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Manual - Banks Power

1. COMPONENT STINGER PLUS POWERPACK 27 GASKET Turbine Inlet GASKET Turbine Outlet 1 4 28 Plug 2001 235 HP Model Only DRILL BIT 55 2001 235 HP Model Only JET Actuator Tube 2001 235 HP Model Only ANTI SEIZE LOCTITE GREASE Dielectric 15 TIES 8 Cable N N N N N N N N N 6 TIES 8 Cable OWNERS MANUAL WARRANTY STATEMENT 5 year WARRANTY STATEMENT 2 year WARRANTY STATEMENT 1 year 28 3 UROCAL Banks Power DECAL Do Not Discard CARD Product Registration SIS ISISI amp SISIS N N N N N N N Except system 49334 49335 59353 and 49354 96397 v 8 0 27 Gale Banks Engineering 546 Duggan Avenue Azusa CA 91702 626 969 9600 e Fax 626 334 1743 Product Information amp Sales 800 438 7693 bankspower com
2. 96397 v 8 0 Figure 2 FUEL INJECTION PUMP FUEL PRESSURE TEST PORT FITTING fitting to the check valve installed in the inlet port of the fuel filter mount This is the check valve farthest away from the engine For 981 2 00 trucks proceed to Step 5 3 Remove protective cap from fuel pressure test port fitting See Figure 2 Clean area around cap and fitting before removing the cap 4 install the included fuel pressure test gauge onto the fuel pressure test port fitting 5 Prevent the engine from starting by removing the fuel injection pump relay in the Power Distribution Center 6 Crank the engine and observe the fuel pressure Cranking pressure should be 5 7 PSI 7 Re install the fuel injection pump relay in the Power Distribution Center 8 start the engine and check the pressure It should be a minimum of 10 PSI at idle NOTE If a fuel pressure of 5 7 PSI while cranking or 10 PSI with the engine idling is not observed this may indicate the presence of a faulty Fuel Lift Pump Replace the faulty Fuel Lift Pump or damage to the Fuel Injection Pump may occur 9 if a Diagnostic Trouble Code was set when the pump relay was removed use a scan tool to remove the trouble code 10 9872 00 trucks only Shut off the engine and switch the fuel pressure gauge from the inlet side check valve to the outlet side check valve closest to engine Start the engine and observe the pressu
3. shown in Figure 4 Use a 7 16 drill keeping the drill perpendicular to the manifold surface Figure 4 DRILL AND TAP 1 4 NPT FORT IN REAR PASSAGE OF EXHAUST MANIFOLD OUTLET LOCATE PORT 3 4 INCH BEHIND FLANGE CENTERED OVER REAR EXHAUST MANIFOLD PASSAGE aa gt 10 the drilled hole with a 1 4 NPT pipe tap Check the thread depth as you tap by periodically removing the tap and screwing the thermocouple into the tapped hole The thermocouple should thread in 3 96397 8 0 9 to 372 turns hand tight Do not install the probe in place at this time 11 Remove as many loose chips as possible from the exhaust manifold A shop vacuum small brush or fingers will help Now remove the rag using a welding rod or coat hanger bent into a hook Caution Make sure rags are removed from exhaust manifold prior to reinstalling turbocharger 12 Install the thermocouple in the manifold using anti seize on the threads Note At this point in the installation process it is necessary to determine which model turbocharger your vehicle is equipped with A turbocharger identification tag is located on the front of the compressor housing of the turbo or on the actuator If your turbocharger is an HY35W follow steps 13 17 If your turbocharger is an HX35W proceed to step 18 ACTUATOR INSTALLATION MODIFICATION 13 Remove the E clip from the wastegate arm allowing the actuator rod to be released S
4. If the fuel filter water separator has not been recently replaced it is highly recommended that this be done at this time Check vehicle owner s manual and factory service manual for replacement intervals and service procedure FUEL TRANSFER LIFT The fuel transfer pump supplies fuel from the fuel tank through the fuel filter water separator to the high pressure injection pump It is a 12 volt vane type self priming pump mounted to the left side of the engine behind the fuel filter water separator Check fuel lines to and from pump for leaks kinks or other restrictions A pump with external housing leaks must be replaced Clean the area around the pump and filter separator before performing the following test FUEL TRANSFER PUMP TEST If a factory service manual is available refer to the Fuel Transfer Pump Test in the Fuel System portion of the manual Otherwise perform the test as indicated For 01 02 trucks proceed to Step 3 1 Remove the two hex plugs from the top of the fuel filter water separator mount and replace them with two inline check adapter fittings Use the fittings supplied in Banks part number 43910 test gauge kit or Parker part number AVU1 2 Access Valve Male connector or equivalent See Figure 1 2 Install the included fuel pressure test gauge with appropriate hose Figure 1 INLINE CHECK YALVE ADAPTER FITTINGS INLET PORT FUEL FILTER WATER SEPARATOR MOUNT
5. Required These tools are necessary for all levels of installation unless otherwise specified e 1 4 and 38 drive ratchets with inch and metric sockets including 5 16 7 16 deep Wa drive sockets and a V4 drive extension e Inch and metric combination or open end wrenches Standard and Phillips head screwdrivers Standard and needle nose pliers Pocket or X Acto knife Clean shop towels or rags Drill motor Tap handle e V8 Allen wrench e 3 16 and 7 16 drill bits 1 4 NPT tap Heat gun suggested or cigarette lighter Pry bar or large groove joint water pump pliers Wire crimping stripping tool Oxy acetylene torch or reciprocating Saw Highly recommended tools and supplies not applicable to all system levels e Inch pound and foot pound torque wrenches Inline fuel pressure test check valve fittings Fuel pressure test gauge Compressed air source and hose Air pressure regulator Rubber tipped air blow gun Multimeter or 12 volt test light Penetrating oil or light lubricant spray 96397 480 Checking Lift Pump Performance NOTE Checking the lift pump performance is required before the installation of the your Banks performance product Complete the following steps and check to see that the fuel lift pump is operating within specified parameters otherwise damage to the fuel injection pump may occur FUEL FILTER AND LINES
6. TT RESTRICTION GAUGE RESTRICTIVE a RED ZONE 24 96397 v 8 0 Notes 96397 v 3 0 25 FIG 1 COMPONENT STINGER PLUS POWERPACK 1 CASTING High Ram Inlet 2 ASSEMBLY Turbine Housing Quick Turbo 3 PIPE Turbine Outlet 4 Intermediate 5 PIPE Extension Extended cab only 6 MUFFLER Banks Dynaflow 7 PIPE Monster Tailpipe 8 Tailpipe Tip 9 FILTER Banks Ram Air 10 ACTUATOR BigHead 11 OTTOMIND Engine Calibration Module P4 12 HARNESS Wire 13 THERMOCOUPLE 14 LEADWIRE Thermocouple 4 15 GAUGE Boost 4 16 GAUGE Pyrometer V 17 HARNESS Gauge Wiring v v 18 PANEL Two gauge Mounting v v KIT Service Banks Ram Air Filter 19 CLAMP Hanger 20 2 CLAMP 4 Exhaust Std 20 3 CLAMP 4 Exhaust Ext Cab 4 HOSE Silicone V KIT Wiring Gauge Lighting v V CONNECTOR Wire tap 4 2 BOLT 3 8 24 x 13 4 HEX 21 2 STUD 8 22 2 STUD 83 8 2 NUT 38 24 Collet Lock Nut 23 4 NUT 5 16 24 Nylock 2 NUT 5 16 24 Standard 2 WASHER 3 8 2 24 4 WASHER 5 16 A N 25 4 STAT O SEAL 2 CLAMP Spring Band 26 GASKET Inlet Casting v 26 96397 v8 0 FIG 1
7. the turbine housing to the center bearing section of the turbocharger See Figure 5 20 Remove the bolts lock plates and clamp plates Carefully remove the center bearing and compressor assembly from the cast iron turbine housing If the turbocharger has been in service for some time rust and carbon may prevent the center bearing and compressor assembly from easily separating from the turbine housing If light hammer blows penetrating oil or heat will not free the compressor assembly from the turbine housing the clamp bolt adjacent to the turbo oil inlet connection may be backed out so as to push against the bearing casting and separate the two components 10 26397 v 8 0 Figure 5 TURBO COMPRESSOR BEARING ASSEMBLY LOCKFLATES CLAMPLATES TURBINE HOUSING Remove any loose rust or carbon from 22 Install the turbine outlet elbow the bearing housing that might prevent onto the new turbine housing using proper engagement into the new the original bolts and the new gasket supplied Install the center bearing 21 install the center bearing and and compressor assembly into the compressor assembly into the new new turbine housing Apply a dab of turbine housing Apply a dab of anti anti seize compound to each of the seize compound to the bolts and then bolts and then torque the bolts to install bolts clamp plates and lock 100 in lbs Make sure the turbine inlet plates finger
8. ave the E clip for reinstallation Remove the two nuts holding the actuator to the compressor housing and remove the actuator 14 Tap the end of the boost reference tube on the stock actuator with the supplied 14 28 UNF tap Tap the tube just deep enough so that the end of the jet is recessed approximately 1 32 to 1 16 when threaded into the end of the boost reference tube and tightened until snug 15 install the jet into the end of the boost reference tube then peen the edge of the tube so that the jet cannot back out DO NOT use a thread locking compound as a substitute for peening the end of the tube Thread locking compounds will become ineffective due to temperature 16 Using the supplied 55 bit drill a hole in the side of the boost reference tube close to the area where the tube is attached to the actuator can 17 Reinstall the actuator on the compressor housing Be careful not to damage the O ring that seals the boost reference tube to the compressor housing Next reinstall the actuator rod end on to the wastegate arm This will be difficult since considerable force is required to extend the rod far enough Reinstall the E clip Proceed to step 23 TURBOCHARGER DISASSEMBLY and RE ASSEMBLY 18 Remove the turbine discharge elbow by removing the five bolts around the backside of the turbo 19 clamp the turbine inlet flange of the turbocharger in a smooth jaw bench vise Loosen the four bolts attaching
9. ble location under the lower edge of the dash panel for mounting the instrument panel provided where the driver can conveniently view it This will typically be above and slightly to the right of the accelerator pedal 18 96397 8 0 Figure 12 211 S63N3 vH OSNZIS A3IQI2VJ OINO J g 3IOL23NNO2 ig CA de SYNY 2114 HSVd GNINOILO amp XNY 8 OLNI SOLOSNNO2 NIVIN 2114 4 1 ONY Ova 02 GNO VO Tdd V NOISSINSNVAL SINE NO 214 AOSNAS CiOJINVA NO AOGNAS AV WAAL MOSNES AWWA NI ava ama AVL L OL LIANNOD STJOOM L104 LWA NOISSIWSNY3M1 DUYAOLNY NO 4 Taria 7 32 OL WO 37118 310103 ENIM 393 10NI1032 HOOT AS QIOVA JO OLNI WOOT all M SANYA OTid N3H L WOQ 133 M A3012V4 NO G3N0123NNO2 NOLUSOd FULOAHL AYA OTANI VAT ana Tana NO 2IO123NNOO dvi 28 44 LATING ON id 19 96397 V 8 0 Figure 13 SLIDE OTTOMIND BRACKET BETWEEN PLASTIC DASH PANEL AND METAL SUB PANEL FIRULE 14 ADDED TO FACTORY WIRE LOOM BLUE WIRE FROM BANKS OTTOMIND WIRE LOOM PCM CENTER PCM CONNECTOR 20 56397 8 0 Note Molded instrument consoles for top of dash or pillar mount and additional gauges are available through Gale Banks Engineering 56 Using the panel as a temp
10. boost leaks Shut off the engine and re tighten all intercooler and turbocharger boost clamps These connections may have loosened with time and if leaking will cause a drop in boost pressure with a loss in performance Check that clamps are properly positioned on hoses and periodically check tightness of hose clamps at regular maintenance intervals such as when the oil is changed Observe the operation of the boost and pyrometer gauges while driving under varying conditions Turbocharger boost pressure will increase as a function of load and engine RPM thus the engine will produce little boost while cruising at light throttle with maximum boost while climbing hills heavily loaded during acceleration Note the boost level seen during hard acceleration with a given load If performance seems to have deteriorated sometime in the future the maximum boost figures may be compared to see if boost has dropped off Lower boost may be caused by turbo ducting leaks a malfunctioning wastegate or fuel injection pump or dirty air filter Typical maximum boost pressure settings for the Dodge Cummins diesel will vary considerably with stick or automatic transmission options year model of vehicle and altitude Use your pyrometer gauge to monitor exhaust gas temperature EGT in the engine At idle exhaust gas temperature will be very low perhaps only 300 F As the engine is accelerated for higher speeds with greater loads
11. e crimped pipes to separate Remove the pin type hangers from the rubber frame mounts by prying with a pry bar or by pressing the pin out of the rubber with large water pump pliers A soapy water solution or a penetrating lubricant will ease the removal of pin type hangers from the rubber frame mounts Remove the two bolts that attach the turbine outlet pipe to the turbine outlet elbow and remove the turbine outlet pipe from the vehicle Keep these bolts for later use To remove the turbine outlet pipe it may be necessary to cut the pipe just to the rear of the pin hanger that slides into the hanger bracket on the transmission mount TURBOCHARGER REMOVAL 2 Loosen the clamps that attach the air inlet tube to the air filter housing and to the turbocharger and remove the air inlet tube from the vehicle Remove the air filter housing from the vehicle This will allow easier access to the turbocharger 3 Loosen the upper hose clamp on the turbocharger oil drain tube hose located between the two sections of the oil drain tube Disconnect the oil supply hose at the turbocharger 5 Note the orientation of the compressor housing in the vehicle When the new assembly is installed the orientation of the compressor outlet should remain the same Remove the turbocharger mounting nuts or bolts and the turbocharger from the exhaust manifold CAUTION Anytime the turbocharger is removed from the engine take care that no fo
12. gnment between the turbine housing and turbocharger center section Retighten bolts and check again 26 Reconnect and tighten the turbo oil supply hose EXHAUST INSTALLATION 27 Position the new Banks Monster T O P turbine outlet pipe onto the turbine outlet elbow See Figure 3 on page 6 7 Install the attaching bolts to hold it in place but do not tighten them yet 28 Place a 4 muffler clamp onto the outlet of the turbine outlet pipe and then slide the intermediate pipe into the hanger at the transmission mount and onto the turbine outlet pipe Note on extended cab short bed models it maybe necessary to shorten the intermediate pipe Install the muffler and tailpipe without clamps and determine how much to trim based on the hanger position 29 extended cab quad cab long bed models only position another 4 clamp onto the outlet end of the intermediate pipe and install the extension pipe onto the intermediate pipe 30 install the muffler assembly onto the end of the extension or intermediate pipe Temporarily support the muffler and install the hanger clamp at the front of the muffler Snug the nuts but do not fully tighten them 31 At the rear of the muffler slip a 4 clamp over the outlet of the muffler Install the tailpipe up over the axle and into the muffler outlet Place the hanger pins into the rubber frame mounts behind the axle Slip the 5 Monster tailpipe tip on Keep the wrapping on
13. he head of the intake bolt Important do not allow the terminal on the element end of the ground cable to come in contact with the upper heater lug or with the injector line Retighten the retaining nut and reinstall the front intake manifold bolt through the ring terminal See Figure 7 35 Thread the four studs provided into the intake casting placing the shorter studs on the inboard side Note The end of the stud with the coarse thread goes into the intake manifold Use Loctite sparingly on the threads Using the two Sie 24 nuts provided tighten the studs into the casting by threading both nuts onto each stud tightening the nuts against each other using two 1 2 open end wrenches and then tightening the Figure 6 e HANGER ANGLE SHOULD ALLOW PIPE TO EXPAND TOWARD REAR OF VEHICLE gn DIRECTION OF EXFANSION 96397 480 13 Figure 7 INSTALL GKOUND WIKE UNDEK INSIDE FRONT BOLT ON MANIFOLD COVER PLATE y stud by turning the wrench on the top compressor outlet and all connection nut Reverse the process and remove points with a non oil based solvent the nuts from the stud and then repeat such as Acetone Mineral Spirits on each remaining stud See Figure 8 Denatured Alcohol or Lacquer Thinner Read and follow the manufactures operation instruction for non oil based solvent cleaner 36 slide the intake gasket provided over the s
14. late drill two 3 16 diameter holes in the dash and mount the panel with two No 10 x 12 machine screws nuts and star washers provided 57 Locate the gauge wire loom with the four wire connector in the Banks system Plug the connector into the corresponding location on the OttoMind box Route the wire loom from the OttoMind box toward the gauges location 58 install the DynaFact boost and pyrometer gauges in the mounting panel using the clamps and thumbnuts provided Plug the BLACK wire lead to the male spade terminal on the BLACK wire of each gauge wire harness Plug the YELLOW wire into the Yellow wire of the boost gauge wire harness and the RED wire into the RED wire of the pyrometer gauge wire harness The ORANGE wire remains unused 59 Connect the 4 pin connector of each gauge into the back of its corresponding gauge a Crimp the remaining Black and RED wires from each 4 pin connector gauge harness to the butt connectors as shown in Figure 15 b Strip one end of the RED wire and crimp it to the butt connector containing the RED wires from step a Strip one end of the BLACK wire and crimp it to the butt connector containing the BLACK wires from step a Route the RED wire to the fuse box Locate the appropriate fuse for instrument lighting in the owner s manual Cut the RED wire as required and strip the end Crimp the push on connector to the RED wire and connect to the fuse as show
15. n in Figure 15 Alternatively locate power wire to dimmer switch and install T tap Cut the RED wire as required and strip the end Crimp the push on T tap connector to the RED wire and connect to T tap on dimmer power wire Locate a metal surface that will serve as an acceptable chassis ground Cut the BLACK wire to a sufficient length that will allow it to reach the chassis ground and strip the end Crimp the ring terminal to the BLACK wire as shown in Figure 15 Drill a 18 hole if required to attach the ring terminal to the chassis ground Caution If drilling check the backside to make sure there are no components that may be damaged by drilling Use the supplied self tapping screw to secure the ring terminal to the chassis ground 96397 480 21 Figure 15 4 CONNECTORS TO GAUGE LED RED WIRE BLACK WIRE BUTT CONNECTORS UI T BLACK WIRE SELF TAPPING SCREW Y IF REQUIRED ni RED WIRE Km gt PUSH ON pF BLADE FUSE TAP MINI BLADE GLASS FUSE TAF FUSE 22 96397 8 0 Checking Engine Performance Go over the entire installation as a precautionary check to ensure that all clamps are tight wiring and hoses are properly routed and connections are tight Start the engine and allow it to warm up Drive the vehicle under light load normal around town driving for 20 to 30 minutes and listen for any exhaust leaks or rattles or intake
16. plug the corresponding connectors on the OttoMind wire loom into the sensor and the factory wire loom See Figure 12 43 Plug the corresponding male bullet connector on the wire loom to the installed connector on the pump 44 Remove three Phillips head screws from the trim panel below the steering column and remove panel by pulling directly toward the rear of the vehicle Toward the right side of the opening remove two Phillips head screws and install the OttoMind as shown in Figure 13 45 Plug the main connector from the wire loom into the OttoMind connector Route all wiring away from any pedals or other moving components Using the cable ties supplied secure the wiring under the dash Reinstall the trim panel Secure all wiring under the hood away from heat sources or sharp edges For manual transmissions the BLUE wire will be unused and may be cable tied out of the way 46 Remove the forward bolt on the fuel filter mounting bracket Install the ring terminal of the ground wire under the head of the bolt and reinstall the bolt See Figure 12 16 96397 8 0 Figure 10 47 Locate the gray Throttle Position mounted on the passenger s Sensor TPS connector just above side of the firewall in the engine the injection pump Unplug the compartment See Figure 14 connector and plug both ends into 49 Make sure that the ignition is off the corresponding connectors on the then disconnect all
17. re it should be no more than 5 PSI lower than the inlet pressure previously recorded If a greater pressure drop is observed replace the fuel filter Once the pressure test is complete remove the check valves and re install the hex plugs in the fuel filter mount 96397 8 0 8 General Assembly Figure 3 Description High Rame Inlet Casting Quick Turbo Turbine Housing Assembly 5 Monster T O P Turbine Outlet Pipe Intermediate Pipe 20 Extension Pipe Extended cab Only Dynaflow Muffler Monster Tailpipe Tailpipe Tip Banks Ram Air Filter 10 BigHead Wastegate Actuator 11 OttoMind TLC Engine Calibration Module 12 Wire Harness 13 Thermocouple 14 Leadwire Thermocouple 15 DynaFact Boost Gauge 16 DynaFact Pyrometer Gauge 17 Wire Harness Gauge COIN DOB WIN SO 6 96397 v 8 0 18 19 20 21 22 23 24 25 26 27 28 Two gauge Mounting Panel Hanger Clamp 4 Exhaust Clamp 2 extended cabs 3 8 Stud 2 89 8 Stud 2 5 16 24 Nylock Nut 4 5 16 AN Washer 4 Stat O Seal 4 Gasket Inlet Casting Gasket Turbine Inlet Urocal Banks Power 3 96397 v 8 0 7 System Installation Procedure EXHAUST REMOVAL 1 Under vehicle remove the entire factory exhaust system Starting at the rear of the vehicle remove each component by either cutting through the pipe near the clamps or by removing the clamps and heating the joints to a red orange color to allow th
18. reign objects enter any of the turbocharger connections on the engine or the turbocharger Foreign objects entering air exhaust or oil connections may cause major damage to the engine and or turbocharger and is not covered under any warranty Cover the open end of the intercooler pipe with a rag as this pipe is very susceptible to foreign object entry 6 Clean and inspect the exhaust flange mounting surfaces on the exhaust manifold Make sure the surface is clean and dry THERMOCOUPLE INSTALLATION 7 The thermocouple monitors the temperature of the exhaust gases entering the turbocharger at the turbine housing Installation requires that the exhaust manifold be drilled near the outlet of the manifold adjacent to the turbine housing For this reason it is essential that the turbocharger be removed from the engine in order to clean out any metal chips from drilling that could cause turbine blade damage The Cummins ISB engine uses a divided exhaust manifold and turbocharger The thermocouple may be installed to sample exhaust temperature in either exhaust passage We recommend the rear passage toward the firewall 8 stuff a small shop towel or rag 4 to 5 inches into the rear exhaust manifold passage through the turbocharger mounting flange This is to prevent chips from entering the manifold while drilling and tapping 8 96397 8 0 9 Drill through the exhaust manifold into the rear passage at the location
19. s or more is recommended where possible 5 When raising the vehicle support it on properly weight rated safety stands ramps or a commercial hoist Follow the manufacturer s safety precautions Take care to balance the 2 96397 v 8 0 vehicle to prevent it from slipping or falling When using ramps be sure the front wheels are centered squarely on the topsides put the transmission in park set the hand brake and place blocks behind the rear wheels Caution Do not use floor jacks to support the vehicle while working under it Do not raise the vehicle onto concrete blocks masonry or any other item not intended specifically for this use 6 During installation keep your work area and components clean to avoid possible dirt entry into the engine 7 For proper performance from your Banks PowerPack components and to prevent engine damage it is essential that your engine s fuel system be capable of delivering fuel at the factory s specification We have often found vehicles with inadequate low pressure side fuel delivery that isn t apparent until performance modifications are made It is very important that the following fuel system components are checked for proper operation before completing the installation Notification The Banks Ram Air Filter comes pre oiled and no oiling is necessary for initial installation Service the filter as specified in the Filter Maintenance Section of this manual Tools
20. t Make a cross shaped incision in the plug and reinstall it in the firewall See Figure 9 For manual transmission models make an incision in the main wiring loom grommet above the wire bundle Take care to not cut any wiring See Figure 9 Insert the black twist connector on the OttoMind wire loom provided through the grommet from the engine compartment side 39 Locate the two black wire sheaths covering four black wires at the top back portion of the fuel injection pump See Figure 10 Caution It is very important that you select the proper wire The Banks OttoMind will not function properly if installed incorrectly 40 At the front of the intake manifold remove the three bolts holding the throttle bracket assembly to the head Move this assembly toward the driver s side battery This will allow easier access to the fuel pump wiring 41 Locate a black wire tap connector and a packet of dielectric grease in the Banks system Squirt a generous 96397 80 15 Figure 9 AUTOMATIC TRANSMISSION VEHICLES MAKE A CROSS SHAPED INCISION IN THE LARGE RUBBER FLUG MANUAL TRANSMISSION VEHICLES CUT A 3 4 SLIT IN THE BOOT ON THE LARGE WIRING HARNESS GROMET amount of the grease into the connector and install the connector onto the wire identified in step 39 as shown in Figure 11 42 Locate the Manifold Absolute Pressure MAP sensor on the intake manifold Unplug the factory connector and
21. t they are proper 96397 v 8 0 23 Filter Maintenance Notification The Banks Ram Air Filter comes pre oiled and no oiling is necessary for initial installation Service the filter as specified in this Section of the manual 1 service Banks Ram Air Filter every 50 100 000 miles on street driven applications Service more often in off road or heavy dust conditions If an air filter restriction gauge is installed then clean the element when the air filter restriction gauge enters the restrictive red zone See Figure 45 2 Use Banks Ram Air Filter cleaning system part 90094 available from Gale Banks Engineering to service the Air Filter Follow the instructions included with the cleaning system to clean and re oil your Banks Ram Air Filter No gasoline cleaning No steam cleaning No caustic cleaning solutions No strong detergents No high pressure car wash No parts cleaning solvents Any of these No s can cause harm to the cotton filter media plus SHRINK and HARDEN the rubber end caps CAUTION Extremely fine dust from agriculture or off road use will pull the oil from the element Frequent re oiling of the element s clean side might be required Completely service when practicable For extra protection use an air filter sealing grease on rubber ends of the element Service only with Banks Ram Air filter cleaner and Banks Ram Air filter oil Figure 45 Typical air filter restriction gauge AIR FILTER
22. the EGT will rise The highest EGT will be seen under maximum load at full throttle such as climbing a steep grade with a heavily laden vehicle Your pyrometer is color coded to assist in your reading of the gauge The red zone indicate a dangerous level of temperature Your engine should not operate in this range for more than a few seconds The blue zone indicates when it is safe to shut the engine off To avoid heat damage to various engine components it is recommended that the exhaust gases cool below 400 before the engine is shut down Your OttoMind is calibrated to maintain a maximum EGT of 1300 F You may experience brief excursions slightly above 1300 F under acceleration This is normal and EGT should return to at or below 1300 within a few seconds If you find that EGT remains high for any length of time check for boost leaks or a dirty air filter If you feel that your OttoMind is not functioning properly some diagnostics can be performed Remove the OttoMind from its mounting location while keeping all three connectors plugged in Observe the two LED s mounted on the programming port The upper left LED will indicate red when the key is on Once the engine is started and idling the red LED will go out and the upper right LED will indicate green As load increases the red LED will progressively grow brighter as fuel delivery is increased If LED s do not indicate as suggested check all connections to ensure tha
23. three connectors OttoMind wire loom See Figure 12 from the PCM for easier accessibility Note For manual transmission to the wires applications proceed to Step 53 50 select the center white connector 48 On automatic transmission and locate the wire in the No 11 models locate the PCM rectangular connector pin cavity This will typically metal box with three connectors be an ORANGE wire with a BLACK 96397 v 3 0 17 Figure 11 tracer stripe Install a T Tap connector on this wire approximately 2 3 inches from the white connector body 51 Plug the three cable connectors back into the PCM The connector bodies are indexed so they cannot be installed in the wrong location 52 Locate the long blue wire emerging from the middle of the Banks OttoMind wire loom Route this wire with the factory wire loom across the base of the cowl and over to the PCM Plug the wire into the T Tap installed on the No 11 pin wire at the center PCM connector 53 Reinstall the throttle bracket and bolts removed earlier Tighten to 18 ft lbs Reinstall the air filter housing on the turbocharger linstall the Banks Ram Air filter 54 Route the thermocouple leadwire through the grommet in the firewall Connect the YELLOW and RED wires of the leadwire to the corresponding connectors on the thermocouple Plug the remaining end into the proper port on the OttoMind DYNAFACT INSTRUMENTATION INSTALLATION 55 Choose a suita
24. tight to allow for final flange does not rotate in the vise while positioning torquing 96397 amp 0 11 TURBOCHARGER INSTALLATION 23 Note Some turbos are mounted with four studs protruding from the exhaust manifold while others have two studs in the manifold and two in the factory turbine housing Use the supplied 3 8 24 x 13 4 bolts and crimplock nuts for the upper holes on the turbine mounting flange Install the new turbine inlet gasket provided and apply a dab of anti seize compound to the four turbo mounting studs Install the turbocharger on the exhaust manifold As the turbocharger is reinstalled slip the oil drain tube into the drain hose Tighten the turbocharger mounting nuts to 24 ft Ibs Tighten the oil drain hose clamp Note Before slipping any boost tubes and the corresponding hoses into position ensure that all connection ends are clean and free of any oil residue and contaminates Clean compressor outlet and all connection points with a non oil based solvent such as Acetone Mineral Spirits Denatured Alcohol or Lacquer Thinner Read and follow the manufactures operation instruction for non oil based solvent cleaner 24 Align the compressor outlet with the intercooler hose adapter and tighten the clamp Tighten the turbine housing clamp plate bolts to 100 in Ibs 25 spin the turbocharger shaft to make sure it turns freely If not loosen the turbine clamp plate bolts and check for misali
25. tuds and set the High Ram in place on the studs Twist a Stat o seal washer over each stud followed 37 on 981 2 00 models rotate the by a flat 5 16 AN washer Install a dipstick tube clamp as shown in 16 24 nylock nut on each stud and Figure 8 then reinstall the dipstick tighten all four evenly tube bolt into the threaded boss provided For 2001 models a spacer bracket is provided Mount it to the High Ram casting using the original factory bolt Fasten the dipstick tube bracket to the spacer bracket using i the 5 16 nylock nut and bolt Install ME tools or excessive the silicone inlet hose onto the inlet of the casting and tighten The wire loom Note Before slipping any boost tubes clamp is not reinstalled and the corresponding hoses into position ensure that all connection OTTOMIND INSTALLATION ends are clean and free of any oil 38 For automatic transmission residue and contaminates Clean models locate and remove the rubber Caution Use only handtools when tightening the High Ram Tighten snugly but do not over tighten Damage to the High Ram casting can result from the use 14 96397 v 8 0 Figure 8 24 NYLOCK NUT BOLT mu Ze AN WASHER d Die STAT O SEAL FACTORY DIPSTICK WASHER T plug mounted in the firewall slightly above and to the right of the steering shaft as viewed facing the firewall through the engine compartmen
26. until installation is complete The tip should be rotated so the clamp nut is pointing down Install the 5 tip so that it hangs past the end of the tailpipe by 1 for fleet side trucks and 21 2 for duallies or where aesthetically pleasing 32 starting from the front of the vehicle tighten all exhaust system attaching bolts and clamps Make 12 96397 8 0 sure each slip joint is fully inserted and that all frame mount hangers are hanging in a forward position See Figure 6 For Stinger Plus Installations proceed to step 38 HIGH RAM INSTALLATION 33 Disconnect the hose joint at the inlet end of the factory intake casting Remove the dipstick tube retaining bolt from the inlet casting Remove the wire loom clamp from the rear of the inlet casting This may break upon removal from the casting it is not reused Remove the four bolts that mount the inlet casting to the intake manifold and remove the factory inlet casting Note at this point it may be easier to complete the OttoMind installation while the intake casting is off Cover the opening in the intake manifold with a clean rag to prevent foreign object entry and proceed to step 38 After you have completed step 54 return to step 34 34 Remove the front inboard bolt from the baseplate of the intake manifold Loosen the nut on the ground strap for the intake heater element and rotate the cable around so that the ring terminal can be reinstalled under t
27. with Installation Instructions Banks PowerPack TLC System Including Stinger Plus 1998 2002 Dodge 5 9L Cummins 24 valve ISB Pickup Trucks THIS MANUAL IS FOR USE WITH SYSTEMS 49320 49335 amp 49351 49356 Gale Banks Engineering 546 Duggan Avenue Azusa CA 91702 626 969 9600 e Fax 626 334 1743 Product Information amp Sales 800 438 7693 bankspower com 2009 Gale Banks Engineering 12 14 09 PN 96397 v 8 0 General Installation Practices Dear Customer If you have any questions concerning the installation of your Banks Power system please call our Technical Service Hotline at 888 839 2700 between 7 00 am and 5 00 pm PT If you have any questions relating to shipping or billing please contact our Customer Service Department at 888 839 5600 Thank you 1 For ease of installation of your Banks Stinger Plus or PowerPack system familiarize yourself with the procedure by reading the entire manual before starting work This instruction manual contains 26 pages of text illustrations and parts listing 2 Throughout this manual the left side of the vehicle refers to the driver s side and the right side to the passenger s Side 3 Disconnect the ground cable from the battery before beginning work If there are two batteries disconnect both 4 Route and tie wires and hoses a minimum of 6 inches away from exhaust heat moving parts and sharp edges Clearance of 8 inche

Manual - Banks Power

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