Banks Power Banks Sidewinder Intercooler 1999-2006 4.0L I-6 Jeep Wrangler Gas Wrangler 4.0L Owner's Manual

Owner’sManual
with Installation Instructions
Banks Sidewinder
®
with Intercooler
1999-2006 4.0L I-6 Jeep Wrangler
THIS MANUAL IS FOR USE WITH SYSTEMS: 2005-2006 WRANGLER - SYSTEM 24245,
2003-2004 WRANGLER - SYSTEM 24243, 1999-2002 WRANGLER - SYSTEM 24242
Gale Banks Engineering strongly
recommends the use of an OEM radiator
and fan assembly with the Banks Sidewinder
Turbo System. Cooling system issues
can result from the use of aftermarket
radiators and electric fans.
The Banks Sidewinder Turbo system results
in significantly higher power and torque
output. Depending on vehicle usage and
driving style, additional drivetrain
upgrades may be required to ensure
vehicle reliability.
Gale Banks Engineering
546 Duggan Avenue • Azusa, CA 91702
(626) 969-9600 • Fax (626) 334-1743
Product Information & Sales: (888) 635-4565
Customer Support: (888) 839-5600
Installation Support: (888) 839-2700
bankspower.com
©2015 Gale Banks Engineering
07/21/15 PN 96323 V.1.0
Additional products available from
Banks for the 1999-2006 Jeep Wrangler
Banks iQ® System
(P/N 61195)
Banks Ram-Air® Filter
(P/N 41506X)
-5
” touchscreen Man-Machine
Interface
- Interchangable gauge display, read
and clear codes, monitor engine
diagnostics, log data, time your
vehicles runs and much more.
- Large Conical lifetime
- High-flow filtration
Banks Straight-Shot WaterMethanol Injection
(P/N 45001)
Banks Blow-Off Valve Spacer
(P/N 24285)
®
-
aximizes Engine Performance
M
Cools Intake Temperatures
Digital Controller (included)
Plug-and-Play wiring
Greater flow than the competition
Higher Pump Volume than others.
Banks Double-Shot® WaterMethanol Injection
(P/N 45003)
Banks Ram-Air®
Pre-Filter (P/N 42640)
- Extra layer of filtration protection
-R
educes intake air temperatures
- Quickens turbo response
- Unmistakable sound
Banks TorqueTubes®
Exhaust Manifold, 4.0L
(P/N 51306)
-
Banks Monster®
Exhaust System
(P/N 51314, 51315)
-Increases exhaust flow.
- Decreases backpressure.
- Lowers exhaust gas temperatures.
- Increases power.
Banks Monster ®
Muffler Delete
(P/N 51306)
-M
inimizes backpressure for
increased turbocharger response,
adds aggressive exhaust tone.
- For use with Banks Monster
Exhaust Systems 51314 and 51315.
Improves power and torque.
Reduces engine load.
Improves economy.
Tough construction.
-T
he Double-Shot system offers
the same benefits of the StraightShot and adds a second stage for
increased output and control.
For More Information please call (888) 635-4565
or Visit us online @ www.bankspower.com
2
96323 v.1.0
Dear Customer,
If you have any questions concerning the installation of your
Banks Sidewinder® Turbo System,
please call our Technical Service
Hotline at (888) 839-2700 between
7:00 am and 4:00 pm (PT). If you
have any questions relating to
shipping or billing, please contact
our Customer Service Department
at (888) 839-5600.
Thank you.
General Installation
Practices
1. For ease of installation of your
Banks Sidewinder® with Intercooler system (BSWI), familiarize yourself with
the procedure by reading the entire
manual before starting work. This
instruction manual contains 32 pages
of text, illustrations and parts listing.
2. Route and tie wires and hoses
a minimum of 6" away from exhaust
heat, moving parts and sharp edges.
Clearance of 8" or more is recommended where possible.
3. When raising the vehicle, sup-
port it on properly weight-rated safety
stands, ramps or a commercial hoist.
Follow the manufacturer’s safety
precautions. Take care to balance the
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.
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.
4. During installation, keep your
work area and components clean
to avoid possible dirt entry into the
engine.
5. For proper performance and to
prevent engine damage it is essential
that your engine systems be capable
of supporting the additional requirements of the Banks Sidewinder®
Turbo System. To ensure proper per-
formance, please complete
every step in the engine health
inspection section.
✓
Tools Required • ¹/₈" and ³/₈" drive ratchets with
inch and metric sockets ............ ¹/₂" drive ratchet or
•
breaker bar.................................. • ¹/₄" and
³/₈" drive extensions ... •Inch and metric combination or
open-end wrenches ................... • ⁵/₈" Spark plug socket ............... •Standard and Phillips head
screwdrivers ............................... •1 ¹/₁₆" Oil pressure sensor socket..
...................................................... • Fuel pressure tester adapter kit.
• 60 PSI gauge................................ Table of Contents
General Installation Practices.............. 3
Tools Required..................................... 3
Engine Health Inspection..................... 4
Banks Sidewinder® Turbo System with
Intercooler Installation Procedure....... 5
Radiator Removal................................. 5
Fuel Injectors....................................... 5
Throttle Body Spacer........................... 6
• T15, T20 and T40 Torx drivers ... PCV Hose/Vacuum Control.................. 9
•Standard, vice grip & needle
nose pliers .................................. Camshaft Synchronizer........................ 9
• Crescent wrench......................... • Pocket or X-Acto knife................ • Tape measure.............................. Alternator Removal............................ 10
Turbocharger Oil Supply.................... 10
Turbocharger Assembly..................... 10
•Clean shop towels or rags.......... ......
Oil Pan and Exhaust Removal............ 11
•Inch-pound or foot-pound
torque wrench............................. Turbine Inlet and Outlet..................... 12
•Pneumatic reciprocating saw
or equivalent................................ •Pneumatic die grinder
or equivalent................................ •Compressed air source
and hoses ................................... • Flashlight or shop light............... Turbocharger Oil Return.................... 12
Ram-Air® Intake &
Super-Scoop®..................................... 13
Super-Scoop® Hood Cut Template.... 16
Intercooler System Installation
Procedure .......................................... 21
Low Temperature Radiator
Install.................................................. 21
• Ear and eye protection............... Pump And Wiring Installation............ 22
• Drill and stepped drill bit............ Techni-cooler Installation.................. 22
• Permanent marker...................... Plumbing Install.................................. 24
•
1 ¹/₂" hole saw............................ Banks Ram-Air® Installation
Procedure........................................... 26
Additional tools for 1999-2002
Model Years
Air Filter and Housing........................ 26
•Wire cutters, strippers and
crimpers....................................... Boost Gauge....................................... 26
•Heat gun/source for
shrink wrap.................................. Fuel and Oil........................................ 28
Highly recommended
Tools and Supplies:
Flash Tune.......................................... 27
Test Drive........................................... 28
Parts List............................................ 29
•Penetrating oil or light
lubricant spray............................. • Deburring tool ............................ •Cylinder leakage and
compression testers................... • 15 mm swivel socket.................. 96323 v.1.0
3
Engine Health Inspection
The Banks Sidewinder® with Intercooler
system (BSWI) MUST be installed
on an engine that is known to be in
good operating condition in order to
maintain engine life. Before installing
your BSWI, you must perform a
cylinder leakage test, compression
test, spark plug inspection, and key
on fuel pressure test. If you are not
familiar and experienced with these
tests, we recommend that you have
the vehicle inspected by a qualified
technician to ensure that your engine
is in good health and will support the
BSWI.
Whether you complete these tests
yourself or have a qualified technician
complete them, fill out the following
tables for future reference.
Reference Figure 1
1. Remove passenger side radiator
support rod by removing two bolts.
13mm socket
2. Disconnect intake air temperature
(IAT) sensor connector from stock
intake tube. Remove and retain sensor
for use on new intake tube.
3. Remove stock intake tube by
loosening one clamp at throttle body
and one clamp at air box. Cover
throttle body inlet with a cap or clean
rag.
8mm socket
4. Remove front positive crankcase
ventilation (PCV) hose from air box lid
and top of engine.
5. Remove air box lid and air filter
element. Remove air box housing by
removing three bolts from inside air
box housing.
8mm socket
6. Remove ignition coil pack to
access spark plugs by removing four
bolts.
13mm socket
Do not disconnect
connector at rear of ignition
coil pack. Set ignition coil pack
where it will not interfere with
removing spark plugs.
4
96323 v.1.0
7. Using compressed air source,
blow any debris away from spark
plugs to prevent any foreign objects
from falling into cylinders once spark
plugs are removed. Remove ALL
spark plugs.
⁵/₈" spark plug socket
Mark each spark
plug with the cylinder number
that it was in. If there is a
problem, this may help locate
which cylinder has the issue.
8. Perform a spark plug inspection,
cylinder leakage test, dynamic
compression test, and key on fuel
pressure test. Record all values in
following tables for future reference.
Engine Component
Good
Bad
Spark Plug 1
Spark Plug 2
Spark Plug 3
Spark Plug 4
Spark Plug 5
Spark Plug 6
Spark plugs should not have any
unusual discoloration or pitting.
We recommend replacing all spark
plugs with new OEM parts. Check
the gap on spark plugs, whether
they are being reused or brand new.
Gap requirements are posted on
the inside of the hood or in vehicle
owner’s manual.
Engine Property
Value
Unit
If you record cylinder leakage
greater than 50% or if the leakage in
a cylinder is 2-3 times greater than
the other cylinders, there may be an
issue with the engine.
Take the vehicle to a qualified
technician before installing the
Sidewinder® Turbo System.
Engine Property
Value
Unit
Cyl. 1 Compression
psi
Cyl. 2 Compression
psi
Cyl. 3 Compression
psi
Cyl. 4 Compression
psi
Cyl. 5 Compression
psi
Cyl. 6 Compression
psi
Typical cylinder compression is
160-185+ psi, with no more than
10% difference between the highest
and lowest values. If you record
compression lower than 160 psi or
a difference greater than 10%, there
may be an issue with the engine.
Take the vehicle to a qualified
technician before installing the
Sidewinder® Turbo System.
Key on fuel pressure:_______________
Verify that the key-on fuel pressure
is within factory-specific tolerance.
Lower or higher fuel pressure can
cause major driveability issues
and lead to engine damage with
installation of the Sidewinder®
Turbo System. If your measured fuel
pressure is outside of the factory
tolerance, take the vehicle to a
qualified technician for repair before
installing the Sidewinder® Turbo
System.
Cyl. 1 Leakage
%
Cyl. 2 Leakage
%
Cyl. 3 Leakage
%
Cyl. 4 Leakage
%
Cyl. 5 Leakage
%
Date: _____________________________
Cyl. 6 Leakage
%
9. Reinstall spark plugs and ignition
coil pack after checking spark plug
gaps. Apply dielectric grease to inside
of ignition coil pack boots.
Ideal cylinder leakage is less than
10%, however you may see higher
values depending on the condition
of your vehicle. Banks Sidewinder®
Turbo System can be installed on a
vehicle with up to 50% leakage in a
cylinder, at the owner’s discretion.
If you are unsure whether your
vehicle can support the Sidewinder®
Turbo System, consult a qualified
technician.
Technician Signature:_______________
Figure 1
IAT Sensor ('05-06)
Radiator Support Rod
Ignition
Coil Pack
IAT Sensor
Location ('99-04)
Front
PCV Hose
Coolant Overflow
Reservoir
Coolant Hose
Fan Shroud
Radiator
BANKS SIDEWINDER® WITH INTERCOOLER INSTALLATION PROCEDURE
If you are not going
to weld oil return bung onto
the oil pan yourself, we recommend starting by removing the
oil pan so that it can be welded
by a qualified welder as you
proceed with installation. See
Oil Pan and Exhaust Removal
and Turbocharger Oil Return on
pages 10 and 15.
The provided drive
belt will only work for stock configuration front engine accessory pulleys. If your vehicle is
equipped with an aftermarket
power steering pulley or other
aftermarket pulley with a diameter smaller than the stock
equivalent, you must purchase
a shorter drive belt from your
local automotive supply shop.
We have found that a 91.0”
(2310 mm 6PK2310 or 910K6 or
equivalent) fits appropriately
with aftermarket power
steering pump pulleys.
RADIATOR REMOVAL
Disconnect
battery or batteries before
beginning this installation.
1.
Remove both radiator support
rods for better access. See Figure 1
15 mm socket
2. Drain coolant system using the
petcock on the bottom passenger
side of the radiator.
3. Remove coolant overflow
reservoir by lifting to release catches
and pulling towards rear of vehicle.
See Figure 1
4. Remove radiator fan and shroud.
Remove radiator by removing 4 bolts
and disconnecting 2 coolant hoses.
Cover open ports and store in clean
area to keep it free of debris.
See Figure 1
11 mm socket (Shroud)
10 mm socket (Radiator)
FUEL INJECTORS
1. Disconnect manifold air pressure
(MAP) sensor connector, throttle
position sensor (TPS) connector, and
idle air control (IAC) valve connector
from throttle body. See Figure 2
96323 v.1.0
5
Figure 2
Throttle Cable
Bracket
IAC Valve
TPS
MAP Sensor
2. Disconnect throttle, trans control
(if equipped), and cruise control cables
from throttle lever.
3. Remove throttle body by
removing four bolts and lifting straight
up. Cover intake manifold inlet with a
cap or clean rag.
4. Remove throttle cable/cruise
control cable bracket by removing
two bolts. See Figure 2
10mm socket
Fuel system may
be under pressure!
5. Using compressed air source, blow
any debris away from fuel injectors to
prevent any foreign objects from falling
into intake manifold once fuel injectors
are removed. Disconnect fuel injector
connectors. Remove injector rail by
removing two nuts and two studs.
10mm deep socket
6. Drain injector rail by placing a
cup under rear of fuel injector rail
and removing the #6 injector (rear
most). Tilt fuel injector rail towards
cup at rear.
7. Remove remaining injectors and
retain securing clips. Injectors should
have O-rings at both ends. Locate and
remove any o-rings that separated
from injectors during removal.
8. Install provided injectors (P/N
43643) into fuel injector rail using
original securing clips. A drop of
oil can be used on o-rings to ease
installation.
Be careful not to
pinch or cut o-rings when
reinstalling fuel injectors as
this will cause a major fuel
leak.
10.Reinstall fuel injector rail and
reconnect fuel injector connectors.
Torque to 10 lb-ft.
12.After installation of upgraded
fuel injectors, a leak check must be
performed under pressure. To check
for fuel system leaks, turn ignition
key on but do not start engine. This
will run the in-tank fuel pump for
a brief time, which will build fuel
pressure in fuel rail. After keying
ignition on, examine area around the
fuel injectors and fuel rail for any
leaks. Turn ignition off and back on
again without starting engine, and
re-examine for leaks. Repeat this
process 4-5 times to insure there are
no fuel system leaks - it may
be helpful to have an assistant during
this process.
THROTTLE BODY
SPACER
11.Reinstall throttle cable/cruise
control cable bracket using provided
spacers (P/N 42730) and bolts (P/N
91759). Torque to 8 lb-ft.
At this point in the
installation disconnect both
leads to the battery. Leave
disconnected until installation
is complete.
Bracket varies
de-pending on model year, one
spacer and one bolt may not
be used.
1. Remove stock MAP sensor from
throttle body by removing two bolts.
T15 Torx
2. Mount high pressure MAP
6
96323 v.1.0
Figure 3
Figure 4
Compression
Ferrule
Stock
MAP
Barb
Brass
Barb
High-Pressure
MAP Sensor
sensor (P/N 43625) in throttle body
spacer (P/N 43628) using provided
washers (P/N 91826) and bolts (P/N
91860). See Figure 3
3. Mount brass barb fitting
(P/N 92131) and brass compression
ferrule (from boost gauge kit) in
throttle body spacer (Figure 3) using
provided thread sealant (P/N 90040).
⁷/₁₆" and ⁹/₁₆" wrenches
4. Carefully scrape intake manifold
and throttle body to remove any
debris that will prohibit sealing. Wipe
clean with rag. Ensure that no debris
enters intake.
5. Install throttle body and spacer
with the provided gaskets (P/N
93078) on both sides of spacer and
secure with bolts (P/N 91761). Torque
to 8 lb-ft.
10mm socket
6. Connect blow-off valve (BOV)
reference hose (P/N 94122) to stock
MAP sensor barb on throttle body
using silver spring band clamp ( (P/N
92775). See Figure 4
7. Reconnect throttle, trans control
(if equipped), and cruise control
cables to throttle lever.
8. Reconnect MAP sensor, TPS, and
IAC valve connectors.
Tape on wire
harness may need to be cut for
MAP sensor connector to reach
new position. Take care while
cutting as to not damage any
wires.
For 1999-2002
Model Years ONLY:
MAP Sensor Connector
Replacement
The 1999-2002 model Wranglers are
equipped with a factory MAP sensor
connector that is not compatible with
the high-pressure (2 atmosphere)
sensor that is required for proper
operation with the Sidewinder®
Turbo kit - your system includes a
connector pigtail kit (PN 43626) to
replace your stock sensor connector.
To install the new MAP sensor
connector:
1. Locate the stock MAP sensor
connector, peel back the electrical
tape at least 2.5" from the connector
and cleanly cut all three wires leading
to it approximately 1.5" back from
the connector. See Figure 5. Strip
approximately 5/16" of insulation
from the end of each wire using an
appropriately sized wire stripping
tool, then crimp one side of the
supplied barrel-butt crimp sleeves to
each wire end. Figure 5
CUT
HERE
Figure 6
2. Locate the three pre-terminated
wires in the MAP sensor pigtail kit,
cut the unterminated end of the lead
down to leave approximately 3" total
lead length, including the crimped-on
terminal. Strip approximately 5/16"
of insulation from the un-terminated
96323 v.1.0
7
Figure 7
end of each wire, then slip a piece of
the supplied heatshrink tubing over
each one.
3. Insert the stripped end of a preterminated lead into the open end of
a barrel-butt crimp sleeve attached
to the factory MAP sensor harness,
and crimp it snugly. Double-check
the crimp by tugging lightly on the
opposing ends of the wire, ensuring
that the crimp is solid. Repeat for the
remaining two leads. 4. Center each piece of heatshrink
over the crimp barb on each lead,
then apply heat using a heat gun to
fully shrink and seal all of the tubing.
5.Locate the connector body
supplied in the 43626 kit and, using a
small screwdriver, remove the purple
8
96323 v.1.0
Figure 8
sensor-side terminal lock inside the
connector - this allows insertion of
the terminals from the other side of
the connector. See Figure 6 6. Place the new connector body
from the pigtail kit onto the HighPressure MAP sensor, ensuring
that it seats and locks properly
- this guarantees the connector
orientation to the sensor, and assists
in reconnecting the newly terminated
factory leads to the proper pins on
the replacement sensor - the pin
orientation IS NOT the same as the
original sensor. 7. Insert the newly terminated
leads into the connector body ,
using the wire color code, terminal
orientation and pin location as
shown in Figure 7 - Green wire
to forward pin (front of vehicle) - Black wire to middle pin - Orange wire to rear pin (rear of
vehicle). Each lead should lock
into place, verify with a light tug
outwards.
8. Remove the connector from
the MAP sensor by depressing the
thumb catch, then re-install the
purple sensor-side terminal lock
inside the connector, ensuring that it
seats fully back onto the connector.
Locate the purple seal retainer clip
from the 43626 kit, and install onto
the back of the connector body. See
Figure 8. Assembly of the new MAP
sensor connector is now complete
- re-connect it to the new highpressure MAP sensor.
Figure 9
PCV Check Valve
PCV HOSE/VACUUM
CONTROL
1. Remove PCV hose from intake
manifold (next to throttle body) and
top of engine (towards the rear).
2. To prevent unintentional overpressurization of crankcase under
boost, install provided PCV check
valve (P/N 47105) into provide 3”
length of ¹/₂" inner diameter PCV
hose (P/N 94138). Install assembly
onto existing PCV elbow on top of
engine (towards the rear). Rotate
PCV check valve to face down.
See Figure 9
Figure 10
3.
Install provided 16” length of
³/₈" inner diameter PCV hose (P/N
94136) from brass barb on throttle
body spacer to PCV check valve
using spring clamps (P/N 92777) on
each end. Mark length and trim, if
necessary.
Figure 11
Camshaft
Synchronizer
Bracket
4. Install PCV cap (P/N 92032) onto
existing PCV barb located on intake
manifold using spring clamp (P/N
92879). Trim cap if desired.
For 1999-2002
Model Years ONLY:
Remove PCV barb from intake
manifold and replace with supplied
1/4" NPT plug (PN 92257) after
applying sealant tape to threads.
¹/4" Allen
Figure 12
5. To prevent unintentional
over-pressurization of vacuum
control system under boost, install
vacuum check valve before tee in
cruise control actuator line. Remove
line from barb on side of intake
manifold (underneath throttle body).
Cut line before tee and push in
vacuum check valve. Replace line on
barb. See Figure 10
Install with black
end of vacuum check valve
towards engine.
CAMSHAFT
SYNCHRONIZER
(2005-2006 MODEL YEARS)
1999-2005 Models Years
skip to Alternator Removal
Rotating the
camshaft synchronizer/oil
pump drive assembly (Figure
8) is ONLY necessary if the
factory position will interfere
with the turbine outlet
pipe. We recommend taking
your vehicle to your local
dealership to have this service
performed.
1. Using compressed air source,
blow any debris away from camshaft
synchronizer to prevent any foreign
objects from falling into the housing
once cap is removed.
2. Remove camshaft synchronizer
cap and use a permanent marker to
mark the position of timing wheel
relative to housing.
T20 Torx
3. Remove camshaft synchronizer
bracket by removing one bolt.
See Figure 11
¹/₂" wrench
4. Remove camshaft synchronizer
by lifting straight up. Rest on clean
rag near motor mount.
Inspect Camshaft
Synchronizer/Oil Pump Drive
Figure 14
Figure 13
Idler Pulley
Standoff
Idler
Pulley
Drive Belt
Tensioner
96323 v.1.0
9
Figure 15
Body Seam
Tee
Oil Pressure
Sensor
Figure 16
REMOVE
2. Remove power cable and
connector from alternator. Remove
plastic clip that secures wiring to
alternator bracket.
3. Remove alternator from bracket
by removing two bolts. See Figure 13
15 mm socket
4. Remove alternator bracket by
removing four bolts.
⁹/₁₆" socket
5. Remove drive belt tensioner
from alternator bracket. Remove idler
pulley from engine.
T40 Torx and
⁹/₁₆" socket
6. Install drive belt tensioner on
new alternator/turbo bracket (P/N
52157). Use original hardware. Torque
to 21 lb/ft. See Figure 14
TURBOCHARGER OIL
SUPPLY
AT LEAST 1/8"
CLEARANCE
Assembly (OPDA) drive for
excessive wear. If worn,
Camshaft Synchronizer/OPDA
should be replaced to prevent
drivablility issues.
5. Use a standard screwdriver
and flashlight to rotate camshaft
synchronizer drive in engine block.
Rotate drive so that sensor and
connector will face towards front of
vehicle. See Figure 12
6. Replace camshaft synchronizer
and check the alignment of your
mark. If misaligned, remove camshaft
synchronizer and rotate drive. Repeat
until alignment is correct.
7. Reinstall bracket and snug
bolt. Check alignment and tighten if
properly aligned. Torque to 18 lb-ft.
Replace camshaft synchronizer cap.
ALTERNATOR
REMOVAL
1. Remove drive belt by relieving
drive belt tensioner and lifting belt off
alternator.
¹/₂" drive breaker bar or ratchet
10
96323 v.1.0
1. Disconnect oil pressure sensor
on passenger side of engine block
(towards rear of vehicle). Remove oil
pressure sensor.
1
¹/₁₆" oil pressure sensor
socket or crescent
wrench
2. Use vice grip pliers to bend
body seam near oil pressure sensor
location to provide clearance for
new oil pressure sensor assembly.
Approximately ¹/₄" of clearance is
needed.
3. Install tee fitting (P/N 92106) into
oil pressure sensor location using
thread sealant. Position tee fitting as
shown. See Figure 15
⁹/₁₆" wrench
4. Install oil pressure sensor into
tee fitting with provided thread
sealant. Reconnect oil pressure
sensor connector. See Figure 15
5. Connect straight end of braided
steel oil supply line (P/N 94075) to tee
fitting. See Figure 15
⁹/₁₆" wrench
The 90-degree end
will connect to turbocharger.
Route accordingly, avoiding
moving vehicle components.
To avoid heat of turbocharger,
route close to engine block.
TURBOCHARGER
ASSEMBLY
1. Inspect turbocharger to
ensure no foreign objects entered
compressor or turbine during
shipping. Cover all turbocharger
openings with caps or clean rags.
2. Using provided blue thread
locker (P/N 90001), install
turbocharger assembly (P/N 24250)
and idler pulley standoff (P/N 65298)
with four short bolts (P/N 91458),
one long bolt (P/N 91468), and five
washers (P/N 91401). See Figure
14. Torque all bolts to 45 lb-ft.
⁹/₁₆" wrench and socket
Long bolt is used in
top right corner of alternator/
turbo bracket, and passes
through both bracket and
standoff.
For 1999-2003
Model Years ONLY:
Test-fit the turbocharger/bracket
assembly to the engine block and
look for any interference with the
compressor cover and the block
boss behind the front engine cover.
If there is interference as shown in
(Fig 16), mark location and remove
turbocharger / bracket assembly.
Using pneumatic die grinder or
reciprocating saw, relieve the block
boss until there is approximately
1/8" clearance to the turbocharger
compressor when installed. Note:
There are no oil galleries in this
location, but take care not to cut
down into the front cover-to-block
seal interface.
3. If A/C lines contact BOV actuator
or alternator case/mounts, gently pull
A/C line to provide approximately ³/₈"
clearance. See Figure 17
4. Using provided blue thread
locker, install idler pulley onto
standoff with one bolt (P/N 91457)
and washer (P/N 91402). Torque to
30 lb-ft.
⁹/₁₆" socket
Figure 17
Figure 19
Photo for illustrative purposes only.
Removal of exhaust not required.
Figure 18
Clearance
Relief
5. Connect braided steel oil supply
line to turbo oil supply fitting on top
of turbocharger.
⁹/₁₆" wrench
6. Install alternator onto new
bracket using original hardware.
Torque to 41 lb-ft. Connect power
cable (9 lb-ft) and connector. If
needed, gently adjust A/C lines for
clearance.
7. Install new drive belt (P/N 65330)
following routing noted at front of
engine compartment or in vehicle
owner’s manual. (Replacement drive
belt 6PK2325 or 915K6 or equivalent.)
8. Check for belt clearance near
thermostat housing. If clearance is
needed, mark location and remove
belt. Using pneumatic die grinder,
relieve thermostat housing to provide
approximately ¹/₄" clearance. Replace
drive belt and check clearance once
more. See Figure 18
Figure 21
Figure 20
GO OD
OIL PAN & EXHAUST
REMOVAL
1. Soak exhaust manifold outlet
to “Y” pipe bolts and clips with
penetrating oil.
2. Place an oil pan under oil drain
and remove plug to drain oil.
⁵/₈" socket
3. Measure 15 ¹/₂" forward of rear
catalytic converter and mark exhaust
with permanent marker. Place a hose
clamp around exhaust at mark and
use permanent marker to create a
line that will ensure a square cut.
Remove clamp. See Figure 19
4. Cut exhaust on mark with
pneumatic reciprocating saw. Take
care while cutting and beware of
surrounding components.
Use eye and ear
protection while cutting.
5. Remove “Y” pipe with front
DAMAGED
catalytic converters by disconnecting
both oxygen sensors and removing
four bolts at exhaust manifold outlet.
15mm swivel socket & extension
Use a flashlight
to inspect all of the catalytic
converters (two front and one
rear) and replace if damaged. A
typical good catalytic converter
is shown in Figure 20. A
damaged catalytic converter
will have cracks or holes in
the ceramic core. Severely
damaged catalytic converters
will be missing parts of the
ceramic core, which may cause
the core to become misaligned
inside the housing, as in
Figure 21. Using damaged
catalytic converters may cause
catastrophic damage to engine
and/or turbo system.
6. With “Y” pipe removed, measure
3 ¹/₄” from where welds join together.
Place a hose clamp around exhaust
at mark and use permanent marker
96323 v.1.0
11
Figure 22
Figure 24
Figure 25
Figure 23
to create a line that will ensure a
square cut. Remove clamp. See
Figure 22
7. Cut exhaust on mark with
pneumatic reciprocating saw. Take
care while cutting and beware of
surrounding components.
Use eye and ear
protection while cutting.
8. Remove oil pan by removing
all bolts. Note stud location for
reinstallation.
⁷/₁₆" deep socket and extension
9. Inspect oil pan gasket. Replace if
damaged or clean if reusable.
TURBOCHARGER
OIL RETURN
1. Thoroughly clean oil pan in
preparation for welding. Scrape
flange to remove any silicone or
gasket material.
2. Mark location for oil return bung.
Measure 2 ¹/₄” from front edge and
³/₄” from top edge. Use a center
punch to mark oil pan once location
is determined. See Figure 23
12
96323 v.1.0
3. Use a stepped drill bit to drill a
⁵/₈” hole in oil pan at marked location.
cover joints. See Figure 25
4. Deburr edge of hole and prepare
oil pan for welding by using a wire
brush to remove paint around hole.
9. Hold gasket and oil pan in
position, install all ¼” bolts and
torque to 7 lb-ft. Install four ⁵/₁₆"
bolts and torque to 11 lb-ft.
5. Center oil return bung on drilled
hole and weld around outer edge.
10.Install oil pan drain plug. Torque
to 25 lb-ft.
If you are not an
experienced welder, take the
oil pan to your local welding
shop to have it welded by a
qualified welder.
6. Clean weld with a wire brush
and inspect for imperfections that
may cause it to leak. Prime and
paint raw metal to prevent rust
and corrosion. Plug bung to protect
threads during painting.
7. Using thread sealant, install
45º brass fitting (P/N 92177) into oil
return bung on oil pan. Position as
shown in Figure 24.
8. Clean gasket surfaces of oil
pan and engine block. Apply silicone
sealant to rear main bearing cap
corners and engine block to front
11.Install oil drain hose (P/N 94203)
from turbocharger to 45º brass barb
with two worm gear clamps (P/N
92810).
TURBINE INLET AND
OUTLET
1. Reinstall modified “Y” pipe
with front catalytic converters. Use
provided anti-seize (P/N 90045) on
original hardware, but do not tighten.
Reconnect both oxygen sensors.
2. Slide flange and clamp (P/N
52462) over turbine inlet pipe (P/N
52096). Slide turbine inlet pipe over
the “Y” pipe until the double-slip cuff
is fully bottomed. If needed, carefully
adjust turbine inlet pipe in vice so that
it will fully slip over “Y” pipe. Using
provided Anti-Seize, mount turbine
inlet pipe to turbo with two bolts (P/N
Figure 26
Figure 28
Four
None
Two
Figure 27
91459). Torque to 45 lb-ft. See Figure
26. Tighten clamp at “Y” pipe.
⁹/₁₆" and 15mm sockets
3. Secure “Y” pipe by tightening
four bolts at exhaust manifold outlet.
Torque to 23 lb-ft.
4. Install starter heat shield (P/N
26062) onto starter with hose clamp
(P/N 92841). Do not tighten.
5. Slide lap joint clamp (P/N 52492)
over exhaust with larger end closer
to turbocharger. Install the turbine
outlet pipe by sliding it over the
exhaust. See Figure 27
Position gasket (P/N 93013) between
turbine and turbine outlet pipe.
Turbine outlet
gasket has marks near each
hole. Position gasket with four
mark hole closest to engine
block, two mark hole closest to
fender, and zero mark hole at
bottom. See Figure 28
Figure 29
6. Using provided anti-seize, install
three bolts (P/N 91817) at the turbine
outlet flange. Torque bolts to 28 lb-ft
Tighten lap joint clamp.
⁹/₁₆" socket, 13mm
wrench
and socket
7. Position starter heat shield half
way between starter and turbine
outlet pipe, as shown above. Tighten
clamp to secure. See Figure 29
8. Install the preformed
turbocharger heat shield (P/N 26110)
over the turbocharger and secure
with bolt (P/N 26110). Secure wire
harness away from turbine outlet
pipe using large cable tie (P/N 62003).
See Figure 30
RAM-AIR ® INTAKE &
SUPER-SCOOP ®
Installing the
Ram-Air® Intake & SuperScoop® requires that you
cut a hole in your hood. The
Banks Sidewinder® Turbo
System can be run without
the Super-Scoop®; however
the performance of the Banks
Sidewinder® Turbo System
will suffer and cannot be
guaranteed.
1. Cover entire turbo with clean
rag. Cover any other open ports or
electrical connectors.
2. Use scissors to carefully cut
provided template on reference lines
labeled bottom of hood and edge of
hood latch.
Edge of Hood Latch
Reference Line refers ONLY to
OEM hood latches!
3. Position template on hood by
aligning bottom of hood reference
line with bottom edge of hood. Then,
align edge of hood latch reference
line with left side of hood latch.
Ensure the upper and lower hood
crease reference lines are aligned
96323 v.1.0
13
Figure 30
Figure 31
with crease in side of hood and
adjust if necessary. Use masking tape
to hold template in place.
See Figure 32
4. Use a center punch to mark
four mounting hole centers and
five intake hole centers for drilling
locations. Carefully remove template
from hood without damaging it. See
Figure 32
Figure 32
5. Using a stepped drill bit, drill
a ³/₈" hole in four mounting hole
locations (outside center marks). Drill
a ⁵/₁₆" starter hole in five intake hole
locations (inside center marks) to
guide 1 ¹/₂" hole saw. Take care while
drilling and cutting and beware of
surrounding components.
Use eye and ear
protection while drilling and
cutting.
6. Use a 1 ¹/₂" hole saw to cut five
intake holes where the ⁵/₁₆" starter
holes were made. See Figure 33
7.
Use scissors to fully cut intake
hole from template (arch shape).
Position intake hole by aligning outer
edge with outer edges of all five
1½” holes. Ensure bottom edge of
intake hole is parallel to bottom edge
of hood. Secure with masking tape
and trace along outer edge to create
intake hole shape on hood.
See Figure 33
8. Use a pneumatic reciprocating
saw or similar cutting implement
to cut along inside edge of trace,
connecting all five outer edges of
1 ¹/₂" holes. Deburr all edges and
carefully remove rags, trapping all
debris. Use touch-up paint to cover
raw metal edge. See Figure 33
9. Center Super-Scoop® (P/N
41565) in intake hole with bottom
14
96323 v.1.0
edge parallel to bottom edge of hood.
Mark mounting locations on SuperScoop® through inside of hood.
See Figure 34
10.Use stepped drill bit to drill four
³/₈" holes in Super-Scoop® at marked
mounting locations. Deburr all edges.
ONLY drill
through inside wall of SuperScoop®.
11. Use four push type retainers
(P/N 92023) to mount Super-Scoop®
on hood. Install edge seal (P/N 93141)
onto inside edge of Super-Scoop.®
See Figure 34
This page left intentionally blank.
Note: If you have downloaded and printed this template from www.
BanksPower.com, use a ruler to check against the ruler markings on
the top and left of this document to insure template size is correct.
INTAKE OPENING REFERENCE LINE
3/8" DRILLED MOUNTING HOLE
UPPER HOOD CREASE
1-1/2" INTAKE HOLE
LOWER HOOD CREASE
3/8" DRILLED MOUNTING HOLE
BOTTOM OF HOOD REFERENCE LINE
1. Cover entire turbo with clean rag.
Cover any other open ports or electrical
connectors.
2. Use scissors to carefully cut
provided template on reference lines
labeled bottom of hood and edge of
hood latch.
Edge of hood latch
reference line refers ONLY to OEM
hood latches!
3. Position template on hood by
aligning bottom of hood reference
line with bottom edge of hood. Then,
16
96323 v.1.0
1.0"
align edge of hood latch reference line
with left side of hood latch. Ensure the
upper and lower hood crease reference
lines are aligned with crease in side
of hood and adjust if necessary. Use
masking tape to hold template in place.
See Figure 27
(outside center marks). Drill a ⁵/₁₆"
starter hole in five intake hole locations
(inside center marks) to guide 1 ¹/₂"
hole saw. Take care while drilling and
cutting and beware of surrounding
components.
4. Use a center punch to mark four
mounting hole centers and five intake
hole centers for drilling locations.
Carefully remove template from hood
without damaging it. See Figure 27
Use eye and ear
protection while drilling and cutting.
5. Using a stepped drill bit, drill a ³/₈"
hole in four mounting hole locations
6. Use a 1 ¹/₂" hole saw to cut five
intake holes where the starter holes
were made. See Figure 28
7.Use scissors to fully cut intake hole
‘99-06 Jeep Wrangler TJ
Super-Scoop® Hood Cut Template
CREASE AROUND HOOD LATCH
3/8" DRILLED MOUNTING HOLE
EDGE OF HOOD LATCH REFERENCE LINE
3/8" DRILLED MOUNTING HOLE
from template (arch shape). Position
intake hole by aligning outer edge
with outer edges of all five 1 ¹/₂" holes.
Ensure bottom edge of intake hole is
parallel to bottom edge of hood. Secure
with masking tape and trace along outer
edge to create intake hole shape on
hood.
See Figure 28
8. Use a pneumatic reciprocating
saw or similar cutting implement to cut
along inside edge of trace, connecting
all five outer edges of 1 ¹/₂" holes.
Deburr all edges and carefully remove
rags, trapping all debris. Use touch-up
paint to cover raw metal edge. See
Figure 28
9. Center Super-Scoop® (P/N 41565)
in intake hole with bottom edge parallel
to bottom edge of hood. Mark mounting
locations on Super-Scoop® through
inside of hood.
See Figure 29
ONLY drill through
inside wall of Super-Scoop.®
11. Use four push type retainers (P/N
92023) to mount Super-Scoop® on hood.
Install edge seal (P/N 93141) onto inside
edge of Super-Scoop.®
See Figure 30
10. Use stepped drill bit to drill four
³/₈" holes in Super-Scoop® at marked
mounting locations. Deburr all edges.
96323 v.1.0
17
This page left intentionally blank.
18
96323 v.1.0
Figure 33
Figure 34
Edge seal
Push type
Retainers
96323 v.1.0
19
Figure 35
Figure 37
LTR Bracket
A/C Condenser
LTR
Figure 36
20
96323 v.1.0
INTERCOOLER SYSTEM INSTALLATION PROCEDURE
LOW TEMPERATURE
RADIATOR INSTALL
Figure 38
Figure 40
11 mm socket (Shroud)
10 mm socket (Radiator)
1. Remove 4 air conditioning
condenser bolts and use tie wraps
to hold condenser clear of radiator
support to allow installation of Banks
low temperature radiator (LTR) (P/N
25411). See Figure 35
10 mm socket
It is NOT necessary
to disconnect air conditioning
lines, move as far as lines
will allow.
Figure 39
Figure 41
LTR
2. Remove front radiator brace
by removing 2 upper bolts and 1
lower bolt.
1-piece
Grommet
10 mm socket
3. Remove windshield washer fluid
reservoir mounting bolts for better
access to drill holes for intercooler
hoses.
Figure 42
LTR
Bracket
10 mm socket
It is NOT necessary
to disconnect windshield
washer fluid hoses, move as
far as hoses will allow.
4. Carefully drill one 1.5" hole in the
corner on each side of the front clip
approximately 13.75" from center for
intercooler hose pass-throughs.
See Figures 36 & 37
Nyloc
Flange
Nut
2-piece
Grommet
Washer
Use extreme
caution when drilling holes,
take care to avoid wiring and
headlight bezel.
5. Completely deburr holes to avoid
damaging the intercooler hoses and
place grommets (P/N 93655) into
holes to cover exposed sheet metal.
See Figure 38
6. Replace windshield washer fluid
reservoir.
7. Cover LTR outlet hose (P/N 9426805) with corrugated loom (P/N W-CCL100), as shown. See Figure 39
8. Place LTR outlet hose with
corrugated loom into bottom of
radiator support and pass through
driver side grommet, as shown. Trim
air deflectors as necessary. See
Figure 40
9. Mount LTR to the LTR mounting
bracket (P/N 25412) using grommets
(P/N 25413) in the lower mounting
holes and bushing isolators (P/N
25414) on the upper studs. Use
fender washers (P/N 91180) and
Nyloc nuts (P/N 91161) to secure LTR
to mounting bracket.
See Figures 41 & 42
7/16" socket
10. Mount LTR and LTR bracket
where the front radiator brace was
located. See Figure 35
11. If necessary, modify ambient
temperature sensor by trimming
catch and rotating the top away from
the LTR, as shown. See Figure 43
12. Connect the LTR outlet hose to
the lower barb of the LTR and secure
using hose clamp (P/N 92810). Trim
air deflectors as necessary.
See Figure 44
96323 v.1.0
21
17. Pass LTR inlet hose (P/N 94267)
through passenger side grommet and
connect to upper barb of the LTR.
Secure using hose clamp (P/N 92810).
Trim air deflectors as necessary.
See Figure 45 components. Secure LTR inlet hose
using push mount cable tie (P/N
62006). See Figure 46
18.Drill a 1/4" hole into airbox to
hold LTR inlet hose away from engine
20.Reinstall radiator using original
Figure 43
19.Reinstall air conditioning
condenser using provided replacement
well nuts (P/N 91164).
hardware and reconnect hoses.
Figure 47
Reinstall coolant overflow reservoir.
Fill radiator with appropiate
automotive coolant to factory specs.
PUMP AND WIRING INSTALL
1. Release 4 tabs on the fuse box
to free entire fuse box for access to
wires on the bottom side. Leave all
wires connected, if possible.
See Figure 47
2. Drill intercooler pump mounting
bracket (P/N 25418) holes (.25") and
wire harness relay mounting holes
(.25") on fuse box sheet metal as
shown in Figure 48 & 49
3. Locate the fuel pump relay and
tap the hot side of signal lead (orange/
red wire) using supplied wire T-tap
(P/N 62032). See Figure 50
Figure 44
Figure 48
4. Connect male faston connector
(yellow lead) of the intercooler pump
wire harness (P/N 62802) to the wire
T-tap. Route with other wires towards
the battery.
5. Mount the relay using 1/4"-20
bolt (P/N 91171) and Nyloc flange nut
(P/N 91161). See Figure 49
6. Mount the intercooler pump
brackets (P/N 25418) using 1/4"-20 bolts
(P/N 91171) and Nyloc flange nuts (P/N
91161). See Figure 51
Figure 45
Figure 49
7. Replace fuse box onto sheet metal
mount and check that all 4 tabs engage.
8. Mount intercooler pump (P/N
25419) in pump bracket with pump
head towards rear of vehicle and
outlet barb horizintal towards engine
as shown. Connect the pump power
connector to the pump and connect the
pump outlet hose. Secure using hose
clamp (P/N 92810). See Figure 51
TECHNI-COOLER INSTALL
Figure 46
Figure 50
1.
Remove underhood light from
bracket by lifting edge. Remove
mounting bracket. See Figure 52
10 mm socket
2. Drill a 3/16" hole approximatley
2-3/8" to the left of the original hole to
relocate the light. Replace bracket and
light as shown in Figure 52.
3. Remove lower two bulkhead
connectors from the firewall (upper
connector for automatic transmission
22
96323 v.1.0
does not need to be relocated) and install
bulkhead connector relocation bracket
(P/N 25408) using 2 bolts (P/N 91115)
and Nyloc flange nut (P/N 91161).
See Figure 53
Figure 51
4. If adding Techni-Cooler kit to a
previously installed Sidewinder turbo
kit, remove the existing boost tube and
disconnect the wastegate reference line.
5. Remove appropriate valve cover
bolts to allow for Techni-Cooler
installation (P/N 25404), as shown.
See Figure 54
6. Replace valve cover bolts with
provided studs (P/N 91193) and flange
nuts (P/N 91160). Install studs with
Threadlocker (P/N 90001) leaving 3/4"
threads above the valve cover, as shown.
See Figure 55 & 56
IN
OUT
Figure 52
Figure 55
Figure 53
Figure 56
7. Install Techni-Cooler brackets (P/N
25405-05, 25405-07) onto studs using
washers (P/N 91102) below the bracket
and Nyloc flange nuts (P/N 91161) to
secure it, as shown. See Figure 57
7/16" socket
8. Check throttle cable and cruise
control cable clearance to the TechniCooler brackets, adjust by sliding
the cables to create at least 1/2" of
clearance. See Figure 58
Nyloc Flange
Nut
9. Check heater hose clearance to
the Techni-Cooler brackets, cover with
corrugated loom to protect hose from the
sheet metal edge. See Figure 59
Techni-Cooler
Bracket
Washer
Flange Nut
.75"
0. Install straight barbed fittings (P/N
1
92188) into Techni-Cooler using 2 layers
of thread sealing tape (P/N 91099).
Tighten 2-3 turns past finger-tight.
See Figure 60
Valve Cover
Stud
Relocate
Figure 54
Figure 57
7/8" socket
fittings.
Do NOT over-tighten
11. Install sight glass (P/N 25417), if not
already installed, into Techni-Cooler using
2 layers of thread sealing tape. Tighten
2-3 turns past finger-tight.
See Figure 61
15/16" socket
sight glass.
Do NOT over-tighten
2. Install Techni-Cooler onto brackets
1
using 5/16"-18 bolts (P/N 91271) and
96323 v.1.0
23
washers (P/N 91202) using threadlocker.
See Figure 62
1/2" socket
PLUMBING INSTALL
1. Install Techni-Cooler to pump inlet
hose (P/N 94269) and secure with
clamps (P/N 92810). Secure hose to
boost tube using double-loop tie wrap
Figure 58
(P/N 62008). See Figure 63
8 mm nut driver
. Install hose barb adapter (P/N
2
92191) and barb to Techni-Cooler inlet
hose (P/N 94268-07) and secure with
clamps (P/N 92810). Secure hose to
radiator support rod using tie wrap
(P/N 62001). See Figure 64
Figure 62
3. Install Techni-Cooler inlet boost tube
using silicone hose (P/N 94262) and
clamps (P/N 92855). Use throttle body
silicone hose and clamp from turbo kit.
See Figure 65
4. Install Techni-Cooler outlet boost
tube using silicone hose (P/N 94262) and
clamps (P/N 92855). Use compressorside silicone hose and clamp from turbo
kit. See Figure 66
5. Install intake air temperature (IAT)
sensor and barbed elbow (from turbo
kit) into the outlet boost tube. Plug
water-methanol injection port if not
used. Connect intake air temperature
sensor connector. See Figure 66
Check Clearance
Here
Figure 59
8 mm nut driver
6. Install wastegate reference hose
(P/N 94123) from wastegate barb to
boost tube barbed elbow using clamps
(from turbo kit). See Figures 67 & 68
Figure 63
7. Connect power (red) lead of wire
harness to fuse box power post and
ground (black) lead to the battery
ground terminal. Reconnect the battery.
See Figure 69
8. Fill Techni-Cooler reservoir using
funnel with automotive coolant such as
Prestone® 50/50 prediluted antifreeze
(or equivalent) fill to top, leaving room
Figure 60
for cap.
Figure 64
9. Cycle the ignition to ON without
starting the vehicle to run the pump and
circulate coolant through the system.
Check the system for coolant leaks.
10. Check the coolant level and add
coolant if needed.
Hose Barb Adapter
Figure 61
Figure 65
11. Repeat steps 9 and 10 until the
coolant level stays in the center of the
sight glass.
12. Place cap onto Tecni-Cooler.
cap.
24
96323 v.1.0
Do NOT over-tighten
Figure 66
Figure 68
Figure 67
Figure 69
96323 v.1.0
25
BANKS RAM-AIR® INSTALLATION PROCEDURE
Figure 70
Figure 72
Long
Screws
Air filter
housing
Isolators
Short
Screw
Figure 71
Figure 73
Compressor
Intake Tube
Engine Fan
Shroud
AIR FILTER AND
HOUSING
1. Install air filter housing isolators
(P/N 92980) onto fender with washers
(P/N 91102) and Keps nuts (P/N
91112). Do not tighten.
See Figure 70
2. Install air filter housing (P/N
41561) onto isolators with washers
and Keps nuts. Torque all fasteners to
8 lb-ft.
⁷/₁₆" wrench and socket
3. Install compressor intake tube
(P/N 41564) onto compressor using
one hose coupler (P/N 94265) and
two worm gear clamps (P/N 92841).
Do not tighten.
Place coupler
and clamps on compressor
(position clamps where worm
26
96323 v.1.0
Front PCV
Hose
gear is accessible), then install
compressor intake tube.
intake tube clamps at compressor
4. Install air filter element into air
filter housing with open end towards
compressor intake tube. Use hose
clamp (P/N 92872) to secure air filter
element to compressor intake tube.
Do not tighten.
See Figure 72
Check for clearance
between compressor intake
tube and engine fan shroud.
If necessary, mark where
clearance is needed and
remove compressor intake
tube. Trim fan shroud to
provide approximately ³∕ 8”
clearance. See Figure 71
5. Install air filter housing cover
(P/N 41562) with one short machine
screw (P/N 91226) in bottom hole and
two long machine screws (P/N 91242)
in top two holes. Tighten compressor
inlet, then the clamp at air filter.
#3 Phillips,
6. Install provided 20” length ¹/₂"
inner diamter front PCV (P/N 94138)
from compressor intake tube to PCV
elbow on top of engine (towards the
front). See Figure 73
7. Reinstall passenger side radiator
support rod.
BOOST GAUGE
1. Using compression ferrule
installed in throttle body, install boost
gauge kit. Refer to provided boost
gauge kit installation instructions for
full procedure.
Figure 74
Figure 76
Figure 78
Figure 75
Figure 77
Figure 79
there is no popup window, click the
Windows icon in bottom left corner.
Then, click on Computer (Windows 7,
Vista) or My Computer (Windows XP)
in right hand column. In new window,
double click on drive labeled CD Drive
Diablosport. Finally, double click
InTune to run software.
Menu will appear with the following
selection options: Tune Vehicle, Scan
Tool, and Settings. See Figure 74
FLASH TUNE:
'05-06 ONLY
FOR '99-04: Refer to
supplimental SCT Tuning
Guide that is included
with your kit for all tuning
instructions.
Banks Sidewinder®
Tune must be successfully
loaded before running vehicle.
1. Run the inTune auto update
software by connecting inTune to
your computer with provided USB
cable.
2. Software should run
automatically. If it does not, click
Run InTune.exe in popup window. If
3. If an update is available, you
will be prompted to not unplug the
device, click OK. The update will
begin, do not unplug device until it
has restarted.
4. Connect inTune to vehicle’s
diagnostic port using OBDII cable.
Diagnostic port is
located below steering column,
on left hand side.
After loading screen, the Main
5. To flash tune vehicle, select
Tune Vehicle from Main Menu. Then,
select Write Vehicle. See Figure 75
6. Wait for prompt, then turn key
to on position without starting the
vehicle. See Figure 76
Select Diablo Tuning and then Banks
Sidewinder® Turbo. Select green
check mark to confirm tune or select
red “X” to go back. See Figures 77
& 78
Device will
automatically backup factory
tune. See Figure 79
7. A prompt will ask if you want
96323 v.1.0
27
Figure 80
Figure 83
It is important to use
synthetic oil due to increased
oil temperature caused by the
turbocharger.
3. Check engine bay for tools and
other items. Start vehicle and let idle
for several minutes. Shut down the
vehicle.
4. Check for leaks. Check oil level
and add oil if needed.
TEST DRIVE
Banks Sidewinder®
Tune must be successfully
loaded before running vehicle.
Figure 81
to modify tune (tire sizes, gear ratios,
etc.). To modify tune, select the green
check mark or to install default tune
select red “X”. See Figure 80
8. Select the green check mark to
install Banks Sidewinder Turbo tune.
9. Cycle key position when prompted
and select green check mark to
continue. See Figures 81 & 82
10.Device will begin installing tune.
Once tune is installed, cycle key
position when prompted and select
green check mark to continue.
See Figure 83
Figure 82
11.Select Continue after successful
install to return to Main Menu or
unplug inTune.
FUEL AND OIL
1. If you were not using 91 octane
gasoline, drain all fuel from the vehicle
and refill using 91 octane gasoline.
Using fuel with an
octane rating lower than 91 will
cause severe damage to engine
and/or turbo system.
2. Fill vehicle with 10W-30 synthetic
motor oil. See vehicle owner’s manual for
quantity. We also recommend replacing
your oil filter.
28
96323 v.1.0
1. After ensuring that there are no
leaks, start the vehicle. Allow vehicle to
idle for several minutes to warm-up.
2. Test drive vehicle in a location
with minimal traffic. Drive for several
minutes at light load, keeping boost at
or below 2 PSI and engine RPM under
3000. Shut down vehicle if engine
temperature increases above 245
degrees Fahrenheit or if boost pressure
increases above 7 psi.
3. Park in a safe location and allow
vehicle to idle. Exit vehicle and check
for any leaks, including oil, fuel, and
exhaust.
4. If no leaks are found, continue
to drive vehicle, gradually increasing
throttle / load and boost pressure while
listening for any pinging / detonation.
It is important to allow the ECU time
to re-learn the new fuel system
configuration - typically, a full tank of
fuel used over several drive cycles
while gradually increasing boost and
RPM will provide adequate time for the
system to adapt.
PARTS LIST
1999-02
2003-04
2005-06
P/N 24242
P/N 24243
P/N 24245
Part #
Description
Quantity
24240-2
Turbocharger, 6-PSI W/G & Mounting Bracket Assy, Turbo Syst - 99-06 Jeep 4.0L
24240-3
Lubrication Parts Kit, Turbo Syst - 99-06 Jeep 4.0L
24240-4
Exhaust Components Kit, Turbo Syst - 99-06 Jeep 4.0L
24240-6
Ram-Air Components Kit, Turbo Syst - 99-06 Jeep 4.0L
✓
✓
✓
✓
✓
✓
✓
✓
24240-7
Fuel Injection Parts Kit, Turbo Syst - 99-02 Jeep 4.0L
✓
✓
✓
✓
✓
✕
✕
24241-7
Fuel Injection Parts Kit, Turbo Syst - 03-04 Jeep 4.0L
✕
✓
✕
24244-7
Fuel Injection Parts Kit, Turbo Syst - 05-06 Jeep 4.0L
✕
✕
24242-1
Owners Manual & Install Kit, Intercooler -Turbo System - 1999-06 Jeep 4.0L
24242-5
Intercooler System Kit - 99-04 Jeep 4.0L
✓
✓
✓
✓
✓
✓
24245-5
Intercooler System Kit - 05-06 Jeep 4.0L
✕
✕
✓
66123
AutoMind Programmer, Hand Held, Sidewinder Turbo only - 1999-04 Jeep 4.0L
✓
✓
✕
66124
AutoMind Programmer, Hand Held, Sidewinder Turbo only - Jeep 05-06-4.0L
✕
✕
96585
Brochure, All Jeep Products-4 pg.
97518
Decal Set, Sidewinder - Turbo System, Jeep Wrangler
✓
✓
✓
✓
✓
✓
✓
24240-2
✕
Turbocharger, 6-PSI W/G & Mounting Bracket Assy, Turbo Syst - 99-06 Jeep 4.0L
24061
Oil Drain, Turbo System - 99-06 Jeep Wrangler, 4.0L
1
1
1
24250
Turbocharger Assembly - 99-06 Jeep 4.0L
1
1
1
24317
Hex Nut, Flex Lock, 1/4-28
2
2
2
24335
Bracket, Wastegate Actuator, Turbo Syst - 99-06 Jeep 4.0L
1
1
1
24373
Linkage, Wastegate Actuator, Turbo System - 99-11 Jeep 4.0/3.8L
1
1
1
24382
Wastegate Actuator, Uncalibrated - Jeep
1
1
1
52157
Bracket, Turbo Mounting, 99-06 Jeep Wrangler 4.0L
1
1
1
62003
Cable Tie, Black, 13" -
2
2
2
65298
Stand-Off, Idler Pulley, Turbo Syst - 99-06 Jeep 4.0L
1
1
1
65330
Belt, Accessory Drive, Turbo Syst - 99-06 Jeep 4.0L, Stock Pulleys, with A/C
1
1
1
91104
Washer, Split Lock, Zinc - 1/4"
2
2
2
91126
Nut, Jam, Thin Hex - 1/4"-28, Zinc
1
1
1
91201
Washer, AN, S/S - 5/16"
6
6
6
91401
Washer, AN, S/S - 3/8"
5
5
5
91402
Washer, Sae Flat, Zinc - 3/8"
1
1
1
91457
Hex Bolt, Flange Head, Non-Serrated, Grade 5, Zinc - 3/8"-16 X 1"
1
1
1
91458
Hex Bolt, Grade 8, Zinc - 3/8"-16 X 1 1/4"
4
4
4
91468
Hex Bolt, Grade 8, Zinc - 3/8"-16 X 1 5/8"
1
1
1
91739
Hex Bolt, Flange Head - 6MM-1.00 X 10MM, 8.8, Zinc
2
2
2
91776
Hex Bolt - 6MM-1.00 X 16MM, 8.8, Zinc
2
2
2
91806
Hex Nut, Locking, 8MM X 1.25, High-temp Steel, Copper Coated
2
2
2
91939
Hex Bolt, 8MM X 1.25 X 30MM, 10.9 Zinc
2
2
2
91943
Hex Bolt, 8MM X 1.25 X 45MM, 10.9 Zinc
2
2
2
92024
Cap, Silicone - 11/64", Turbocharger Assy - Various Applications
1
1
1
93010
Gasket, Turbine Inlet - 99-06 Jeep 4.0L
1
1
1
96059
Decal, Banks Big Head - Wastegate Actuator
1
1
1
1
1
1
24240-3
92106
Lubrication Parts Kit, Turbo Syst - 99-06 Jeep 4.0L
Fitting, Tee, 1/8 MPT X 1/8"FPT X -4 AN
96323 v.1.0
29
92177
Fitting, 3/8" NPT X 5/8" Hose 45° Brass
1
1
1
92275
Weld Bung, 3/8" NPT
1
1
1
92810
Hose Clamp, #10
2
2
2
94075
Hose, Turbo Oil Feed - 99-06 Jeep 4.0L
94203
Hose, Oil Drain, Turbo System - 99-11 Jeep 4.0/3.8L (feet)
24240-4
30
1
1
1
0.25
0.25
0.25
Exhaust Components Kit, Turbo Syst - 99-06 Jeep 4.0L
52096
Up-Pipe, Turbo System - 99-06 Jeep 4.0L
1
1
1
52098
Turbine Outlet Pipe, Turbo System - 99-06 Jeep 4.0L
1
1
1
52340
Flange, Exhaust - Various Applications
1
1
1
52462
Exhaust Clamp, Band Style - 2 1/2"
1
1
1
52492
Exhaust Clamp, Lap Joint, 2-1/2", 304 SS
1
1
1
91459
Hex Bolt, Flange Head, Grade 8, Zinc - 3/8"-16 X 1 1/2"
2
2
2
91817
Hex Bolt, Flange Head, 10.9 Zinc - 8MM-1.25 X 25MM
3
3
3
24240-6
Ram-Air Components Kit, Turbo Syst - 99-06 Jeep 4.0L
24240-61
Small Parts Kit, Ram-Air - Turbo Syst - 99-06 Jeep 4.0L
1
1
1
41561
Housing, Air Filter, Turbo System - 99-06 Jeep 4.0L
1
1
1
41562
Cover, Air Filter Hsg, Turbo System - 99-06 Jeep 4.0L
1
1
1
41563
Air Filter Element, Turbo System - 1999-06 Jeep 4.0L
1
1
1
41564
Intake Tube, Turbo System - 96-06 Jeep 4.0L
1
1
1
41565
Super-Scoop, Turbo System - 99-06 Jeep 4.0L
1
1
1
24240-7
Fuel Injection Parts Kit, Turbo Syst - 99-02 Jeep 4.0L
24241-7
Fuel Injection Parts Kit, Turbo Syst - 03-04 Jeep 4.0L
24244-7
Fuel Injection Parts Kit, Turbo Syst - 05-06 Jeep 4.0L
42730
Spacer, 0.85" H X .600 OD X .25 ID - Aluminum
3
3
3
43625
MAP Sensor, 2-Bar, Turbo System - 99-11 Jeep 4.0/3.8L
1
1
1
43626
Harness, Pigtail - MAP Sensor, 2-Bar, Chrysler - 99-02 Jeep 4.0L
1
0
0
43628
Spacer, Throttle Body/Mount, MAP Sensor - Turbo System - 99-06 Jeep 4.0L
1
1
1
43643
Fuel Injector, 35 lb/[email protected] PSI, EV6 - Turbo Syst - 99-06 Jeep 4.0L
6
6
6
47102
Valve, Vacuum Check - Turbo System, 1999-06 Jeep
1
1
1
47105
Valve, PCV Check - Turbo System, 1999-06 Jeep
1
1
1
62001
Cable Tie, Black, 6" -
12
12
12
91759
Hex Bolt, Flange Head - 6Mm-1.00 X 35Mm
3
3
3
91761
Hex Bolt, Flange Head - 6MM-1.00 X 45MM
4
4
4
91826
Washer, Int Tooth Lock, Zinc - #10
2
2
2
91860
Hex Bolt - 10-32 X 3/4"
2
2
2
92032
Cap, Vacuum/Boost, 5/8" ID, Rubber
0
0
1
92131
Fitting, 1/4" NPT Male X 3/8" Push On Barb, Brass
1
1
1
92251
Plug, 1/8" NPT- Hex Countersunk, Zinc
1
1
1
92257
Plug, 1/4" NPT - Hex Countersunk
1
1
1
92775
Clamp, 11/32" Spring Band, Silver
2
2
2
92777
Clamp, 19/32" Spring Band, OD Green
2
2
2
92879
Clamp, 3/4" Spring Band, Black - 97-06 Jeep 4.0L
1
1
1
93078
Gasket, Throttle Body - 99-06 Jeep 4.0L
2
2
2
94122
Hose, Silicone, Black - 3/16" ID X 3/8" OD Bulk (feet)
5
5
5
94136
Hose, PCV, 3/8"Id X 1/2"Od - Bulk (feet)
1.33
1.33
1.33
94138
Hose, 1/2"Id X 3/4"Od, Bulk - Jeep 4.0L, PCV Hose (feet)
0.25
0.25
0.25
96323 v.1.0
24242-1
Owners Manual & Install Kit, Intercooler -Turbo System - 1999-06 Jeep 4.0L
26111
Heatshield, Turbocharger/Turbine Outlet Pipe, Turbo System - 99-06 Jeep 4.0L
1
1
1
26114
Heatshield, Starter Solenoid - Jeep 4.0L
1
1
1
62001
Cable Tie, Black, 6" -
10
10
10
62003
Cable Tie, Black, 13" -
5
5
5
63001
Mounting Panel, One Gauge - Black, W/Fasteners
1
1
1
64050
Boost Gauge Kit, 0-15 PSI
1
1
1
90001
Threadlocker, Blue .5Ml
1
1
1
90040
Thread Sealant w/PTFE - 1oz Tube
1
1
1
90045
Anti Seize, 5 Grams
1
1
1
91102
Washer, Sae Flat, Zinc - 1/4"
1
1
1
91117
Hex Bolt, Grade 5, Zinc - 1/4"-20 X 3/4"
1
1
1
92841
Hose Clamp, #40 W/Liner
1
1
1
93013
Gasket, Turbine Outlet - 99-06 Jeep 4.0L
1
1
1
96002
Decal, Stop Do Not Discard - Ram Air Filter
1
1
1
96009
Urocal, Banks Power, Small - Red, Black & Silver
2
2
2
96239
Decal, Carb Eo D-161-97 - Banks Sidewinder Turbo-99-06 Jeep 4.0L Wrangler
1
1
1
96323
Owners Manual, Sidewinder Turbo Syst - Intercooled -1999-06 Jeep 4.0L
1
1
1
96399
Product Registration Card - All Products
5
5
5
24242-5
Intercooler System Kit - 99-04 Jeep 4.0L
24245-5
Intercooler System Kit - 05-06 Jeep 4.0L
25407
Intercooler Kit - 1999-06 Jeep 4.0L Wrangler
1
1
1
25415
Heat Exchanger Kit - 1999-06 Jeep 4.0L Wrangler
1
1
1
25420
Water Pump & Plumbing Kit - CAC, 1999-06 Jeep 4.0L Wrangler
1
1
1
25424
Harness Kit, 1999-06 Jeep 4.0L Wrangler
1
1
1
42451
Boost Tube-1, Intercooled Turbo System - 99-06 Jeep 4.0L
1
1
1
42453
Boost Tube-2, Intercooled Turbo System - 1999-04 Jeep 4.0L
1
1
0
42454
Boost Tube-2, Intercooled Turbo System - 2005-06 Jeep 4.0L
0
0
1
92122
Fitting, 1/8" Npt X 1/4" Hose - Elbow, 90 Degree
1
1
1
92251
Plug, 1/8" NPT- Hex Countersunk, Zinc
1
1
1
92850
Hose Clamp, T-Bolt Style, 2 3/8" - Various Applications
2
2
2
92855
Hose Clamp, T-Bolt Style - 3"
4
4
4
94123
Hose, Silicone, Black - 1/4" ID X 7/16" OD Bulk (feet)
4
4
4
94253
Hose, 2.0" ID x 1.875" Lng, Reinforced silicone, Black w/Brick Red Liner
1
1
1
94272
94276
Hose, 2.5" X 2.5", Black - Various Applications
Hose, Throttle Body Inlet - 1997-06 Jeep 4.0L
2
1
2
1
2
1
Intercooler Kit - 1999-06 Jeep 4.0L Wrangler
Techni-Cooler Assembly - Jeep Wrangler, 4.0L
Mounting Bracket, Left, CAC - Jeep Wrangler 4.0L
Mounting Bracket, Right, CAC - Jeep Wrangler 4.0L
Plug, External Hex - M26 x 1.5, O-ring
Bracket, Relocation, Bulkhead Connectors - Jeep Wrangler, 4.0L
Washer, Sae Flat, Zinc - 1/4"
Hex Bolt, Grade 5, Zinc - 1/4"-20 X 1/2"
Nut, Hex Flange, Zinc - 1/4"-20
Nut, Hex Flange, 1/4"-20 Nylock
Stud, Internal Hex Drv - 1/4"-20 x 2"
Washer, Sae Flat, Zinc - 5/16"
Hex Bolt, Flange Head - 5/16"-18 x 3/4", Grade 8, Zinc
Fitting, Straight - 1/2" NPT Male X 3/4" Hose Barb
1
1
1
1
1
4
2
4
5
4
4
4
2
1
1
1
1
1
4
2
4
5
4
4
4
2
1
1
1
1
1
4
2
4
5
4
4
4
2
25407
25404
25405-05
25405-07
25406
25408
91102
91115
91160
91161
91193
91202
91271
92188
96323 v.1.0
31
25415
25411
25412
25413
25414
91103
91161
91164
25420
25418
25419
91161
91171
92191
92810
93655
94267
94268-05
94268-07
94269
W-CCL-100
25424
62032
62802
91161
Heat Exchanger Kit - 1999-06 Jeep 4.0L Wrangler
Heat Exchanger, Water-Air, w/End Tanks-3/4" Barbs, Mtng tabs
Mounting Bracket, w/Studs - LTR - Jeep 4.0L
Grommet, Lower Isolator, 3/8" (1 pc) - LTR - Jeep 4.0L
Grommet, w/Steel Insert - Upper Isolator, 1/4" (2 pc) - LTR - Jeep 4.0L
Washer, Uss, Zinc - 1/4"
Nut, Hex Flange, 1/4"-20 Nylock
Well Nut, 1/4"-20, 0.5" OD x 0.63 Length
1
1
2
2
2
2
4
1
1
2
2
2
2
4
1
1
2
2
2
2
4
Water Pump & Plumbing Kit - CAC, 1999-06 Jeep 4.0L Wrangler
Bracket, Mounting, Water Pump, CAC - Jeep 4.0L
Pump, Water - 12VDC, 5.3GPH/4.4 PSI, 0.750"
Nut, Hex Flange, 1/4"-20 Nylock
Hex Bolt, Flange Head - 1/4" -20 x 5/8", Grade 8
Fitting, Union, 3/4" to 3/4" Hose Barb
Hose Clamp, #10
Grommet, Pass-through, 1.25" ID, CAC - Jeep 4.0L
Hose, Pump to LTR, Jeep 4.0L
Hose, LTR to Barb - Jeep 4.0L
Hose, Barb to CAC, Jeep 4.0L
Hose, CAC to Pump, Jeep 4.0L
Corrugated Loom, Nylon, 1.0" Id
1
1
2
2
1
8
2
1
1
1
1
5
1
1
2
2
1
8
2
1
1
1
1
5
1
1
2
2
1
8
2
1
1
1
1
5
Harness Kit, 1999-06 Jeep 4.0L Wrangler
Connector, T-Tap, Blue - 16-14 Gauge
Wire Harness, CAC Pump Relay - 99-06 Jeep Wrangler 4.0L
Nut, Hex Flange, 1/4"-20 Nylock
1
1
1
1
1
1
1
1
1
Gale Banks Engineering
546 Duggan Avenue • Azusa, CA 91702
(626) 969-9600 • Fax (626) 334-1743
Product Information & Sales: (888) 635-4565
Customer Support: (888) 839-5600
Installation Support: (888) 839-2700
bankspower.com