insert the Allen head screw through the install nut with the 

serrated end facing towards the nutsert. Use a wrench to hold the nut in place while 

tightening the Allen screw with the provided Allen key. Continue to tighten the Allen 

key until the force needed to turn it drastically increases. Reinstall the tube into 

place on the truck, making sure the all the intercooler boots are clean of oil and the 

clamps are tight. Route the black nylon house over to the switch valve. 












Ford 7.3/ 6.0L (R/S) Installation 

The installation of the turbo guard for the Ford is slightly different as the other 

‘T’ into boost sensor line 

Mount valve in this location. 

applications although the concept is still the same. It is highly recommended that 

you read over the Dodge installation portion of this manual. 

Although the installation pictures show a 6.0L the concept is still the same for the 

7.3L. 

The intercooler tubes that you will be mounting the blow-off valve adapter to are 

made of steel; ideally a TIG welder looks the nicest but a MIG welder will do. The 

intercooler tube of choice is the turbocharger compressor outlet tube, which is 

located on the driver side (7.3L) and on the passenger side (6.0L). If you cannot 

mount it there, then the opposite side (engine inlet) will do, although you may suffer 

some response time. 

You will need to use the brass three-way adapter to tap into the boost sensor line as 

a boost source. The APPS/TPS wire that you are looking for is mounted inside the 

cab just off the pedal. Use the table to locate the proper color wire. 






Vehicle Year APPS/TPS Wire Color 

1999.5-02 7.3L Grey w/White 

2003-04 6.0L Yellow w/White 

2005-07 6.0L White w/Red 

A suggested location for the spool valve is on the trucks firewall. Remember to 

keep the plastic & rubber hoses as short as possible and away from any heat 

source. 


used to adjust the valve opening pressure. The more shims you use the higher the 

opening pressure. 












Ford Powerstroke 6.4 

Being that you have twin turbocharger’s, you will not be able to pull boost pressure 

from the turbocharger waste gate line. In your case you will need to pull the boost 

srouce from the turbocharger compressor outlet pipe located on the driver’s side. 

While the valve should be located on the manifold air intake side located on the 

passenger side. 

BOV Location 

Boost Source 

To install the boost pressure source there should be a nutsert included with the kit. 

You will need to remove the turbocharger outlet pipe and install the nutsert in it (You 

can install nutsert without removing the pipe but you will need to ensure that none of 

the drill debris is left in the pipe). Once this pipe is removed, drill a 3/8” hole on the 

top of the pipe closest to the turbo. Use a file or de-burring wheel to clean to hole. 

Coat the nutsert with a moderate temperature silicon or gasket maker. Insert the 

coated nutsert into the 3/8” hole in the pipe. Insert the Allen head screw through the 

install nut with the serrated end facing towards the nutsert. Use a wrench to hold the 

nut in place while tightening the Allen screw with the provided Allen key. Continue to 

tighten the Allen key until the force needed to turn it drastically increases. Reinstall 

the tube into place on the truck, making sure the all the intercooler boots are clean 

of oil and the clamps are tight. Route the black nylon house over to the switch 

valve. 

















TGE Adjustment & Testing 

The unit is abundant with features as it offers the user the most advanced custom 

functions available. The unit works by monitoring the APPS/TPS signals and 

quickly reacts to the decrease in voltage associated to a quick release of the 

throttle. 

To achieve the correct setting for the activation of the Blow-Off valve in relation to 

the throttle pedal, the TGE module must be calibrated for your vehicle. The 

adjustable settings are: APPS, TIME, RE-APPLY, PULSE, and CLUTCH CANCEL. 

The adjustment screws are accessed by removing the cover from the module. To 

remove the cover, trim away the center of the sticker on the top of the module so 

you can access the cover screw. Remove the screw & the cover will lift off. See 

photo on page 29. 

APPS 

This option allows the user to adjust the amount of voltage (APPS/TPS) that needs 

to be dropped before the valve will open and discharge boost. Turn the unit 

clockwise to increase the voltage or amount of throttle that has to be lifted. Turn the 

unit counter-clockwise to initiate a faster or quicker activation with less of a TPS 

drop. 

TIME 

This setting allows the user to adjust the period of time that the APPS/TPS setting 

must be initiated in to activate the valve. It controls the amount of time that the 

microprocessor monitors the APPS/TPS signal. 

If you would like to increase the time frame (Volts/Seconds) then you would turn the 

potentiometer in the clockwise direction. To decrease the scanning period, turn the 

potentiometer in the counter-clockwise direction. Increasing the scanning timing 

tends to slow down the response. Most likely you will only need to adjust this 

setting once; usually the factory default setting is fine. 

For example, a decrease of 0.5 Volts in 0.25 seconds would respond faster than a 

decrease of 0.5 Volts in 1 second. 

The next diagram is a simulation of the APPS/TPS voltage over time on what 

typically happens when the throttle is quickly released. You can see by adjusting 

the APPS/TPS sensitivity you can control when the valve activates based on the 

amount of voltage dropped. The TIME setting controls activation assuring the 

voltage drop occurred in the right period of time. This eliminates any valve 

activations that are not quick or fast. 





APPS (Voltage) 

This is adjusted by the APPS 

adjustment POT 


This is adjusted by the TIME adjustment POT 

Time (Seconds) 

RE-APPLY 

This setting basically allows the user to adjust how much of a re-apply APPS/TPS 

voltage to allow before canceling the valve activation. If this setting were not 

present every time the throttle was re-applied while the valve was open you would 

be dumping boost. With this setting the user will cancel that valve activation when 

the throttle is pressed which allows for a faster transition and less wasted energy. 

The stock setting should be appropriate. Turn the potentiometer counter-clockwise 

for less APPS apply, and Clockwise for a more APPS apply. 

PULSE 

This is the length of time that the valve should be pulsed open for. Turn the 

potentiometer counter-clockwise for less time, and Clockwise for a longer pulse. 

CLUTCH CANCEL 

This option basically cancels any operation whenever 12 volts is applied to this 

input. If a user wanted they could hook a 12-volt switch up to this input to cancel 

the operations when shifting or if they wanted to turn the unit off. This option is not 

normally used. 

DEFAULT SETTINGS 

You’ll notice that there are small arrows on the dials of the potentiometers, in the 

graphic below these arrows have been emphasized to show the default settings. 






When setting this unit up it is advised to 

have the Key On, Engine Off (KOEO). 

Have the unit mounted underneath the 

dash in an easy to reach location. First 

depress the pedal and rapidly release 

to see if the TGE activates. You will not 

only hear the solenoid energize but you 

will also see a red LED that will mimic 

the Blow-Off valve. 

It is best to have the unit sensitive 

enough to control a turbo surge when 

approximately 25% of the throttle is 

quickly released. The value can be customized for any application. 

Screw Post 

Now adjust the APPS potentiometer to reflect your desired activation point based on 

the amount of throttle released. Remember if you would like the valve to activate 

only when a large amount of throttle is release turn the dial clockwise. Conversely 

turn the dial counter clockwise if you want the valve to activate on smaller amount of 

throttle release. 

Note if you have turned the APPS dial to its minimum you may get oscillations or an 

unstable valve opening. 

The TIME setting is by far the most misunderstood. Basically this value controls the 

amount of time that the APPS setting must be release in. Say if you set the TIME 

dial for an unusually large time, say 1 second, this would setup the TGE to activate 

the valve when the APPS voltage (say 2 volts) had been released in 1 second. As 

you know 1 second is a long period of time, and this setting would not be very 

reasonable. 

Note if you have turned the TIME dial to its minimum you may get oscillations or an 

unstable valve opening. 

When adjusting the PULSE setting, you must keep in mind that you want the valve 

open for the least amount of time. This is dependant on how badly your 

turbocharger surges. If the valve pulse time is too long the valve may stick open 

while accelerating. The REAPPLY setting typically does not need to be adjusted. 

In some instances the valve may stick open, if this does happen reduce the PULSE 

time setting and use the shims. 

When the valve first opens, there maybe some stickition between the valve seat and 

the oring. To prevent this you can use a mild grease or lubricant. 






Troubleshooting 

Following the diagrams in this manual, tracing hoses and wiring, checking continuity 

through electric components or checking for any lines that are disconnected, should 

solve any problems that may arise. If you have any problems or need replacement 

parts, call us at 1-800-887-5030, between 8:30am and 4:30pm Pacific Time. 

Use the table below to troubleshoot some common problems 

Large boost leak 

o The Blow-Off valve is being powered while the throttle is depressed. 

This is the opposite of what should happen. Check the voltage at the 

spool valve, as well as check the adjustment of the TGE or throttle 

switch. 

o The spool valve air input/outputs is incorrect. Please check the 

schematic of the applicable part number. 

Small Boost leak 

o Check hose clamps and rubber hose that connect the spool valve to the 

Blow-Off Valve 

o Check quick connects and the hard plastic tubing 

o Check that all the mounting bolts have been tightened (i.e. intake horn 

10mm bolts and intake manifold plate bolt). 

o Check the welded Blow-Off Valve flange. 

Blow-Off valve does not open 

o Check adjustment of TGE or throttle switch 

o Check for Power and ground continuity 

Blow-Off Valve sticks open 

o Adjust activation point or reduce “Pulse” time 

o Install shims 

OPERATING GUIDELINES 

The higher performance aftermarket turbo chargers that are being used today offer 

very large horsepower levels that were unthinkable just years ago, but unfortunately 

with their high flow numbers, their reliability has been of some concern. 

The larger turbo chargers are more susceptible to an off-throttle surge. Typically 

this surge is referred to as a “bark”. This is caused from the engine not consuming 

enough air from the turbo, which then causes the compressed air to stall or stop the 

compressor wheel. 






This surge can have catastrophic effects on the turbo. Typically, the thrust bearings 

will wear out or even cause the wheel to move in the bore, which may result in a 

snapped shaft. Both of these effects severely hurt the longevity of the turbo 

charger. This “Off Throttle Surge” is caused once the throttle is cut, the air that the 

engine was consuming stops, then almost reverses its direction and stalls or stops 

the compressor wheel. 

The Blow-Off valve helps this problem by dumping the airflow before it has a chance 

to stall the compressor wheel. Once you quickly lift off of the throttle, the Blow-Off 

valve opens and exhausts all the compressed air quickly. After installing this kit you 

will notice that the throttle has to be cut back all the way to an idle position for the 

Blow-Off valve to effective.

BD Turbo Guard / Blow-Off Valve Installation Manual - BD Power

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