Banks Power Systems

Banks Power Systems
…with installation instructions
OWNERS MANUAL
©2016 GALE BANKS ENGINEERING
Banks
Power
Systems
PowerPack system
Stinger system
®
®
2000-2007 GM 8.1L Class-A
Workhorse W-Series Chassis
Motorhomes
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
09/12/16
PN 96431 v.9.0
Dear Customer,
If you have any
questions concerning
the installation of
your Banks Power
System, please call
our Technical Service
Hotline at (888) 8392700 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 PowerPack
system, familiarize yourself
with the procedure by
reading the entire manual
before starting work. This
manual contains 12 pages
of copy, illustrations and
parts listing. If any pages are
missing from this manual
please call Gale Banks
Engineering immediately for a
replacement.
2. The exploded view of the
PowerPack assembly (page
11) provides only general
2 | 96431
v.9.0
General Installation Practices
guidance. Refer to each step
and section diagram in this
manual for proper instruction.
3. Throughout this manual,
the left-side of the vehicle
refers to the driver’s side,
and the right-side to the
passenger’s side.
4. Banks Power systems
are designed to fit Chevy
8.1L Workhorse Class-A
motorhome chassis. Due to
differences in coach layouts, it
may be necessary to relocate
or modify some coach or
Banks system components to
accommodate installation of
the Banks Power system.
5. Disconnect the ground
cable from the battery before
beginning work. If there are
two batteries, disconnect
both.
6. Route and tie wires and
hoses a minimum of 6 inches
away from exhaust heat,
moving parts and sharp edges.
Clearance of 8 inches or
more is recommended where
possible.
7. During installation, keep
the work area clean. If foreign
debris is transferred to any
Banks system component,
clean it thoroughly before
installing.
NOTE: If installing the Stinger
system proceed to Step 29.
8. The front of your
motorhome should be raised
a minimum of 5-6 inches
to allow the installation of
Banks TorqueTube® exhaust
manifolds. If you have access
to a hoist, the vehicle can be
elevated and the front wheels
removed for easiest access.
9. When raising the vehicle,
support it on properly weightrated safety stands, ramps or
a commercial hoist. Follow
the manufacturer’s safety
precautions. Take care to
balance the motorhome 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.
NOTIFICATION! The Banks
Ram-Air Filter comes
pre-oiled and no oiling
is nesessary for initial
installation. Service the
filter as specified in the
Cleaning and Oiling the
Banks Ram-Air Filter
section of this manual.
96431 v.9.0
|3
Item #
1
2
3
4
5
6
7
8
9
10
11
12
13
Part #
53651
53650
53696
53695
53654
53655
53656
53685
53664
53663
53660
53661
53697
QTY
TorqueTube, Right Side
1
TorqueTube, Left Side
1
Head Pipe, Right Side
1
Head Pipe, Left Side
1
Balance Tube
1
Cross-over Pipe
1
Muffler Inlet Pipe
1
Dynaflow Muffler
1
Tail Pipe Extension, Right Side Exit 1
Tail Pipe, Right Side Exit
1
Tail Pipe, Left Side Exit
1
Tail Pipe Extension, Left Side Exit
1
Adapter, Head Pipe
2
Description
PowerPack, General Assembly
Installation Instructions
10. With the vehicle safely
Figure 1
raised, ground wire(s)
disconnected, and other
precautions in place, the
factory exhaust system can be
removed.
11. Locate the oxygen
sensors in the exhaust
headpipes on each side of
the engine, forward of the
catalytic converters. Unplug
the connectors and unscrew
the oxygen sensors, keeping
track of the left and right
sensors.
12. Disconnect from the
headpipes the oval 2-bolt
flange at the front of
the catalytic converters.
Disconnect the headpipes
from the exhaust manifolds
and remove the headpipe
assembly.
NOTE: Whenever possible,
it is recommended that
the catalytic converters be
inspected. Restricted or
damaged catalytic converters
can impede performance of
your Banks PowerPack.
13. To provide better access
to the manifolds remove the
front wheels from the vehicle.
NOTE: Before removing the
lug nuts, make sure a capable
torque wrench is available
to tighten the lug nuts to
the manufacturer’s torque
specifications.
4 | 96431
v.9.0
If the vehicle is equipped with
inner front fender shields,
remove them for improved
access. If applicable, remove
the two nuts securing the EGR
tube to the rear of the rightside exhaust manifold.
14. Unbolt the brackets from
the alternator support and
manifold stud (see Figure
1). Remove the dipstick
and dipstick tube by pulling
and twisting upward. If the
dipstick tube o-ring is stuck
inside the hole in the engine
block, remove it and place it
back onto the dipstick tube.
15. Remove the spark-plug
wires and the spark plugs
from both sides of the engine.
Note their original locations
so they can be properly
reinstalled.
16. Remove the nuts
holding the spark-plug wire
heatshields to the exhaust
manifold studs. Remove the
heatshields.
17. With a wrench or socket,
back the exhaust manifold
nuts at least one turn away
from the manifolds. Use a #7
female torx socket to unscrew
each stud from the head. If
this tool is not available use a
7⁄ 32 socket. Take out the studs
so the exhaust manifolds can
be removed.
18. CAUTION: Make sure
all ground cables are
removed from vehicle’s
battery(s). Remove the
starter wire battery cable
from the starter motor. If the
starter cable runs to the front
of the motor home re-route
the starter cable as shown in
Figure 2. Reinstall the cable
onto the stud on the starter
and tighten the retaining
nut. Secure the starter cable
to the other cable running
through this area using the
steel wire ties provided. You
will not need the starter cable
extension provided.
Figure 2
19. If the starter cable runs
from the back of the motor
home install the 90-degree
terminal end of the supplied
starter cable extension onto
the starter motor and tighten
the retaining nut. Route
the starter cable extension
forward through the frame
rail under the cross member
then back over the cross
member to the starter motor
and at least 6” away from
all heat sources as shown
in Figure 3. Slide the 4-inch
length of heat shrink over
the extension. Attach the
extension to the factory
starter cable using (1) 5⁄16-18
x 1⁄2” bolt, (1) 5⁄16-18 crimplock
nut, and (1) 5⁄16 SAE. Slide
the heat shrink over the
connection and heat with
a heat gun until the heat
shrink tightly conforms to
the connection. Make sure
the connection is completely
covered.
20. Inspect the exhaust
mounting surfaces of
the cylinder heads and
remove any rust or carbon,
which would prevent the
Figure 3
TorqueTube manifolds from
sealing. Tie cables away
from left-side Torque Tube as
shown in Figure 4.
NOTE: Do not use the factory
exhaust manifold gaskets
upon reinstallation. Banks
TorqueTube manifolds are
a machined surface and are
designed to seal without
gaskets.
21. Apply a small amount
of anti-seize on the threads
of the 8 mm manifold bolts
supplied. Lift the right side
TorqueTube manifold into
place and install one 8 mm
x 25 mm bolt at the front of
the manifold and one at the
rear to hold the TorqueTube
in place. Install the remaining
8 mm x 25 mm manifold bolts
96431 v.9.0
|5
to secure the TorqueTube.
Repeat this step for the left
side TorqueTube. NOTE: Do
not install a manifold bolt in
the bolt hole used to mount
the dipstick tube bracket (see
Figure 1). Torque all manifold
bolts to 26 ft-lbs.
Figure 4
22. Reinstall the dipstick
tube and o-ring. Using the
one 8 mm x 30 mm manifold
bolt and spacer provided,
attach the bracket to the
flange as shown in Figure 5.
Torque this bolt to 26 ft-lbs.
Re-secure the bracket to
the alternator support using
the bolt previously removed.
Re-install the spark plug wires
in their original locations.
Figure 5
23. If applicable, bolt the
EGR tube to the TorqueTube
manifold using the gasket and
5⁄ 16-18 x 1.0” bolts, crimplock
nuts, and washers provided
(see Figure 6). It may be
necessary to rotate the flange
on the EGR tube to align with
the flange on the TorqueTube
manifold.
24. Attach the supplied
heat wrap insulation to the
starter cable extension, if
installed, using the steel wire
ties provided. Locate the
insulation to shield the cable
from the heat source.
25. Place a conical seal in
the flare on the right side
headpipe. Attach the headpipe
to the right-side TorqueTube
manifold using (2) 3⁄8-16 x 1
3⁄ 4-inch bolts and (2) 3⁄ 8 SAE
6 | 96431
v.9.0
washers provided. Tighten the
bolts just enough to hold the
headpipe in place. Insert the
balance tube onto the right
side headpipe. Slide (2) 2 1⁄4”
clamps over the balance tube.
Place a conical seal in the
flare on the left side headpipe.
Attach the headpipe to the
left-side TorqueTube manifold
and balance tube.
bolts provides. Insert the (2)
3” clamps onto the left and
right head pipes and insert
the head pipe adapters onto
each head pipe. Using the
(1) 2-bolt gasket and (2) 7⁄1620 x 11⁄2” bolts, (2) crimplock
nuts, and (4) 7⁄16 SAE washers
for each head pipe adapter,
attach the adapters to the
catalytic converter inlets.
26. Apply a small amount of
27. Position the 3” clamps
anti-seize to the first couple
threads of the (8) 7⁄16-20 x 11⁄2”
over the slip joint. Align the
adapters so that the holes
on the adapter line up with
the cat-converter. Tighten
the bolts and the clamps on
the adapters, then tighten
the front of the head pipes.
Position the 21⁄4-inch clamps
over the slip joint with the
threaded studs pointing to
the rear of the vehicle. See
Figure 7. Tighten the clamps.
Figure 6
28. Apply a small amount of
anti-seize to the threads of
the oxygen sensors previously
removed.
CAUTION: Make sure no
anti-seize gets on the tip
of the oxygen sensor. This
will damage the sensor.
Install the oxygen sensors
in the headpipe making
sure they are in their
original locations. Zip ties
may need to be removed
and new zip ties added
to properly position the
oxygen sensor cables.
Figure 7
29. Remove the factory
tailpipes. If the slip joint at
the rear of the muffler will
not come apart, heat the
joint until it can be separated.
Unbolt the 2-bolt flange at
the front of each muffler and
remove the mufflers.
30. Insert the crossover
pipe hanger into the rubber
hanger previously used for
the front hanger on the rightside muffler. Bolt the 2-bolt
flange of the crossover pipe
to the 2-bolt flange on the
intermediate pipe. Install
the 2-bolt flange of the
96431 v.9.0
|7
muffler inlet pipe onto the
2-bolt flange on the left-side
intermediate pipe. Use (1)
2-bolt gasket, (2) 7⁄16-20 x 11⁄2”
bolts, (2) crimplock nuts, and
(4) 7⁄16 SAE washers for each
flanged joint.
Figure 8
31. Install the supplied frame
mounted muffler hanger
inboard of the frame rail using
the (2) M12x1.75x40mm bolts
through the two holes in the
frame rail approximately 3
inches in front of the frame
cross member (see Figure
8). If the tailpipe is to exit
the left-side install the frame
mounted tailpipe hanger
outboard of the frame rail
using the same M12 bolts.
Place a 1⁄2” SAE washer over
the end of the M12 bolt and
thread a M12 nut onto the
end of each bolt. Tighten
the nuts and bolts. Remove
the rubber hanger used by
the factory for its muffler
hanger and install it on the
Banks frame mounted muffler
hanger.
32. Slide a 3-inch clamp
onto the crossover pipe and
muffler inlet pipe. With the
unshielded portion of the
muffler facing the driveshaft
insert the muffler hanger into
the rubber hanger. Make sure
the two inlets to the muffler
are vertical. Push the muffler
forward and hold. Make
sure the crossover pipe and
muffler inlet pipe are fully
seated into the slip joints of
8 | 96431
v.9.0
Figure 9
the muffler. Tighten the 3-inch
clamps.
Figure 10
33. For a left-side exit
tailpipe insert the 31⁄2” end of
the tailpipe into the outlet of
the muffler.
For a right-side exit tailpipe
remove the factory frame
mounted hanger used to
support the rear of the rightside muffler and install it
inboard of the frame rail
through the holes in the frame
rail approximately 3 inches
in front of the frame cross
member (see Figure 9). If
a factory installed tail pipe
hanger is installed in these
holes remove the hanger.
Install the supplied frame
mounted tailpipe hanger
outboard of the frame rail
adjacent to the relocated
frame mounted hanger using
its studs and nuts. Route
the tail pipe up and over the
driveshaft. Insert the tailpipe
hanger into the relocated
rubber hanger. Slide the 31⁄2”
end of the tailpipe into the
outlet of the muffler.
34. Slide the tailpipe
extension onto the tailpipe,
without installing the clamps.
Level the tailpipe extension
to the vehicle. The tailpipe
extension should be 11⁄2 to 21⁄2
-inches below the bottom of
the vehicle body. If the pipe is
more than 21⁄2-inches below
the body, trim the tailpipe
at the slip joint to raise the
tailpipe extension. Make sure
to trim the tail pipe and not
the extension. Also, be sure
to leave at least 3.5-inches of
straight on the tailpipe at the
slip joint so it can be correctly
inserted into the slip of the
extension.
35. With the proper height
established, install the 4-inch
clamp over the tailpipe
extension slip joint and snug
up the clamp. Do not tighten
completely at this time incase
more adjustment is required.
36. Level the tailpipe
extension with the vehicle
and place the 4-inch universal
hanger clamp onto the
extension pipe. Determine
which hole in the hanger
strap should be inserted
over the stud on the frame
mounted tailpipe hanger and
place the strap onto the stud.
Using the 3⁄8” SAE washer
and crimplock nut provided
secure the hanger strap to the
frame mounted hanger. Slide
the 4-inch hanger clamp on
the extension pipe until the
hanger strap is square to the
extension pipe. Lightly tighten
the clamp. See Figure 10.
37. Check the extension
pipe to ensure it is level and
the gap between it and the
body is correct. If not loosen
the connections and adjust
accordingly. Once pipe is
level and at the correct height
tighten all clamps. Install a
31⁄2” clamp on the outlet of
the muffler. Make sure the
tailpipe is inserted fully into
the slip joint of the muffler
and tighten the clamp.
96431 v.9.0
|9
38. Slide the tailpipe tip
40. Re-install the inner
onto the tailpipe extension.
Position the tip so it extends
1-inch beyond the coach body
or wherever aesthetically
pleasing and tighten the bandclamp.
front fender shields and
wheels if removed. Make
sure to torque the wheels
to the manufacturer’s
specifications. Lower the
vehicle and reconnect the
battery cables. Start the
engine and listen for any
exhaust leaks. Tighten bolts
or clamps to correct any leaks
or improper adjustments.
Whenever possible, tackwelding slip connections to
prevent disengagement is
recommended.
BANKS RAM-AIR®
FILTER:
39. Locate the factory air
filter housing and access it
from inside the right-side
wheel-well. Replace the
factory air filter element
with Banks Ram Air element.
Place the “STOP!” decal on
the air filter housing so that
it is clearly visible to service
personnel.
10 | 9 6 4 3 1
v.9.0
NOTE: It is normal for the
vehicle exhaust to smoke
upon initial start-up. This
indicates the lubricant applied
during the tube-bending
process is burning off the
pipes.
Cleaning and Oiling the Banks Ram-Air Filter
NOTIFICATION! The Banks Ram-Air Filter comes
pre-oiled and no oiling is necessary for initial
installation.
Use Banks Ram-Air Filter cleaning system (part#
90094), available from Gale Banks Engineering to
service the Ram-Air Filter. Follow the instructions
included with the cleaning system to clean and
re-oil your Banks Ram-Air Filter.
1. PRE-CLEANING
Tap the element to dislodge any
large embedded dirt, then gently
brush with a soft bristle brush.
NOTE: If complete cleaning is
not practical at this time, re-oil
the element and reinstall in your
vehicle.
2. SPRAY-ON CLEANING
Spray air-filter cleaner
liberally onto the entire
element and let soak
for 10 minutes.
PAN CLEANING
Large air-filter elements
can be rolled or soaked
in a shallow pan of airfilter cleaner. Remove
immediately and let soak for
approximately 10 minutes.
3. CLEANING HINTS
Use only an air-filter cleaner. 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.
4. RINSE OFF
Rinse off the element with lowpressure water. Tap water is
okay. Always flush from the clean
side to dirty side. This removes
the dirt and does not drive it into the
filter.
5. DRYING HINTS
Always dry naturally. After rinsing, shake off all
excess water and let the element dry naturally. DO
NOT USE COMPRESSED AIR – DO NOT USE OPEN
FLAME – DO NOT USE HEAT DRYERS!
EXCESS HEAT WILL SHRINK THE COTTON
FILTER MEDIA. COMPRESSED AIR WILL
BLOW HOLES IN THE ELEMENT.
6. AEROSOL OILING
After cleaning air filter
always re-oil before
using. Spray Banks RamAir filter oil down into
each pleat with one pass
per pleat. Wait 10 minutes
and re-oil any white spots
still showing.
7. OILING HINTS
Never use a Banks Ram-Air filter without oil (the
filter will not stop the dirt without the oil). Use
only an air filter oil. Air-filter oil is a compound
of mineral and animal oil blended with special
polymers to form a very efficient tack barrier. Red
dye is added to show just where you have applied
the oil. Eventually the red color will fade but the
oil will remain and filter the air. NEVER USE
Automatic Transmission Fluid. NEVER USE
Motor Oil. NEVER USE Diesel Fuel. NEVER
USE WD-40, LPS, or other light-weight oils.
8. RE-INSTALL
Reinstall your Banks Ram-Air filter element with
proper care. Make sure the element seats properly
in the filter case. Install the cover making sure it’s
in the right position. Tighten all the nuts, bolts,
screws or clips to factory specifications.
9. DO NOT DISCARD
Affix the “Do Not Discard” sticker to the filter case
(included with every Banks replacement element).
Make sure you put the sticker in a highly visible
place to alert your mechanic not to discard.
10. PERFORMANCE HINTS
Service every 50-100,000 miles on street-driven
applications. Service more often in offroad or
heavy-dust conditions. If an air-filter restriction
gauge is installed, then change the element when
the air-filter restriction reaches 18”/H O.
2
CAUTION! Extremely fine dust from agriculture
or offroad 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
air-filter cleaner and air-filter oil.
96431 v.9.0
| 11
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
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