Banks Six-Gun® Diesel Tuner

Banks Six-Gun® Diesel Tuner
Banks Six-Gun
Diesel Tuner
®
Compatible with Optional Banks PowerPDA®
Vehicle Command Center
For use with Palm® Tungsten™ E2 only
2003-2005 (235, 250, 305 and 325 HP) Dodge
5.9L Cummins (24-valve) ISB Pickup Trucks
THIS MANUAL IS FOR USE WITH SYSTEMS 61022, 61046 AND 61062
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
©2007 Gale Banks Engineering
05/25/06 PN 96807 v.5.0
>>
f
THIS IS A HIGH PERFORMANCE
PRODUCT. USE AT YOUR OWN RISK.
Do not use this product until
you have carefully read the
following agreement.
This sets forth the terms and
conditions for the use of this
product. The installation of
this product indicates that
the BUYER has read and
understands this agreement
and accepts its terms and
conditions.
Disclaimer of Liability
Gale Banks Engineering Inc., and its
distributors, employees, and dealers
(hereafter “SELLER”) shall in no way
be responsible for the product’s
proper use and service. The BUYER
hereby waives all liability claims.
The BUYER acknowledges that he/she
is not relying on the SELLER’s skill or
judgment to select or furnish goods
suitable for any particular purpose
and that there are no liabilities which
extended beyond the description on
the face hereof and the BUYER hereby
waives all remedies or liabilities,
expressed or implied, arising by law
or otherwise, (including without
any obligations of the SELLER with
respect to fitness, merchantability,
and consequential damages) whether
or not occasioned by the SELLER’s
negligence.
The BUYER is responsible to fully
understand the capability and
limitations of his/her vehicle according
to manufacturer specifications
and agrees to hold the SELLER
harmless from any damage resulting
from the failure to adhere to such
specifications. The SELLER disclaims
any warranty and expressly disclaims
any liability for personal injury or
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96807 v.5.0
damages. The BUYER acknowledges
and agrees that the disclaimer of
any liability for personal injury is a
material term for this agreement
and the BUYER aggress to indemnify
the SELLER and to hold the SELLER
harmless from any claim related to
the item of the equipment purchased.
Under no circumstances will the
SELLER be liable for any damages or
expenses by reason of the use or sale
of any such equipment. The BUYER
is responsible to obey all applicable
federal, state, and local laws, statutes,
and ordinances when operating his/
her vehicle, and the BUYER agrees
to hold SELLER harmless from
any violation thereof. The SELLER
assumes no liability regarding the
improper installation or misapplication
of its products. It is the installer’s
responsibility to check for proper
installation and if in doubt, contact the
manufacturer. The BUYER is solely
responsible for all warranty issues
from the automotive manufacturer.
Limitation of Warranty
Gale Banks Engineering Inc., (hereafter
“SELLER”) gives Limited Warranty as
to description, quality, merchantability,
fitness for any particular purpose,
productiveness, or any other matter of
SELLER’s product sold herewith. The
SELLER shall be in no way responsible
for the product’s open use and service
and the BUYER hereby waives all rights
except those expressly written herein.
This Warranty shall not be extended
or varied except by written instrument
signed by SELLER and BUYER.
The Warranty is Limited to two (2) years
from the date of sale and is limited
solely to the Gale Banks Engineering
parts contained within the products kit.
Parts or devises outside the products
kit, such as the Palm® Tungsten™ E2,
are not covered under Gale Banks
Engineering warranty. The warranty for
the Palm Tungsten E2 is determined by
the manufacturer’s warranty terms and
conditions, and limited to a period of 90
days from purchase. All products that
are in question of Warranty must be
returned shipping prepaid to the SELLER
and must be accompanied by a dated
proof of purchase receipt. All Warranty
claims are subject to approval by Gale
Banks Engineering Inc.
Warning: The PDA may be
susceptible to damage as a
result of extended exposure
to sunlight, heat or extreme
cold. It is highly recommended
that the PDA be removed from
its mounting location if the
vehicle will be subjected to
high concentrations of sunlight,
heat or cold for an extended
period of time. Gale Banks
Engineering is not responsible
for damage to PDAs resulting
from exposure conditions.
Under no circumstance shall the SELLER
be liable for any labor charged or travel
time incurred in diagnosis for defects,
removal, or reinstallation of this product,
or any other contingent expense.
Under no circumstances will the
SELLER be liable for any damage or
expenses incurred by reason of the
use or sale of any such equipment.
In the event that the buyer does
not agree with this agreement:
The buyer may promptly
return this product, in a new
and unused condition, with
a dated proof-of-purchase, to
the place-of-purchase within
thirty (30) days from date-ofpurchase for a full refund:
Table of Contents
General Installation Practices . . . . 5
Section 1 . . . . . . . . . . . . . . . . . . . . . . 7
Installation of Wiring Harness,
Connections and Six-Gun Diesel Tuner
Section 2 . . . . . . . . . . . . . . . . . . . . . 16
Mounting the Docking Station and
Connecting the Banks PowerPDA
Vehicle Command Center
Section 3 . . . . . . . . . . . . . . . . . . . . . 21
Installation of the Six-Gun Selector
switch and Speedloader Module
Section 4 . . . . . . . . . . . . . . . . . . . . . 24
Optional Thermocouple Installation
(Required for Optional Banks PowerPDA
or Speed-Loader Module)
Section 5 . . . . . . . . . . . . . . . . . . . . . 26
Speed-Loader Learning Sequence
(Applies to Six-Gun Switch Installations
Only)
Section 6 . . . . . . . . . . . . . . . . . . . . . 27
Automatic Transmission Learning
Section 7 . . . . . . . . . . . . . . . . . . . . . 28
Checking Engine Performance
Section 8 . . . . . . . . . . . . . . . . . . . . . 29
Troubleshooting
Section 9 . . . . . . . . . . . . . . . . . . . . . 32
Clearing Learned Information
Section 10 . . . . . . . . . . . . . . . . . . . . 33
Placement of the Banks Power Decals
Section 11 . . . . . . . . . . . . . . . . . . . . 34
Removal of the Six-Gun Diesel Tuner
The installation of this product
indicates that the buyer has
read and understands this
agreement and accepts its
terms and conditions.
96807 v.5.0
3
Dear Customer,
If you have any question
concerning the installation
of your Banks Six-Gun Diesel
Tuner, please call our Technical
Service Hotline at (888) 839270 between 7:00am and
5:00pm (PST). If you have any
questions relating to shipping
or billing, please contact our
Customer Service Department
at (888) 839-5600.
Thank you.
The Banks Six-Gun Diesel Tuner has six
power levels adjustable by the supplied
Six-Gun switch, or seven power levels
adjustable by the optional Banks
PowerPDA.
The optional Banks PowerPDA is a
versatile touch-screen interface to the
Six-Gun tuner and your truck that also
increases the Six-Gun’s power output
by up to 27 hp and 40 lb-ft of torque.
With the push of a button, you can
change power levels on-the-fly-just one
of the numerous Six-Gun parameters
Banks PowerPDA lets you custom-tune.
It displays four engine functions at a
time, two of which are user-selectable
(over a dozen to choose from). It will
clock your 0-60 mph, 1⁄ 8-mile and 1⁄ 4mile performance runs, recording peak
boost and EGT values. Performance
runs are automatically stored for later
retrieval with a time-and-date stamp.
With the Banks PowerPDA, you can also
scan and clear OBD II diagnostic codes.
It gives you the endless functionality of
a Palm® Tungsten™ E2 PDA, and fits in a
custom dash-mounted docking station
using infrared wireless connectivity.
The Six-Gun Diesel Tuner comes with a
Six-Gun switch that has six selectable
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96807 v.5.0
power levels. The Six-Gun switch is
included in the Six-Gun Diesel Tuner. The
optional Speed-Loader module can be
added to the Six-Gun for off-road use only
to increase the power output of Levels
2-6. Level 1 is stock with or without
Speed-Loader installed. Each additional
higher level adds approximately 20% of
the available power increase.
To prevent damage to the factory
transmission, Banks recommends
that both automatic and manual
transmission vehicles do not exceed
Level 4 or Level 3 with optional
PowerPDA or Speed-Loader while the
vehicle is experiencing load (towing,
climbing a steep grade, carrying a load,
etc.).
To use the higher levels of the Six-Gun
Diesel Tuner while towing or climbing,
airflow improvements must be made
to lower the exhaust gas temperature
(EGT) entering the turbo. The EGT should
not exceed 1400º F for more than a few
seconds. Elevated EGT can damage the
turbocharger and the engine.
Attention! Before proceeding with
these instructions, please carefully
read the DISCLAIMER OF LIABILITY
and LIMITATION OF WARRANTY
statement located on page 2 of
this manual.you.
General Installation Practices
TOOLS REQUIRED:
• Inch and metric deep sockets
• Inch and metric combination and openend wrenches
• Standard and Philips head screwdrivers
• Pocket or X-Acto knife
• Pliers
• Shop towels
• Multimeter or 12-volt tester
• Wire cutters
• Scissors
• Drill motor
• 1⁄8”, 13⁄32” and 7⁄16” drill bits
• Tap handle
• 1⁄4” NPT tap
• Foot-pound torque wrenches
• Penetrating oil or light lubricant spray
• Anti-seize compound
• Heat gun
1. Before starting work, familiarize
yourself with the installation procedure
by reading all of the instructions.
2.
The exploded views provide only
general 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 side, and the right side to the
passenger side.
4.
Disconnect the negative (ground)
cable from the battery (or batteries, if
there are two) before beginning work.
5.
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.
6.
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 vehicle to
prevent it from slipping or falling. When
using ramps, be sure the front wheels
are centered squarely on the topsides.
When raising the front of the vehicle,
put the transmission in park (automatic)
or reverse (manual), set the parking
brake, and block the rear wheels. When
raising the back of the vehicle, be sure
the vehicle is on level ground and the
front wheels are blocked securely.
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.
7.
During installation, keep the work
area clean. Do not allow anything to
be dropped into intake, exhaust, or
lubrication system components while
performing the installation, as foreign
objects will cause immediate engine
damage upon start-up.
8.
Save this Owner’s Manual as a
reference for system maintenance and
service.
9.
Banks recommends either a Banks
PowerPDA or a Pyrometer (EGT)
gauge and Boost gauge be installed
with the Six-Gun Diesel Tuner to help
monitor performance and exhaust
gas temperature of the vehicle (see
part numbers next page). To further
increase engine life by lower EGT’s,
Banks also recommends installing a
Monster Exhaust® system (see next
page).
96807 v.5.0
5
Banks PowerPDA System
Banks PowerPDA
Docking Station Kit. . . . . . . . . . . 61048
Palm Tungsten E2 PDA . . . . . . . 61004
Banks Monster® Exhaust:
325-hp Rated Engines:
Std. Cab Long Bed. . . . . . . . . . . . . 48700
Quad Cab Short Bed . . . . . . . . . . . 48700
Quad Cab Long Bed . . . . . . . . . . .48701
235-, 250- and 305-hp Rated Engines:
Std. Cab Long Bed w/ Cat . . . . . . 48640
Quad Cab Short Bed w/ Cat . . . . . 48640
Std. Cab Long Bed w/o Cat . . . . . 48641
Quad Cab Short Bed w/o Cat . . . .48641
Quad Cab Long Bed w/ Cat . . . . . 48642
Quad Cab Long Bed w/o Cat . . . . 48643
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96807 v.5.0
Additional Equipment:
Ram-Air® Filter. . . . . . . . . . . . . . . . . 41028
Ram-Air® Filter Service Kit . . . . . . . 90094
TechniCooler® (‘03-05) . . . . . . . . . . 25980
Gauge Assembly,
Boost and Pyro . . . . . . . . . . . . . . . ..64507
Thermocouple. . . . . . . . . . . . . . . . ..63042
Thermocouple Lead Wire. . . . . . . . 63062
Banks BigHead® Actuator. . . . . . . . 24331
Turbine Inlet Gasket . . . . . . . . . . . . 93033
Speedloader . . . . . . . . . . . . . . . . . . 62978
Section 1
INSTALLATION OF WIRING HARNESS, CONNECTIONS AND SIX-GUN
DIESEL TUNER
1. Disconnect the battery ground
cables from each of the batteries.
Secure the cables so that they do not
come in contact with the batttery
posts during the installation.
2. Place the Six-Gun Diesel Tuner
box on top of the fuse box located
in the left front side in the engine
compartment. See Figure 2. The
in-cab cable with the three small
connectors will be routed into the
cabin via the grommet on the firewall.
The other two harnesses will be routed
under the intake to their prospective
locations listed in the following steps.
3. Locate the rubber grommet on the
drivers side firewall. Using a utility
knife, make a 1.5-inch-long slit in the
grommet next to the wire harness.
Be careful not to cut or damage
the harness. See Figure 3 for the
proper location of the required cut.
Insert a screwdriver from the engine
compartment into the cut hole and
gently thrust it through the grommet.
4. Inside the vehicle, remove the
lower dash panel beneath the steering
column by removing the two (2)
screws at the bottom of the panel.
Retain the screws for re-installation.
NOTE: There are also two (2) clips
located at the top corners of the
panel, which hold the panel in place.
These clips can be released by gently
pulling on the corners of the panel.
Use caution to avoid damaging the
panel during removal.
Figure 1 Six-Gun and supplied wiring harnesses
96807 v.5.0
7
Figure 2
Figure 3
8
96807 v.5.0
5. Remove the electrical connector
bracket on the left hand side of the
support below the steering column in
front of the firewall by removing the
two (2) bolts. This will allow access to
the inner grommet. See Figure 4.
6. Cut the grommet on the firewall
inside the vehicle along the hole
created by the screwdriver in Step 3.
7. Locate the in-cab cable with the
three connectors. From the engine
compartment, push the in-cab cable
through the hole cut in the firewall
grommet.
NOTE: Taping the end of the cable to
a piece of stiff wire (i.e. coat hanger)
may make routing the cable through
the firewall a simpler task. The stiff
wire should be pushed through the slit
in the grommet and then the wires can
be attached to the stiff wire and pulled
through the hole in the grommet.
CAUTION: Pull gently to avoid
damage to the cable connectors.
Always pull on the cable sheath
rather than the wires themselves.
8. From inside the vehicle, continue
to pull the in-cab cable through the
firewall until it is approximately 22”
inside the cab. Secure the cable
to the lower access panel area.
Take precaution to leave the three
connectors accessible for usage
further in the installation process.
9. Locate the Banks OBDII Interface
Cable and 11” cable tie in your kit.
Connect the OBDII Interface Cable to
the vehicle OBDII connector. Use the
11” cable tie as shown in Figure 5
to secure the Banks interface cable
to the vehicle OBDII connector. Now,
connect the 8-pin connector from
the Banks OBDII Interface Cable to
the 8-pin connector on the Six-Gun
Tuner in-cab cable. Note: If you are
not installing the optional Banks
Figure 4
96807 v.5.0
9
PowerPDA then coil up and secure the
cable with the RJ12 (telephone style)
connector end.
10. In the engine compartment find
the Fuel Rail Pressure (FRP) sensor
on the fuel rail. It is located on the
drivers side of the engine. Unplug
the factory connector and plug it into
the corresponding male FRP sensor
connector on the Six-Gun harness.
Plug the Six-Gun’s female FRP sensor
connector into the sensor. See Figure 6.
11. Locate the Manifold Pressure
(MAP) sensor on top of the intake
manifold. Unplug the factory connector
and plug it into the corresponding male
MAP sensor connector on the Six-Gun
harness. Plug the Six-Gun’s female MAP
sensor connector into the sensor. See
Figure 6.
CAUTION: The Camshaft Position
(CMP) sensor and the Crankshaft
Figure 5
10
96807 v.5.0
Position (CKP) sensor have the
same type of connectors and
they are in close proximity to
one another. Make sure the
right connectors are used when
installing these connections. Refer
to Figure 7. for their locations
on the Six-Gun Diesel Tuner wire
harness.
12. Locate the Crankshaft Position
(CKP) sensor on the lower front left
side of the engine. It is behind the
engine crankshaft pulley (engine
harmonic balancer). Unplug the
factory connector and plug it into
the corresponding male CKP sensor
connector on the Six-Gun harness.
Plug the Six-Gun’s female CKP sensor
connector into the sensor. Take care
to route the wire harness away
from the power steering pump
pulley and secure it with the
supplied cable ties. See Figure 8.
Figure 6
Figure 7
96807 v.5.0
11
13. Locate the Camshaft Position (CMP)
sensor below the fuel injection pump
between the timing gear cover and
the ECM. Unplug the factory connector
and plug it into the corresponding male
CMP sensor connector on the Six-Gun
harness. Plug the Six-Gun’s female CMP
sensor connector into the sensor. See
Figure 9.
14. Remove the fuse box cover,
located in left front side of the engine
compartment. Locate the mini-fuse
#50 and remove it. Install the mini-auto
blade tap onto the removed mini fuse
as shown in Figure 10.
Re-install the mini fuse with the
attached blade tap into location #50 as
shown in Figure 11. Note: Install the
mini-auto blade tap on the terminal leg
closest to the firewall. This is the “hot”
side of the circuit.
Caution: It is very important that
you select the proper fuse. The
Figure 8
12
96807 v.5.0
Banks Six-Gun Diesel Tuner will
not function properly if installed
incorrectly.
15. It is recommended to cut a small
notch in the fuse box cover as shown
in Figure 12, to avoid a crimped or
stressed wire. Locate the RED/WHT
wire with the Power Terminal on
the Six-Gun tuner wire harness and
connect it to the mini-fuse blade tap.
Replace the fuse cover and make sure
not to pinch the RED/WHT power wire.
16. In the engine compartment,
locate the BLACK Ground wire with
the ring terminal on the Six-Gun Diesel
Tuner wire harness. Install this ring
terminal onto the fender ground stud,
over the ring terminals already there,
and re-install the nut. See Figure 13.
Note: Go over the entire installation as
a precautionary check to ensure that
all clamps are tight, wiring and hoses
are properly routed, and connections
Figure 9
Figure 10
96807 v.5.0
13
Figure 11
Figure 12
14
96807 v.5.0
are correct and tight. Make sure that
the Six-Gun wire harness is not lying in
the way of the brake and gas pedals,
or any moving parts.
17. (Engine Compartment) After
confirming all of the system connections
are correct, make sure the entire
mounting surface is clean and free of
dirt and oil before mounting the SixGun Diesel Tuner. Clean and dry as
required using a cloth dampened with
rubbing alcohol or a similar cleaning
solution.
CAUTION: Do not spray fluid
directly onto any electrical
equipment, or equipment damage
may result. Mount the Six-Gun
Diesel Tuner on the top of the fuse
box cover as shown in Figure 2, by
peeling the protective backing off
the adhesive tape on the back of
the Six-Gun Diesel Tuner.
18. Hold the Six-Gun Tuner against
the fuse box cover for approximately
1 minute while applying pressure to
allow the adhesive to properly adhere
to the surface.
-END, SECTION 1-
Figure 13
96807 v.5.0
15
Section 2
MOUNTING THE DOCKING STATION AND CONNECTING THE BANKS
POWERPDA VEHICLE COMMAND CENTER
If not installing the optional Banks
PowerPDA, skip to Section 3.
run to bring the inside temperature up
to “room temperature” (at least 68°F).
Note: This system has been
designed for use with the Palm
Tungsten E2 PDA.
1. Clean mounting area with isopropyl
alcohol or similar residue free cleaning
agent to prepare the surface for the
adhesive tape.
Warning: The PDA may be
susceptible to damage as a result
of extended exposure to sunlight,
heat or extreme cold. It is highly
recommended that the PDA
be removed from its mounting
location if the vehicle will be
subjected to high concentrations
of sunlight, heat or cold for
an extended period of time.
Gale Banks Engineering is not
responsible for damage to PDAs
resulting from exposure conditions.
Locate the Docking Station in your kit.
The mounting location of the Docking
Station is vehicle specific. It is not a
universal fit. Make sure to do a dry
pre-fit before permanently mounting.
For mounting location, refer to
Figure 14.
Note: In cold climates, best results will
be obtained if the vehicle’s heater is
Figure 14
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96807 v.5.0
2. The Docking Station has adhesive
tape applied to it at the factory. Prior
to removing the protective liner from
the tape, test fit the unit on the dash
as indicated in Figure 14. The Docking
Station will fit the dash contours only
where shown in the photo.
3. After test fitting, remove the liner
from the adhesive tape on the back of
the Docking Station.
4. Carefully align and secure the
Docking Station to the dash in the same
location as it was test fit. Press the
Docking Station firmly against the dash
for one minute to ensure good adhesion.
5. To route the RJ12 cable connecting
the Docking Station to the Six-Gun, you
will need to unclip the knee panel. (See
Figure 15) Pry and unclip as needed
to gain enough clearance to route the
cable behind the panel.
Figure 15
Figure 16
96807 v.5.0
17
6. Locate the RJ12 cable on your SixGun wiring harness and pull enough
cable through to reach the bottom of
the Docking Station.
7.
Locate and remove the screw in
the dash panel above the hook as
shown in Figure 16.
8. Remove the dash panel by gently
pulling and unclipping it as needed.
(See Figure 17).
Figure 17
Figure 18
18
96807 v.5.0
9. Guide the RJ12 cable through the
clearance between the removed panel
and the dash as shown in Figure 18.
10.
Looking at the back of the dash
panel, locate the screw for the dash
plate as shown in Figure 19. This
panel may be blank, or contain the
airbag deactivation switch. Remove
the screw and the plate.
11.
Route the RJ12 cable through
the opening and connect it to the left
most receptacle on the bottom of the
Docking Station. Replace the dash
plate and screw.
WARNING: THE CHARGING CABLE
ON THE DOCKING STATION
IS DESIGNED TO SUPPLY A
CONSTANT LOW-VOLTAGE POWER
SOURCE (+5VDC) TO THE BANKS
POWERPDA AND IS “LIVE” AS
LONG AS THE SYSTEM’S OBD II
INTERFACE CABLE IS COMPLETELY
INSTALLED AND THE RJ12
CONNECTOR IS PLUGGED INTO
THE DOCKING STATION.
ALTHOUGH THIS CHARGING CABLE
IS SHORT AND ITS CIRCUITRY IS
FUSE-PROTECTED, THE USER IS
EXPECTED TO TAKE APPROPRIATE
MEASURES TO PREVENT SMALL
CHILDREN AND/OR PETS FROM
CONTACT WITH ANY PART OF THIS
SYSTEM.
12.
Re-install the electric connector
bracket that was removed in Step 5 of
Section 1, below the steering column
in the front of the firewall with the
original two (2) bolts.
Route all wiring away from any pedals
or other moving components. Using
the cable ties supplied, secure the
wiring under the dash. Secure all
wiring under the hood away from heat
sources or sharp edges. Re-install the
lower dash panel with the original 2
bolts. (See Figure 20)
13.
Your Docking Station is now
installed and is ready for the
Banks PowerPDA. Install the Banks
PowerPDA into the Docking Station.
Be sure the Banks PowerPDA is
completely seated in the Docking
Station against the lower support
bracket.
14.
Plug the Docking Station’s
charging cable into the charging
receptacle on the lower edge of the
Banks PowerPDA. NOTE: There may
be a snug fit when installing the Banks
PowerPDA into the Docking Station.
Take care not to force this process.
15.
Re-install all remaining dash
components
-END, SECTION 2-
96807 v.5.0
19
Figure 19
Figure 20
20
96807 v.5.0
Section 3
INSTALLATION OF THE SIX-GUN SELECTOR SWITCH AND
SPEEDLOADER MODULE
Not needed if optional Banks
PowerPDA is installed.
CAUTION: Do not use force
when working on plastic parts.
Permanent damage to the part
might result.
1. The Six-Gun switch will be installed
on the drivers side of the instrument
panel (IP) next to the steering column.
See Figure 21.
2. Remove the headlamp switch bezel
on the drivers side by gently pulling on
it. Disconnect the electrical connector
once the bezel is removed.
3. To remove the center bezel, open
the ashtray and cup holder and
remove the retaining screw. Gently
pull on the center bezel to disengage
all the clips that attach the bezel
to the dash. Disconnect the four
(4) electrical connections after the
bezel is removed. Keep the screw for
reinstallation.
4. Remove the cluster bezel by first
removing the two (2) screws at the
top. Gently pull on it and disengage
all the clips that attach the bezel
to the dash. Retain the screws for
reinstallation.
5. Cut out the supplied template (see
Figure 26 on page 35) and align the
template onto the front of the cluster
bezel by placing its left edge against
the cluster rib, and its bottom edge
against the cluster bottom edge. Use
masking tape to securely hold down the
template. NOTE: Do not tape over the
markings on the template.
6. Using a 3/8” Uni-drill, center the
bit onto the 3/8” drill location on the
template and slowly drill through the
IP. Using a 1/8” drill bit, center and
drill through the 1/8” location on the
template. Remove and discard the
template and any plastic shavings.
NOTE: It is important that the hole
is drilled at the recommended
location. The switch may not clear the
instrument panel structure if the hole
is shifted to another location.
7. Align the Banks Six-Gun label onto
the previously drilled hole. Make
sure the entire mounting surface is
clean and free of dirt and oil before
mounting the label. Clean and dry as
required using a cloth dampened with
rubbing alcohol or similar cleaning
solution.
CAUTION: Do not spray fluid
directly onto any electrical
equipment, or equipment damage
may result. Mount the Six-Gun Diesel
Tuner switch label onto the cluster
by peeling the protective backing off
the adhesive tape on the back of the
switch label. Hold the label against the
panel for approximately 20 seconds
while applying pressure to allow the
adhesive to properly adhere to the
surface.
8 Remove the nut and internal tooth
washer from the Six-Gun switch.
Rotate the shaft counter clockwise
until the shaft stops. Verify that the
locating washer tab is inserted into the
#6 position on the switch (see Figure
22).
NOTE: If the washer is in any position
other than the #6, your Six-Gun Diesel
Tuner will not select power levels
correctly.
9. After confirming the locating washer
is in the #6 location, install the switch
through the 3/8” hole on the backside of
the bezel. The alignment pin should rest
in the 1/8” hole and with the switch fully
rotated counter clockwise; the shaft’s
flat side should be facing the steering
column. Secure switch with internal
tooth washer and nut. Snug the nut. Be
careful not to over torque the nut and
damage the plastic threads.
96807 v.5.0
21
Figure 21
Figure 22 Six-Gun switch, orientation of the tab on the washer
22
96807 v.5.0
10. Install the knob onto the shaft
facing the #1 Level on the Six-Gun
label. On the knob, snug the two (2)
set screws with the supplied 0.050”
hex key wrench.
11. Reinstall the cluster bezel by
pressing on it to ensure all the
clips are engaged. Secure it with the
original a two (2) screws.
12. Reconnect the electrical
connector to the headlamp switch
bezel. Reinstall this bezel by gently
pushing on it until all clips are
engaged.
13. Reconnect the four (4) electrical
connections to the center bezel.
Reinstall this bezel by pushing on
it to engage all the clips. Open the
ashtray and cup holder and reinstall
the original screw.
14. Route the Six-Gun switch wires
down to the steering column.
Speed-Loader Module installation (for
off-road, short duration use only)
15. For installation of the SpeedLoader option:
a.) Install the 4-pin connector of the
Speed-Loader harness to the 4- pin
connector on the Speed-Loader
module.
b.) Connect the Six-Gun switch’s 2- pin
plug to the Speed-Loader’s 2-pin
receptacle. Connect the SpeedLoader’s 2-pin plug to the Banks
wire harness that was routed into
the passenger compartment from
the Six-Gun module.
c.) If necessary, cable tie the SpeedLoader module and harness under
the dash away from pedals or any
moving components.
16. Route the Six-Gun switch’s cable
to the wire harness that was routed
into the passenger compartment from
the Six-Gun module, and plug the 2pin connector into the corresponding
connector on the Six-Gun harness.
Note: The 8-pin plug on the wire
harness routed from the Six-Gun
module to the passenger compartment
will not be used by either the Banks
Six-Gun or Speed-Loader option. The
8-pin plug is used for the optional
PowerPDA.
17. Re-install the electric connector
bracket that was removed in Step 5 of
Section 1 below the steering column
in the front of the firewall with the
original two (2) bolts.
18. Route all wiring away from any
pedals or other moving components.
Using the cable ties supplied, secure
the wiring under the dash. Secure all
wiring under the hood away from heat
sources or sharp edges. Re-install the
lower dash panel with the original 2
bolts.
NOTE: The optional Speed-Loader
provides access to an additional power
level of the Six-Gun Diesel Tuner.
Installing the Speed-Loader will allow
Levels 2 through 6 to experience an
increase in power above that of the
Banks Six-Gun Diesel Tuner alone.
Level 1 remains at stock power output
regardless if the Speed-Loader is
installed.
Once the Speed-Loader is installed
and detected, the green LED on
the Six- Gun connector will flash
twice at power up. Refer to the
following “SPEED-LOADER LEARNING
SEQUENCE” in Section 5 for more
details.
-END, SECTION 3-
96807 v.5.0
23
Section 4
OPTIONAL THERMOCOUPLE INSTALLATION (REQUIRED FOR OPTIONAL
BANKS POWERPDA OR SPEED-LOADER MODULE)
1. 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.
NOTE: The Cummins ISB engine uses
a divided exhaust manifold. The
thermocouple may be installed to
sample exhaust temperature in either
exhaust passage. We recommend the
rear passage (toward the firewall).
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
that is located between the two
sections of the oil drain tube.
4. Disconnect the oil supply hose
at the turbocharger. Disconnect the
compressor outlet hose that goes to
the intercooler.
5. Disconnect the turbine outlet pipe
by loosening the V-band. Save V-band
for re-installation.
6. Remove the turbocharger mounting
nuts/bolts and the turbocharger from
the exhaust manifold. Clean and
inspect the exhaust flange mounting
surfaces on the exhaust manifold.
Make sure the surface is clean and dry.
CAUTION: Anytime the
turbocharger is removed from
the engine, take care that no
foreign objects enter any of the
24
96807 v.5.0
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 clean rag, as this pipe is
very susceptible to foreign object
entry.
7. Stuff clean shop towels into the
compressor outlet and inlet hoses to
prevent contamination from entering
the pipes. Cover the turbo oil drainpipe
to avoid contamination.
8. Stuff a small clean 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.
9. Use a 7⁄ 16” drill, keeping the drill
perpendicular to the manifold surface
and drill through the exhaust manifold
into the rear passage as shown in
Figure 23.
10. Tap 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 pipe coupling
into the tapped hole. The coupling
should thread in 3 to 31⁄ 2 turns hand
tight. Do not install the probe in place
at this time.
11. Remove all loose chips from the
exhaust manifold. A shop vacuum or
small brush 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.
Figure 23
13. Attach the thermocouple to the
supplied thermocouple lead wire
extension with the supplied nuts and
bolts. The YELLOW thermocouple wire
attaches to the YELLOW extension
wire’s, the RED thermocouple wire
attaches to the RED extension wire.
Cover this joint with the supplied heat
shrink tubing and heat until the tubing
conforms to the joint. Make sure the
entire joint is insulated.
14. Route the thermocouple lead wire
extension along the factory harness
to the driver’s side and connect it to
the Six-Gun harness with the supplied
nuts and bolts. The YELLOW wire
attaches to the free YELLOW wire on
the Six-Gun Diesel Tuner. The RED
extension wire attaches to the free
RED wire on the Six-Gun Diesel Tuner.
Cover this joint with the supplied heat
shrink tubing and heat until the tubing
conforms to the joint. Make sure the
entire joint is insulated.
CAUTION: Remove all the rags that
are inside the compressor hoses
and the exhaust manifold before
re-installing the turbocharger.
15. 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-lbs. Tighten the oil drain
hose clamp.
16. Reconnect and tighten the turbo
oil supply hose.
17. Reconnect the turbine outlet pipe
to the turbocharger and secure it with
the V-band.
18. Re-connect the compressor outlet
hose that goes to the intercooler.
19. Re-install the air filter housing
that was previously removed.
96807 v.5.0
25
20. Reconnect the ground cables to
the vehicles batteries.
Note: Once the Six-Gun Diesel
Tuner is powered up at key-on, it
will ‘learn’ that a thermocouple
is installed and automatically
enable the EGT limiting function.
If the thermocouple is removed after
being installed and run on the vehicle,
the Six-Gun Diesel Tuner will assume
that the sensor or connection has gone
bad, and cease adding power while
triggering the [2,3] diagnostic code
(see Trouble Shooting Section 8). To
ensure that the Six-Gun Diesel Tuner
operates properly after removing a
previously installed thermocouple,
see the ‘Clearing Learned Information’
Section 9. EGT limiting will not be
operational and excessive EGTs
may develop at higher power
levels.
-END, SECTION 4-
Section 5
SPEED-LOADER LEARNING SEQUENCE
(APPLIES TO SIX-GUN SWITCH INSTALLATIONS ONLY)
Once the Speed-Loader is installed
or removed from the vehicle, the
following learning sequence will need
to be performed.
1. Key the ignition ON.
2. Turn the Six-Gun switch to level 6
and stay there for 5 seconds.
3. Rotate the switch to level 1 and
stay there for 5 seconds.
26
96807 v.5.0
4. Rotate the switch again to level 6
and stay there for 5 seconds.
5. The Six-Guns Tuner’s GREEN LED
will flash twice as soon as the SpeedLoader is learned. The GREEN led will
now flash twice each time the Six-Gun
Tuner is powered-up, indication the
Speed-Loader is present.
-END, SECTION 5-
Section 6
AUTOMATIC TRANSMISSION LEARNING
Your Six-Gun Diesel Tuner displays
the “4,3” diagnostic code (refer to
TROUBLESHOOTING in Section 8 on
how to read codes) when it needs to
learn your transmission configuration.
This always occurs when the SixGun Diesel Tuner is first installed on
the truck. The Six-Gun Diesel Tuner
is equipped with advanced safety
features to preserve your automatic
transmission. One of them is the
capability to detect the occurrence
of transmission slip, and it will
automatically de-rate the engine
output power accordingly.
Before this safety feature can take
effect, the Six-Gun Diesel Tuner needs
to learn that your truck is equipped
with an automatic transmission.
(Please read the “Disclaimer of
Liability” on page 2.)
1. The following driving test shall
be performed in an area where
speeds over 55mph are safe and
traffic is light. For a vehicle with a
manual transmission, follow Step
2. For a vehicle with an automatic
transmission, follow Step 3. While
driving, listen for any exhaust leaks or
rattles, or intake boost leaks. After the
engine cools, re-tighten clamps and
hoses if leaks are detected.
2. (Manual trans) To teach the Six-
Gun Diesel Tuner that your truck is
equipped with a manual transmission
drive the truck at a speed over 55
mph for at least 2 minutes. The “4,3”
diagnostic code will be eliminated.
Repeat if necessary to eliminate code.
Proceed to Section 7.
3. (Auto Trans) To teach the Six-
Gun Diesel Tuner that your truck
is equipped with an automatic
transmission drive the truck at a speed
over 55mph untill the torque converter
is locked (the toque converter is
usually locked at speeds over 55mph).
With the torque converter locked and
with turbo boost below 10psig (ie, light
load), maintain the attained speed
steadily for at least 30 seconds. Once
the transmission is learned, the “4,3”
diagnostic code will be eliminated.
Repeat if necessary to eliminate code.
-END, SECTION 6-
96807 v.5.0
27
Section 7
CHECKING ENGINE PERFORMANCE
The Six-Gun Diesel Tuner requires the
engine coolant temperature (ECT) to be
above 110º before it will add fuel. If the
optional Banks PowerPDA or DynaFact®
gauges are installed, observe the
operation of the boost and pyrometer
(EGT) gauge values 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 will vary considerably with
stick or automatic transmission
options, year model of vehicle and
altitude. Note: Before key-off, check
tuner for error codes.
28
96807 v.5.0
Use your Banks PowerPDA or EGT
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, 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.
To avoid heat damage to various
engine components it is recommended
that the exhaust gases cool below
400º before the engine is shut down.
Your Six-Gun Diesel Tuner is calibrated
to maintain a maximum EGT of 1350°F
(1500°F with Speed-Loader). You may
experience brief excursions slightly
above 1350°F under acceleration. This
is normal and EGT should return to
1350°F or below 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.
-END, SECTION 7-
Section 8
TROUBLESHOOTING
Six-Gun Troubleshooting Using
The Banks PowerPDA Vehicle
Command Center
The standard Six-Gun Diesel
Tuner requires the engine coolant
temperature (ECT) to be above 110º
before it will add fuel. If you feel
that your Six-Gun Diesel Tuner is not
functioning properly, some diagnostics
can be performed.
Check the Banks PowerPDA’s Status
Indicator for the “OK” icon. Any SixGun Tuner fault will be indicated by
the “Banks Engine” icon (see Figure
24) and its cause can be investigated
by going to the ‘Self Diagnostics’
screen and scrolling through the list of
logged tuner events.
Figure 24
SIX-GUN TUNER ICON
1.
Press the center button on the
5- way navigator to take you to the
System Menu screen.
2.
Touch the button labeled ‘More>’
Figure 25
to move to the second screen of the
System Menus.
3.
Next, touch the ‘Self Diagnostics’
button. (See Figure 25)
4.
The ‘Self Diagnostics’ screen
displays a log of diagnostic events
related to the Six-Gun tuner (See
Figure 26). The ‘Logged Events’ list
takes a moment to update each time
this screen is opened (as indicated
by a slight flickering of the list). Once
the list is updated, the most current
event will appear at the top of the
list. Each event has an associated
timestamp and description, which will
be displayed below the list when that
event is highlighted. Each key cycle
of the vehicle produces a minimum of
two logged events.
5.
Touch the ‘Down’ or ‘Up’ buttons
to scroll through the list of recorded
events. Table 1 on page 30 lists the
available diagnostic codes and the
recommended course of action for
each.
6.
Touch the center button on the 5way navigator (or the ‘Back’ button) to
return to the System-Monitor screen.
Figure 26
96807 v.5.0
29
Six-Gun Troubleshooting
(No Banks PowerPDA Installed)
Your Six-Gun Diesel Tuner is equipped
with diagnostic features that will
detect and display certain errors.
Remove the Six- Gun Diesel Tuner
from its mounting location while
keeping all connectors plugged
in. Turn the vehicle key to the ON
position. Observe the two LEDs
mounted on the end of the Six-Gun
Diesel Tuner, next to the harnesses.
If all wire connections are correct, a
steady GREEN LED is illuminated. If the
GREEN LED is not illuminated when
the ignition is ON, check power supply
hookup and the fuse on the Six-Gun
main wire harness. If the connections
and fuse are okay, contact Banks
Technical Service.
If a connection is incorrect or if
there is a problem with the system,
when the ignition is ON the RED LED
will flash in sequence to identify a
diagnostic code. A Six-Gun Diesel
Tuner’s diagnostic code is comprised
of 2 digits. Each code is expressed in a
sequence of 2 sets of the flashing RED
LED separated by a brief flashing of the
GREEN LED in between. Each set of a
number of RED LED flashes represents
a digit. A longer flashing of the GREEN
LED separates the sequences. The
LEDs will continue to flash to display
all the errors, and then repeat. Table
1 lists the available diagnostic codes
and the recommended course of
action for each. For example, if a
faulty thermocouple is detected (code
“2,3”) by the Six-Gun Diesel Tuner, the
30
96807 v.5.0
following RED and GREEN LED flashing
sequence is observed when the
ignition is ON:
(1) Two times flashing RED LED
(2) One time quick flashing GREEN LED
(3) Three times flashing RED LED
(4) One time longer flashing GREEN
LED. The above flashing sequence
will repeat continuously. When
the problem is corrected, the
diagnostic code will be eliminated
and replaced by a steady GREEN
LED.
Note: If multiple codes are set, they
will be displayed in a series separated
by the longer flashing GREEN LED.
When reading codes, make sure to
watch the entire series until you see
the first code repeat.
Note: The “4,3” code comes on when
the Six-Gun Diesel Tuner module is
first installed on a vehicle. To eliminate
this code, follow the instructions
described in “Transmission Learning”
(Section 6). If problem persists,
contact Banks Technical Service.
If the Six-Gun Diesel Tuner should ever
need to be removed from the vehicle,
all vehicle connectors must be reconnected to their stock configuration.
Failure to reconnect the vehicle may
result in a “Check Engine” light on the
dash and a Diagnostic Trouble Code
being stored in the factory computer,
and the engine may not start.
-END, SECTION 8-
Table 1 Banks Six-Gun Fault Codes
Code
Event
Course of Action
1,1
Fuel Rail Pressure (FRP)
Input Voltage Out of
Range.
Turn ignition OFF and check 3-pin FRP sensor connections. Turn
ignition back ON and re-check for presence of code. If problem
persists, call Gale Banks Engineering Tech Support.
1,2
Manifold Absolute
Pressure (MAP) Input
Voltage Out of Range.
Turn ignition OFF and check 4-pin MAP sensor connections. Turn
ignition back ON and re-check for presence of code. If problem
persists, call Gale Banks Engineering Tech Support.
1,3
Six-Gun Switch Input
Value Out of Range.
Turn ignition OFF and make sure either Banks PowerPDA or Six-Gun
switch is connected to Six-Gun tuner. If Six-Gun switch is connected
(no Banks PowerPDA), check 2-pin connection on tuner’s in-cab
cable. Turn ignition back ON and re-check for presence of code.
If problem persists, call Gale Banks Engineering Tech Support.
1,4
SCI Communications
Error With Vehicle.
Turn ignition OFF and check in-cab OBD II and 8-pin cable
connections. Turn ignition back ON and re-check for presence of
code. If problem persists, call Gale Banks Engineering Tech Support.
2,1
Fuel Rail Pressure (FRP)
Output Voltage Out of
Range.
Turn ignition OFF and check 3-pin FRP sensor connections. Turn
ignition back ON and re-check for presence of code. If problem
persists, call Gale Banks Engineering Tech Support.
2,2
Manifold Absolute
Pressure (MAP) Output
Voltage Out of Range.
Turn ignition OFF and check 4-pin MAP sensor connections. Turn
ignition back ON and re-check for presence of code. If problem
persists, call Gale Banks Engineering Tech Support.
2,3
Exhaust Gas
Temperature (EGT)
Sensor Open Circuit or
Out of Range.
Turn ignition OFF and check thermocouple ring-terminal
connections (2). Turn ignition back ON and re-check for presence
of code. If problem.
2,4
J1850 Communications
Error With Vehicle.
Turn ignition OFF and check in-cab OBD II and 8-pin cable
connections. Turn ignition back ON and re-check for presence of
code. If problem persists, call Gale Banks Engineering Tech Support.
3,1
Crankshaft Position
(CKP) Signal Fault or
Intermittent Power.
Turn ignition OFF and check 3-pin CKP and CMP sensor connections
and fuse-tap power connection to Six-Gun tuner (in engine
compartment fuse box). Start engine and re-check for presence of
code. If problem persists, call Gale Banks Engineering Tech Support.
3,2
Internal Module
Malfunction.
Turn ignition OFF and check all Six-Gun tuner connections. Turn
ignition back ON and re-check for presence of code. If problem
persists, call Gale Banks Engineering Tech Support.
3,3
Low Battery Voltage
or Internal Module
Malfunction.
Turn ignition OFF and check fuse-tap power connection to Six-Gun
tuner (in engine compartment fuse box). Turn ignition back ON and
re-check for presence of code. If problem persists, call Gale Banks
Engineering Tech Support.
4,2
Transmission Slippage
Detected.
Transmission is slipping excessively. Code will automatically clear
once transmission stops slipping (repaired).
4,3
Unlearned Transmission
Type and Gear Ratios.
Perform Transmission Learning procedure in Section 6. Code will
automatically clear once transmission type and gear ratios (auto
trans. only) have been learned successfully. If problem persists, call
Gale Banks Engineering Tech Support.
4,4
Engine Rating Changed
or Not Learned.
Turn ignition ON and allow Six-Gun to learn engine rating (approx.
10 seconds). If Six-Gun has been moved to a different truck and
engine platform, perform “throttle
96807 v.5.0
31
Section 9
CLEARING LEARNED INFORMATION
CAUTION: The following procedures
can only be carried out with the
engine not running.
NOTE: If clearing the Six-Gun’s learned
parameters then all PowerPDA tunable
settings will be reset to factory
defaults. (Refer to the PowerPDA
Owners Manual for more detail.)
1. Turn the vehicle key to the ON
This procedure should only be
performed if:
2. Fully depress the accelerator pedal
-
A ”4,2” code for transmission slip
detection is repeatedly set or will
not clear and the transmission is
not actually slipping; or
-
The Six-Gun Diesel Tuner is
moved to a new vehicle; or
-
The vehicle’s speedometer has
been factory recalibrated for
different gearing or tire size; or
-
Instructed to do so by Banks
Technical Staff. Your Six-Gun Diesel
Tuner also has the capability to
clear the information related to the
learned transmission type and gear
ratios. The diagnostic code “4, 3”
will reappear after the procedures
are carried out correctly. Follow
the steps below to unlearn the
transmission on your Six-Gun
Diesel Tuner.
32
96807 v.5.0
position but DO NOT start the engine.
and then release it completely. Repeat
for 5 times. The GREEN LED will flash
when this is completed successfully.
3. Turn the key OFF. Wait 10 seconds,
or until the GREEN LED goes off and
stays off. Turn the key to the ON
position but DO NOT start the engine.
4. Fully depress the accelerator pedal
and then release it completely. Repeat
for 5 times. The “4,3” diagnostic code
will flash when this is completed
successfully. NOTE: When the
transmission type and gear ratios are
cleared (with code “4,3” displayed),
the engine power returns and remains
in stock level until the Six-Gun Diesel
Tuner re-learns the transmission and
the “4,3” code is eliminated. Follow
the procedures in ”Transmission
Learning” (Section 6) to eliminate
the “4,3”.
-END, SECTION 9-
Section 10
PLACEMENT OF THE BANKS POWER DECALS
Figure 25
LEFT SIDE
RIGHT SIDE
-END, SECTION 1096807 v.5.0
33
Section 11
REMOVAL OF THE SIX-GUN DIESEL TUNER
If the Six-Gun Diesel Tuner should ever
need to be removed from the vehicle,
perform the following:
8. Re-connect the vehicle’s CMP
Note: The ignition must remain in the
OFF position throughout the removal
process.
terminal from the fender stud and retighten the stud’s 10mm nut.
connector back into the CMP sensor.
9. Unbolt the Six-Gun’s ground ring
1. Disconnect the Six-Gun’s Fuel Rail
10. Unplug the Six-Gun’s RED/WHT
power wire from the mini-fuse tap and
remove the tap.
2. Re-connect the vehicle’s FRP
11. Disconnect the 2 ring terminals
nearest the Six-Gun from the EGT
thermocouple lead wire.
Pressure (FRP) connections from the
vehicle’s FRP sensor and harness.
connector back into the FRP sensor.
3. Disconnect the Six-Gun’s Manifold
Absolute Pressure (MAP) connections
from the vehicle’s MAP sensor and
harness.
4. Re-connect the vehicle’s MAP
connector back into the MAP sensor.
12. Disconnect the 3 small
connectors on the Six-Gun’s in-cab
cable and gently pull the cable back
through the firewall.
13. Remove the Six-Gun Diesel Tuner.
connector back into the CKP sensor.
NOTE: Failure to follow the above
instructions when removing the SixGun Tuner will result in a “Check
Engine” light on the dash and a
Diagnostic Trouble Code being stored
in the factory computer, in addition to
the engine not running.
7. Disconnect the Six-Gun’s Camshaft
-END, SECTION 11-
5. Disconnect the Six-Gun’s
Crankshaft Position (CKP) connections
from the vehicle’s CKP sensor and
harness..
6. Re-connect the vehicle’s CKP
Position (CMP) connections from the
vehicle’s CMP sensor and harness.
34
96807 v.5.0
Figure 26
96807 v.5.0
35
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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