Installation Instructions
owners
manual
with installation
instructions
POWERPACK
S Y S T E M
®
INCLUDING STINGER™ & STINGER-PLUS™
WITH OTTOMIND™ ENGINE CALIBRATION MODULE
1994–1998 FORD POWER STROKE 7.3L TURBO DIESEL
this manual is for use with STINGER SYSTEMS 48501-48528
this manual is for use with STINGER-PLUS SYSTEMS 48451-48478
this manual is for use with POWERPACK SYSTEMS 48401-48528
Gale Banks Engineering
546 duggan avenue • azusa, ca 91702
(626) 969-9600 • fax (626) 334-1743
Product Information & Sales: (800) 438-7693
Customer Support: (888) 839-5600
Installation Support: (888) 839-2700
www.bankspower.com
©2010 gale banks engineering
06/28/10
p.n. 96322 v.6.0
Also Available from Banks Power
for ‘94-98 Ford 7.3L
‘94-98 Ford 7.3L
Thermocouple
- Add a temperature limiting
function to your Diesel Tuner
Banks QuickTurbo
(P/N 24450)
- More boost through the
powerband
- Does not over-boost
- Turbo-diesel efficiency
Banks Monster® Exhaust System
Single (P/N 46296-46299)
- Increases exhaust flow, cuts
backpressure, lowers exhaust gas
temperatures (EGTs) and increases power.
Banks Techni-Cooler® System
(P/N 25970)
- Provides increased air flow to the
engine by increasing air density for
more increased power, lower EGTs
and improved fuel economy.
Banks TransCommand
(P/N 62560)
- Produces smooth, firm, light
throttle shifts and solid,
decisive heavy-load shifts.
- Eliminates excessive clutch
slippage
Banks Billet Torque Converter
94-03 (P/N 72521)
- Higher torque capacity over stock
- Lockup clutch is slip-resistant so
transmission fluids stay cooler and
transmission life is prolonged.
Banks Git-Kit Systems
(P/N 48550)
Contains:
- Monster Exhaust
- Big Hoss Module
Banks Diesel Tuner
94-03 Big Hoss (P/N 66505)
- Adds power safely to your vehicle
- Engine and transmission safeguards
- Change power levels on-the-fly
2
P.N. 96322 V.7.0
Banks Stinger Systems
Contains:
- Ram-Air Intake Filter
- Monster Exhaust
- Big Hoss Module
- TransCommand
Banks PowerPack Systems
Contains:
- Ram-Air Intake Filter
- Monster Exhaust
- Big Hoss Module
- TransCommand
- Quick Turbo Assembly
- Techni-Cooler
Banks Stinger-Plus Systems
(P/N 48553-48554, 48559-48560)
Contains:
- Ram-Air Intake Filter
- Monster Exhaust
- Big Hoss Module
- TransCommand
- Quick Turbo Assembly
For More Information please call (800) 438-7693
or Visit us online @ www.bankspower.com
3
P.N. 96322 V.7.0
GENERAL INSTALLATION PRACTICES
For ease of installation of your Banks Stinger™,
1. Stinger-Plus™ or PowerPack® system, familiarize
yourself with the procedure by reading the entire manual
before starting work.
The exploded views provide only general
2. guidance. Refer to each step and section diagram
in this manual for proper instruction.
Throughout this manual, the left side of the vehicle
3. refers to the driver’s side, and the right side to the
passenger’s side.
Disconnect the ground cables from the battery (or
4. batteries, if there are two) before beginning work.
Route and tie wires and hoses a minimum of 6
5. inches away from exhaust heat, moving parts and
sharp edges. Clearance of 8 inches or more is
recommended where possible.
When raising the vehicle, support it on properly
6. 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. 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.
During installation, keep the work area clean. If
7. foreign debris is transferred to any Banks
component, clean it thoroughly before installing.
Notification
The Banks Ram-Air Filter comes pre-oiled and no
oiling is necessary for initial installation. Service
the filter as specified in the Oiling and Cleaning
the Banks Ram-Air Filter Section of this manual.
4
P.N. 96322 V.7.0
Installation instructions
Replace the stock air filter element with the
the decorative black cover directly
11. Remove
over the engine. Remove the engine lifting
8. Banks Ram-Air filter.
hook at the rear of the right cylinder head.
Raise vehicle on a hoist or safety stands
9. to provide access to the exhaust system.
Mark a point 2 3⁄ -inches from the rear-most edge
of the weld joining the tailpipe to the muffler. At
the mark, cut through the tailpipe square to the
muffler. Remove the tailpipe from the vehicle by
prying the pin from the hanger and pulling the
pipe rearward over the axle. De-burr the cut on
the tubing which remains attached to the muffler.
See Figure 1.
TRANSMISSION ONLY
12. AUTOMATIC
Remove the transmission dipstick and
4
unbolt the dipstick tube and engine ground wire
from the rear of the passenger-side cylinder head.
Pull the dipstick tube up out of the transmission.
Cover the dipstick tube opening with a rag or
paper towel to prevent contaminants from
entering the transmission. For additional
clearance, remove the transmission-fluid cooler
line that runs to the passenger-side of the
transmission, nearest the dipstick tube. DO NOT
start the vehicle while this line is disconnected,
as transmission fluid will quickly pump out of the
line.
Loosen the clamp at the outlet of the
10. catalytic converter. Unbolt the catalytic
converter from the turbine outlet pipe and
remove the converter from the vehicle. Heat from
a torch will most likely be required to separate
the converter slip joint. NOTE: It is very important
to inspect the catalytic converter. Diesel catalysts
may become plugged with soot and can cause
a restriction to exhaust flow. Performance may
be impeded if this is the case. Shine a powerful
flashlight into the slip joint end of the converter.
Observe the light through the other end of the
converter. The full circle of the flashlight should
be visible without any blockage in the grid work
of the catalyst. If excessive soot is observed,
the catalyst may need to be cleaned. TAKE
PRECAUTIONS to avoid blowing soot toward the
work area or where it could be inhaled. ALWAYS
use breathing protection. Also inspect the catalyst
for damage (i.e. chips, bent corners, etc.) to the
gridwork. If your catalytic converter is damaged,
it may be covered under your vehicles emissions
warranty.
Remove the V-clamp that secures
13. the factory turbine outlet pipe to the
turbocharger outlet. Pull the pipe up as far as
possible and cut the pipe as close to the engine
as possible. Discard the top section then remove
the bottom portion of the pipe from under the
vehicle.
For Stinger installations, proceed to Step 26.
TURBOCHARGER REMOVAL
the clamps holding the air intake
14. Loosen
hose to the turbocharger compressor inlet
and the aluminum air intake casting. Remove the
hose. See Figure 2.
Disengage the exhaust backpressure control
15. actuator rod by sliding the cover on the
end of the rod back toward the turbocharger and
pulling the rod downward.
FIGURE 1
5
P.N. 96322 V.7.0
FIGURE 2
6
P.N. 96322 V.7.0
Loosen the four clamps on the compressor
16. discharge plenum hoses and the clamp
attaching the plenum to the compressor. Pull the
compressor discharge plenum up off the engine.
Remove the O-ring that seals the compressor
outlet to the plenum.
section by tapping with a hammer and brass drift
or a soft face hammer. Work from side to side and
use plenty of lubricant until the housing is loose
from the center section. Pull the housing straight
off of the center section to avoid damaging the
turbine blades.
the rear of the turbine housing, remove
17. At
the two bolts at the top and the two nuts
23. onto the center section, again paying careful
Place Banks Quick-Turbo® turbine housing
attention to the turbine blades. Apply some antiseize to the four bolts and reinstall them. Check
the orientation of the assembly, then tighten the
bolts.
at the bottom attaching the turbine housing to
the turbine inlet adapter. See Figure 2. Save the
turbine inlet gasket for reuse.
Unplug the electrical connector at the
18. driver-side of the compressor housing.
sure the gasket is on the turbine
24. Make
inlet adapter on the engine. Place the new
turbocharger pedestal mount must be
19. The
removed with the turbocharger. Remove
O-rings provided into the recesses on the engine
block and make sure that the sealing area of the
pedestal bottom is clean.
the four bolts attaching the pedestal mount to the
engine block. The front two are easily accessible.
The rear two will require the use of a swivel
socket or a universal joint - socket combination.
After these bolts have been removed, lift the
assembly off of the engine towards the front.
Remove the two O-rings located on the engine or
under the pedestal mount.
Reinstall the turbocharger and pedestal
25. Îassembly. Make sure the O-rings are in
place before installing any bolts. Put a small
amount of anti-seize on the turbine inlet bolts
and nuts and start them. Install and tighten the
pedestal mounting bolts then tighten the turbine
inlet bolts and nuts. Plug the electrical connector
back together.
the turbocharger assembly in a vise.
20. Clamp
Do not use the compressor inlet or outlet to
Bend the firewall lip seam as far back as
clamp the turbocharger. The compressor housing
is aluminum and could be damaged. Observe and
mark the relationship of the exhaust backpressure
control valve to the turbine housing and the
turbine housing to the center section of the turbo
assembly.
26. possible, on the right side corner of the
transmission tunnel, to allow for installation of
Banks two-piece turbine outlet pipe. A 3-4 foot
piece of pipe or heavy metal bar may be used as
a lever and extended hammer to fold and flatten
the seam against the floorpan. NOTE: If access to
a Sawzall or an air chisel is available, a series of
cuts in the seam will ease the bending operation.
It may also be necessary to somewhat compress
and reshape the floorpan heatshield behind the
firewall lip seam using a pipe or heavy prybar. See
Figure 3.
Remove the exhaust backpressure control
21. valve from the turbine housing, and install
it onto the new turbine housing with the original
hardware. Duplicate the orientation of the original
assembly. Use anti-seize on the bolts.
22. Remove the four bolts securing the turbine
housing to the turbocharger center section.
If the turbocharger is more than a few months old,
it may be necessary to spray some Liquid Wrench
(or similar rust penetrating lubricant) into the
joint between the turbine housing and the center
section. Work the housing loose from the center
Reinstall the dipstick tube, dipstick and
27. cooler line if removed. Be sure to connect
the electrical ground between the cylinder head
and dipstick mount on the passenger-side.
FIGURE 3
7
P.N. 96322 V.7.0
FIGURE 4
FIGURE 5
8
P.N. 96322 V.7.0
BANKS TECHNI-COOLER INTERCOOLER
INSTALLATION
Secure the heatshield blanket provided to
28. the Banks turbine outlet pipe with the wire
ties provided, as shown in Figure 4. Loosely
clamp the upper portion of the turbine outlet
pipe to the exhaust backpressure control valve
on the turbocharger. Slide the 3-inch clamp
over the end of the lower turbine outlet pipe.
Reinstall the catalytic converter in its original
position and install the lower portion of the
turbine outlet pipe between the upper pipe and
catalytic converter from underneath the vehicle.
Adjust the position of the turbine outlet pipe
to allow the maximum amount of clearance
between the pipe and the firewall. Tighten the
3-inch clamp at the pipe joint under the vehicle
and the V-band clamp at the turbine outlet.
Remove the grille. there are four Phillips-
33. head screws across the top and two in
the center of the grille that secure it to the grille
support.
Remove the headlight bezels. These are
34. secured to the grille support with two
screws across the top and two nuts behind the
radiator core support. The two nuts are accessed
by reaching down between the battery and the
radiator core support. The batteries may be
removed for easier access to the hardware. When
each bezel is loose, pull it gently away from the
front of the truck. Label and remove the signal
and running light bulbs from the rear of the bezel.
Banks Monster™ tailpipe over the
29. Slide
muffler outlet and install it into the original
the narrow front valance. It is
35. Remove
attached to the front of the truck by four
rubber hanger. Install two 31⁄ -inch U-clamps over
the tailpipe at the muffler outlet connection, as
shown in Figure 5. Note the positions of the
clamps in relation to the expanded section of
the tubing. Lightly tighten the clamps to allow
adjustment for 3⁄ - to 1-inch of clearance between
the tailpipe tip and the bottom edge of the
fender. With the tailpipe and muffler/catalytic
converter assembly properly positioned, tighten
the U-clamps at the muffler outlet and catalytic
converter inlet flange bolts. Reinstall the engine
lifting hook on the passenger-side of the engine.
2
small bolts which may be reached through the
front of each wheelwell and three small bolts
across the front. Remove the two front bolts
attaching the inner wheelwell to the fender and
pull it back towards the rear of the vehicle. The
bolts can then be reached with a socket and
extension. The plastic filler panel is attached to
the fenders at the front with plastic clips that
must be pried out of the holes in the fenders. A
door-panel-clip removal tool works well for this.
4
The plastic grille support must now be
36. removed. Push the dangling parking and
For Stinger installations, proceed to Step 70.
signal light bulbs through the holes into the engine
compartment to get them out of the way. Remove
the headlight bulbs with sockets from the rear
of the headlight reflectors. Do not remove the
headlight reflectors from the plastic grille support.
Avoid touching the headlight bulbs themselves. If
necessary, wipe bulbs clean with alcohol.
To reconnect the exhaust backpressure
30. control valve, hold the cover on the end of
the rod back and have someone start the engine.
When the rod extends after a few seconds, push
it up onto the valve linkage and allow the cover to
snap back into position.
WARNING! Stay clear of moving parts such as
the engine cooling fan and belts. Do not drive
the vehicle until the remainder of the installation
is complete. Any airborne objects entering the
turbocharger may cause damage.
the eight bolts attaching the
37. Remove
plastic grille opening panel to the radiator
core support. There are two on each side at the
extreme outer edge of the panel and two on each
of the brackets inside the radiator opening. Do not
remove the sheet-metal brackets from the vehicle.
the engine is running, check for oil
31. While
leaks around the base of the turbocharger
On automatic transmission-equipped
center section or the pedestal mount. Repair any
leaks before continuing. NOTE: The most likely
cause of an oil leak in this installation is a pinched
O-ring at the base of the turbocharger.
38. models, unbolt the transmission-fluid cooler
from the passenger-side of the radiator opening.
Remove the mounting brackets and clamps from
the cooler. It is not necessary to disconnect the
hoses.
the compressor inlet and discharge
32. Cover
with clean rags so that no foreign material
the template pages from this
39. Remove
manual. Line up the templates with the
will enter the turbo during the remainder of the
installation.
bolt-holes and edges of the radiator core support.
Mark the core support and cut away the areas
of sheet-metal shown in Figures 6 and 7 at the
back of this manual. A reciprocating saw such
as a Sawzall with a fine tooth blade works best
for this, however a hole saw in a drill motor may
be used to make a set of overlapping holes that
may be ground or filed to make the final shape.
For Stinger-Plus installations, proceed to Step
70.
9
P.N. 96322 V.7.0
Lower Banks Techni-Cooler™ intercooler into
48. position behind the bumper brackets on the
De-burr the cut edges once cutting is complete. It
is suggested that the raw edges be painted with a
rust-preventative primer or paint.
frame. Make sure the plastic bumper stud assemblies
are in place with the studs pointing forward. See
Figure 12. One end of the intercooler may have
to be tilted down to guide the hose connections
through the holes cut in the radiator core support.
It may also be necessary to back out one or more
radiator mounting bolts as these can get hung up
while lowering the intercooler into position. Guide
the studs with the rubber isolators into the slots on
the lower mounting brackets. If the vehicle has an
automatic transmission, route the transmission-fluid
lines above the intercooler hose connection rather
than below it to position the lines away from sharp
edges. Tuck the air-dam flaps inside the radiator
opening in the core support. Check the clearance
of the cut edges to the sides of the intercooler end
tanks. Remove the Techni-Cooler and trim the sheetmetal again if necessary.
Pry out and remove the four plastic buttons
40. holding the outer corners of the rubber
air-dam to the radiator core support as shown in
Figure 8. Remove the buttons from the air-dam.
Install the left and right lower intercooler
41. mounting brackets and nut plate assemblies
using four 1⁄ x 3⁄ -inch hex bolts and washers
through the holes in the core support as shown
in Figure 8. Leave the bolts just loose enough to
slide the brackets for adjustment.
4
4
On all models install the two transmission-
42. fluid cooler mounting brackets provided, as
shown in Figure 9. These brackets mount over
the factory studs in the core support between
the air-conditioning condenser brackets and the
core support. If the vehicle does not have airconditioning, install two 8 mm x 1.25 mm nuts
provided over the studs with two 5⁄ flat washers.
the Techni-Cooler side-to-side position
49. Adjust
to provide an identical distance between the
intercooler hose connections and the sides of the
radiator. Once this location has been established,
push each lower mounting bracket away from the
center of the vehicle and tighten the upper two
bracket bolts, then the lower two bolts.
16
On automatic transmission models only,
43. install two rubber lined loop clamps onto
the transmission-fluid cooler as shown in Figure.
9. Mount the cooler to the brackets using the two
1
⁄ x 3⁄ - inch bolts, two washers, and two Nylock
nuts. Route the hoses as shown in Figure 9.
4
Install two rubber isolator stud mounts
50. through the existing holes in the radiator
4
core support. See Figure 8. Secure the mounts
using the 5⁄ -inch Nylock nuts and washers as
shown. Note that a washer is placed between
each mount and the core support as well as
under the nuts. Leave the nuts just loose enough
to allow positioning of the mounts.
16
vehicles with a front sway-bar crossing
44. On
under and just ahead of the radiator area,
unbolt the two sway-bar bushings from the
bottom of the frame rails. Reinstall the bar and
bushings using the 2-inch square spacers, four 3⁄
x 31⁄ - inch hex bolts, washers, and Nylock nuts
provided. See Figure 10.
8
Install left and right upper intercooler
51. mounting brackets between the rubber
4
stud mounts and the intercooler end tanks.
Thread four 5⁄ x 3⁄ - inch hex bolts and washers
through the bracket and into the threaded holes
in the end tank finger tight. Install and tighten a
5
⁄ -inch Nylock nut and washer onto each stud
mount to secure the brackets.
Cut a slit in each side of the factory rubber
16
45. air-dam as shown in Figure 9. Slide the slit
over the edge of each lower intercooler mounting
bracket as shown. Mark through the two holes
on the forward facing tabs on the transmissionfluid cooler mounting brackets onto the rubber
air-dam. Drill a 1⁄ -inch hole through the rubber at
these two locations. Bolt the factory air-dam to
the transmission-fluid cooler brackets using two
1
⁄ x 3⁄ -inch hex bolts, washers, and Nylock nuts
provided.
16
Again check the side to side position of the
52. intercooler hose connections with respect
4
4
4
to the radiator, then remove and reinstall each of
the 5⁄ -inch hex bolts one at a time with a drop of
thread-locker, supplied, on the threads. Tighten
the two 5⁄ - inch Nylock nuts on the rubber stud
mounts behind the core support.
16
4
16
Install two rubber air-dams provided onto
46. the drilled tabs on the intercooler end tanks.
Use four #10-32 screws, washers, and Nylock nuts
to attach each air-dam. See Figure 11.
Check to see that the rubber air-dam flaps
1
0
53. rest flush against the sheet-metal
without
preventing the intercooler from resting in its
proper location. Due to factory tolerances, it may
be necessary to trim the air-dam flaps for proper
fit.
Install two 5⁄ -inch studs into the lower front
47. threaded holes in the end tanks. Slide a
16
rubber isolator bushing onto each of the studs.
See Figure 8.
the clearance between the intercooler
54. Check
hose connections and the surrounding
sheet-metal below and on the outer sides of the
10
Continued on page 15
P.N. 96322 V.7.0
FIGURE 8
11
P.N. 96322 V.7.0
FIGURE 9
12
P.N. 96322 V.7.0
FIGURE 10
13
P.N. 96322 V.7.0
FIGURE 11
FIGURE 12
14
P.N. 96322 V.7.0
the joint. When all tubes are positioned for best
clearance, tighten the clamps on the hump hose,
the intercooler inlet, and the compressor outlet.
hose connections. There should be a minimum
of 5⁄ -inch clearance around the connection to
accommodate the thickness of the hose and
clamp. If additional trimming to the sheet-metal
is necessary, remove the intercooler by removing
the upper brackets from the rubber isolator
studs. Remember to have the bumper stud plates
and the transmission-fluid cooler lines in the
proper places when reinstalling the intercooler.
NOTE: Before slipping any boost tubes and the
corresponding hoses, into position, ensure that
all connection ends are clean and free of any oil
residue and contaminates. Clean compressor
outlet and all connection points with a non-oil
based solvent such as Acetone, Mineral Spirits,
Denatured Alcohol or Lacquer Thinner. Read and
follow the manufactures operation instruction for
non-oil based solvent cleaner.
16
Disconnect the hose between the radiator
61. and the coolant recovery tank at the
recovery tank end. Insert the lower end of the
intercooler outlet tube into the silicone hose on
the intercooler outlet. The bracket supporting
the battery cable will need to be bent slightly
to provide enough clearance for the tube. Push
the tube all the way in and then pull it out
approximately 1⁄ -inch. Install a 3-inch diameter
hump hose and two #313 T-bolt clamps onto the
upper end of the intercooler outlet tube.
4
Remove the two center bolts from the upper
62. edge of the passenger-side rocker cover.
Install the two hoses removed from the factory
discharge plenum onto Banks TwinRam™ intake
assembly. Push them all the way on until the tube
just begins to come through the hose. Slide two
original clamps onto each hose.
With the intercooler bolted in place, push a
55. 3 x 3-inch silicone hose onto each intercooler
hose connection until the hose bottoms against the
stop on the connection. Slide a pair of #313 T-bolt
clamps onto each hose. Position the clamps so that
they can be tightened from above.
Slide the 3-inch end of the TwinRam into
63. the hump hose on the intercooler outlet
tube and position the legs of the TwinRam over
the openings on the engine intake manifolds.
Slide the hoses down the legs of the TwinRam
until they are bottomed on the intake manifolds.
Attach the bracket to the rocker cover using the 8
mm x 30 mm metric bolts and spacers provided.
See Figure 13.
Loosen the clamps and remove the flexible
56. engine air intake hose from between the
plastic air filter housing duct and the aluminum
elbow. Unbolt and remove the aluminum elbow
and its mounting bracket from the engine.
Push the lower end of the intercooler inlet
57. tube into the silicone hose on the driver’s
Tighten the lower clamp on each of
64. the intake manifold hoses. Attach the
side of the intercooler. The tube will have to
be maneuvered under the A/C hose on airconditioned models. Push the inlet tube into
the hose until the tube touches the intercooler
connection, then pull it out approximately 1⁄ inch.
tabs on the TwinRam and the compressor
outlet elbow with a 5⁄ x 1- inch bolt with two
washers and a Nylock nut. Leave this bolt
loose enough for adjustment. Check all bolts,
hoses and wires around the intercooler outlet
tube for clearance. Make any adjustments
necessary, then tighten all clamps and the
5
⁄ -inch nut and bolt.
16
4
Install a 3-inch diameter silicone hump
58. hose and two #313 T-bolt clamps onto the
upper end of the intercooler inlet tube. Insert the
turbocharger compressor outlet elbow into the
hump hose. Place a new compressor outlet O-ring
in the groove on the compressor, then attach the
elbow to the compressor with the original clamp.
Leave the clamp loose enough to rotate the elbow
for adjustment.
16
the plastic grille support as shown in
65. Mark
Figure 14 for cutting. Use a hacksaw to cut
out the areas indicated for intercooler clearance.
Hold the grille support up to the front of the
vehicle and check that the outside corners of
the intercooler end tanks clear the support. Trim
additional material if required to provide 1⁄ -inch
minimum clearance on each end tank.
the aluminum air intake elbow
59. Reinstall
and flexible air inlet hose onto the engine.
8
Tighten the clamps on the air inlet and elbow, and
any other clamps loosened or removed from the
elbow.
Reinstall the grille opening support panel
66. onto the front of the truck using the original
Adjust the position of the intercooler inlet
hardware. Place the turn signal and marker light
bulbs through the proper holes.
adjacent parts. Make sure that nothing can chafe or
cut through the hump hose from engine vibration.
Position the hump hose so that it is centered on
the junction of the inlet tube and the compressor
outlet elbow. There should be approximately 1⁄ -inch
separation between the tube and elbow inside the
hump hose, they should not rub together within
the valance panel onto the front
67. Reinstall
of the vehicle with the plastic clips and the
60. tube to provide the maximum clearance to
original bolts. CAUTION: When reinstalling the screw
that attaches the bottom of the grille support to the
center of the valance panel, make sure that the end
of the screw does not protrude through the assembly
to the extent that it could come into contact with
4
15
P.N. 96322 V.7.0
FIGURE 13
16
P.N. 96322 V.7.0
FIGURE 14
DYNAFACT INSTRUMENTATION INSTALLATION
and puncture a tube in the intercooler core. There
should be a minimum of 1⁄ -inch clearance between
the end of the screw and the intercooler core. If
necessary, shorten the screw.
4
GAUGE PANEL
If the gauges are being installed into an
71. existing gauge panel, this step may be
skipped. If gauges and a gauge panel are being
installed, choose a location where the gauges can
be easily viewed by the driver. This will typically
be to the right of the accelerator pedal, under the
lower edge of the dash panel. Mount the gauge
panel with the machine screws, washers, and
nuts provided. NOTE: Molded instrument panels
for top of dash mounting are available from Gale
Banks Engineering.
the headlight bezels. Be sure that
68. Reinstall
the lights are in the correct locations. If
in doubt, turn on the hazard flashers. The turn
signals will be the flashing ones.
Reinstall the grille against the grille support
69. with the original hardware. Reinstall the
front bumper onto the stud plates and tighten
the nuts. Once again, check the tightness of all
hose clamps to ensure the integrity of the hose
connections at high boost levels.
DYNAFACT PYROMETER
the DynaFact ® pyrometer probe
72. Install
(supplied in the pyrometer kit) in the 1⁄ -inch
NPT bung located at the top of the turbine outlet
pipe. Use anti-seize compound on the threads.
Connect the lead-wire to the sensor with the
supplied screws. The wires are different lengths
to prevent cross connecting. Make sure that the
screws are tight. Slip the heat shrink tubing provided
over the wire ends.
Clean an area that is easily visible on the
70. upper radiator core support with a non-oil
based solvent, such as Acetone, Mineral Spirits,
Denatured Alcohol or Lacquer Thinner. Allow to
dry and then attach the Banks E.O. sticker to the
upper radiator core support.
4
17
P.N. 96322 V.7.0
moderate heat to the heat shrink
73. Supply
tubing to seal the connections. A heat-gun or
cover the small hole in the fitting. Do not
over-tighten the plastic fitting.
lighter works well.
passing through the firewall either
74. When
make a hole in a factory grommet or drill
For Stinger and Stinger-Plus installation,
proceed to Step 81.
a hole and use a new grommet. If a hole needs
to be drilled, drill a 5⁄ -inch hole and debur it on
both sides, so that the wiring or tubing does not
get cut as it passes through the hole. For added
protection, wrap the wiring with several layers of
electrical tape in the area where it passes through
the hole. When drilling, check the backside to
make sure that there are no components blocking
the backside of the hole that would be damaged
by drilling.
Locate the 1⁄ -inch NPT bung on the Banks
80. compressor
outlet elbow and install the
8
16
adapter fitting. Sparingly apply pipe sealant tape
or past on the pipe threads. If you are upgrading
from Stinger or Stinger-Plus, replace the cut
segments of hose between the intake manifold
and the manifold pressure sensor with the single
piece of hose provided.
one end of the 1 ⁄ - inch diameter
81. Install
plastic tube provided into the fitting and
8
Route the pyrometer lead-wire up and across
75. the top of the firewall then down and through
the hole in the firewall. Inside the vehicle, route the
wire to the gauge location. If routing the lead-wire
under the carpet, avoid placing it where the driver’s
feet will rest on the wire. Tie the wire to existing wire
looms and hoses with the cable ties provided.
tighten the nut. Be sure the plastic tube cannot be
pulled out of the ferrule, but do not over-tighten
the nut.
Route the free end of the tube up and along
82. the top of the firewall toward the brake
master cylinder assembly. Tie the tube to existing
wires and hoses with the cable ties provided.
Follow the routing of the pyrometer lead-wire
through the firewall.
the gauge through the console
76. Position
or gauge panel. Slip the plastic U-clamp,
provided with the pyrometer, over the studs
on the rear of the gauge and tighten the nuts,
provided.
Route the plastic tube to the DynaFact boost
83. gauge and cut the tube to the proper length.
Follow the instructions supplied with the gauge
for mounting, lighting and tubing connections.
IMPORTANT: Remove the bare shorting wire from
between the gauge terminals before connecting
the lead-wire to the pyrometer. Attach the spade
connectors to the back of the gauge. Connect the
yellow wire to the (+) terminal and the red wire to
the (-) terminal. If the lead-wires are accidentally
reversed, the gauge will read backwards.
one wire from each gauge light
84. Connect
to a good ground location under the dash,
DYNAFACT BOOST GAUGE
such as a metal support bracket where other
wires may already be grounded. Connect the
remaining light wires together and to an 18-gauge
or larger wire, connected to either the headlight
circuit or the dash lighting circuit. The dash
lighting circuit is located on fuse #10 on the fuse
panel at the left side of the dashboard. (Wiring
and terminals for gauge lighting are not supplied
with the PowerPack system.) NOTE: On vehicles
with an automatic transmission, complete the
TransCommand installation before proceeding.
For PowerPack installation, proceed to Step
80.
BANKS OTTOMIND ENGINE CALIBRATION
MODULE INSTALLATION
any excess wire through the firewall,
77. Pull
coil it and secure it up under the dash, out
of the way. Do not shorten the lead-wire. Note:
If it is necessary to replace one of the terminal
ends, use a crimp tool only. Do not solder to the
wires.
Be certain battery ground cables have been
Locate the rubber hose connecting the
78. intake manifold on the passenger-side
85. disconnected.
of the engine to the manifold pressure sensor
mounted on the firewall. Cut through this hose at
a point 3 inches below the sensor. Install the 1⁄ inch hose by 1⁄ -inch NPT tee fitting and the spring
band clamps, provided, between the cut ends of
the hose as shown in Figure 15.
Locate the engine control unit (ECU) in a
86. recess
in the firewall on the engine side,
8
between the steering column and the left front
fender. All that will be visible is an elongated
electrical connector and wire loom, surrounded
by a retainer plate attached with two nuts. See
Figure 16.
8
Install one 1⁄ -inch NPT female by 1⁄ -inch
8
8
79. compression
90-degree fitting onto the
the bolt attaching the electrical
87. Remove
connector to the ECU, unplug the
threaded end of the tee. Sparingly apply
pipe sealant tape or paste on the male pipe
threads, and adjust the 90-degree fitting to
point back toward the firewall, as shown
in Figure 15. Do not allow any sealant to
connector, and swing it out of the way.
88. Remove the two nuts and retaining plate
18
P.N. 96322 V.7.0
FIGURE 15
FIGURE 16
19
P.N. 96322 V.7.0
from against the firewall. Pull the ECU out of the
firewall toward the front of the vehicle. It may be
necessary to remove the rearmost bolts attaching
the flexible inner fenderwell to the body to provide
clearance to remove the ECU.
is rotated 180 degrees off. Place the OttoMind
module over the connector, and press firmly to
seat the connection. DO NOT FORCE the OttoMind
onto the connector, as damage may result to
either the ECU or the module. If the module
does not install with firm pressure, check the
orientation and try again. Place a piece of duct
tape over the module, fastening it firmly to the
ECU. See Figure 17.
89. Note the code printed on the plastic cap on
the back of the ECU. This code should compare
to the code printed on the Banks OttoMind™ box
label. Pry the plastic cap from the rear of the ECU
using a small screwdriver, exposing the printed
circuit board edge connector inside. Retain the
plastic cap. The connector will be coated with
grease and a clear silicone type coating which
must be completely removed before installing the
Banks OttoMind engine calibration module.
returning the ECU to the recess in
92. Before
the firewall, it is a good idea to reconnect
the wire harness and the batteries and start the
vehicle. The vehicle may not start if the coating on
the ECU connector is not completely removed or if
there is a mismatch of codes. A quick indication of
module connections that are not cleaned properly
is that the “Wait to start” indicator will fail to light
and the “Check engine” warning indicator will
stay lit after the key is switched on. If the engine
fails to start, re-clean the ECU connector, reinstall
the module and try again. After the engine has
started, shut it off, disconnect the batteries
and the ECU wire harness, and complete the
installation.
BOTH sides of the connector. First,
90. Clean
clean the white grease off with a tissue.
Next, scrape the clear silicone type coating
from the connector fingers with the abrasive
square provided. It is very important to clean
both sides of the board in order to have a good
connection between the ECU and the Banks
OttoMind module. It is only necessary to clean the
connector fingers. Be careful not to damage any
circuit traces on the board further inside the ECU.
the ECU in the firewall. Reinstall
93. Reinstall
the retaining plate against the firewall.
the module so that its edges line
91. Orient
up with the edges of the ECU. If the edges
Reattach the wire harness to the ECU. Reinstall
the inner wheel well bolts, if removed. Reconnect
the batteries.
do not line up, or it looks as if the ECU will not
fit back into the hole in the firewall, the module
FIGURE 17
20
P.N. 96322 V.7.0
computer diagnostic link to the vehicle regardless
of the type of service being performed. When the
OttoMind is installed, the computer will return
a code that indicates a memory fault with the
vehicle ECU. The suggested repair for a fault of
this type is replacement of the ECU.
94.
Start the engine and allow it to warm up.
Drive the vehicle, listening for any exhaust leaks
or rattles. Adjust and tighten clamps or reposition
the piping if required. When positioning of piping
is finalized, it is a good practice to place tack
welds at any slip joints in the exhaust system to
prevent slippage. NOTE: The exhaust may smoke
slightly after initial startup. This is normal and will
go away shortly as the grease used in the bending
process burns off the inside of the piping.
The operation of the OttoMind is such that
the computer is directed to reference certain
information in the OttoMind rather than the ECU.
Therefore, the memory fault that occurs is not
an ECU failure, but rather the presence of an
electronic device that the diagnostic computer
cannot identify.
CHECKING ENGINE PERFORMANCE
Observe operation of the boost and pyrometer
gauges while driving under varying conditions.
Turbocharger boost pressure fluctuates as a
function of load and rpm. The engine produces
lower boost while cruising at light throttle.
Maximum boost occurs while climbing hills and
heavily loaded during acceleration. Note the boost
level during hard acceleration with a given load. If
future performance declines, the maximum boost
figures may be compared to see if boost has
decreased. Lower boost can be caused by turbo
ducting leaks, a malfunctioning fuel injection
system, or dirty air filter. Maximum boost pressure
settings for the Power Stroke turbo-diesel
vary considerably, due to manual or automatic
transmission options, vehicle year and model, and
altitude. Boost readings may vary between 15 and
22 psi. NOTE: Vehicle performance may be erratic
and improper if the module connections are not
properly cleaned.
To avoid confusion about whether or not an
ECU is properly functioning, simply remove the
OttoMind from the ECU before having the vehicle
serviced, and reinsert the plastic cap in the ECU
access port. The OttoMind can be easily accessed
from inside the truck by removing three 13 mm
hex nuts from the emergency brake assembly and
pulling the assembly away from the side panel of
the vehicle. The OttoMind may be reinstalled after
the service is complete. Be sure to reinstall with
duct tape to firmly retain the OttoMind.
It is also not uncommon for a service provider
to update the program in the vehicle ECU. If this
occurs, it is possible that the programming in the
OttoMind will no longer match the ECU program.
If you experience any difficulty with the operation
of the Banks OttoMind after service, check with
the service provider to determine if an update
was performed. Then contact customer service at
Gale Banks Engineering for an updated OttoMind,
if necessary.
Use your pyrometer gauge to monitor exhaust gas
temperature (EGT) in the engine. At idle, EGT will
be very low, perhaps only 300°F. As the engine
accelerates and is under load, the EGT rises. The
safe maximum for the EGT is 1050°F. The highest
EGT occurs under maximum load at full throttle,
such as climbing a steep grade with a heavily
laden vehicle. If the vehicle reaches maximum
EGT during these conditions, downshift to reduce
the load, or back off the throttle. CAUTION:
Exceeding 1100°F can cause engine damage.
We recommend that engine oil temperature not
exceed 250°F. Optimum oil temperature is around
230°F.
NOTE: An optional oil temperature gauge is
available from Gale Banks Engineering.
SERVICE TIPS
If the need should arise for you to have your
vehicle serviced, the Banks OttoMind should be
removed from the engine control unit (ECU). It
is common for the service provider to connect a
21
P.N. 96322 V.7.0
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 Air Filter. Follow
the instructions included with the cleaning
system to clean and re-oil your Banks Ram-Air
Filter.
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.
5.
AEROSOL OILING
After cleaning air filter
always reoil before using.
Spray Banks Ram-Air
filter oil down into each
pleat with one pass per
pleat. Wait 10 minutes
and re-oil any white
spots still showing.
6.
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, reoil the
element and reinstall in your
vehicle.
1.
oiling hints
Never use a Banks Ram-Air filter without
oil (the filter will not stop the dirt without the oil).
Use only Banks Ram-Air filter oil. Banks 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
WD40, LPS, or other light-weight oils.
7.
spray-on cleaning
Spray Banks air-filter cleaner
liberally onto the entire
element and let soak
for 10 minutes.
2.
PAN CLEANING
Large air-filter elements
can be rolled or soaked
in a shallow pan of Banks
air-filter cleaner. Remove
immediately and let soak for
approximately 10 minutes.
reinstall
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.
8.
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.
9.
cleaning hints
Use only Banks air-filter cleaner. No
gasoline cleaning, No steam cleaning, No caustic
cleaning solutions, No strong detergents, No highpressure car wash, No parts cleaning solvents.
Any of these Nos can cause harm to the cotton
filter media plus SHRINK and HARDEN the rubber
end caps.
3.
performance hints
10. 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”/H2O.
rinse off
Rinse off the element
with low-pressure 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.
4.
CAUTION! Extremely fine dust from agriculture
or offroad use will pull the oil from the element.
Frequent reoiling of the element’s clean side might
be required. Completely service when practicable.
For extra protection use an air-filter sealing grease
on rubber ends of the element. Service only with
Banks air-filter cleaner and Banks air-filter oil.
22
P.N. 96322 V.7.0
BILL OF MATERIALS
Ford 7.3L Turbo Diesel • 1994–1998
Banks PowerPack systems 48501–48528
Banks Stinger-Plus systems 48451–48478
Banks Stinger systems 48401–48428
Item # Part # Description
PowerPack Stinger-Plus Stinger
1
1-23
25970 BANKS TECHNI-COOLER SYSTEM
1
1
25504 TECHNI-COOLER INTERCOOLER
1
2
25511 INTERCOOLER MOUNTING BRACKET, Lower Left
1
3
25512 INTERCOOLER MOUNTING BRACKET, Lower Right
1
4
25515 INTERCOOLER MOUNTING BRACKET, Upper Left
1
5
25516 INTERCOOLER MOUNTING BRACKET, Upper Right
1
6
25530 TRANSMISSION-FLUID COOLER MOUNTING BRCKT, Left
1
7
25531 TRANSMISSION-FLUID COOLER MOUNTING BRCKT, Right
1
8
41304 INTERCOOLER INLET TUBE
1
9
41308 INTERCOOLER OUTLET TUBE
2
10
94285 SILICONE HOSE, 3 x 3”
2
11
94510 SILICONE HUMP HOSE, 3 x 3”
1
12
41312 TWINRAM INTAKE ASSEMBLY
1
13
41300 COMPRESSOR OUTLET ELBOW
1
14
93603 O-RING, Compressor Outlet
2
15
25510 AIR DAM
1
16
25513 NUT PLATE ASSEMBLY, Left
1
17
25514 NUT PLATE ASSEMBLY, Right
2
18
62075 LOOP CLAMP, 3 ⁄ x 5 ⁄ ”
8
19
92871 T-BOLT CLAMP, #313 with Liner
2
20
25900 ISOLATOR STUD MOUNT
2
21
41360 SPACER, 5 ⁄ ”, Aluminum
2
22
81100 SPACER, Sway Bar
2
23
91501 STUD, 5 ⁄ x 11⁄ ”
1
24-31 25970-5 FASTENER KIT
4
24
91225 BOLT, 5 ⁄ ” 18 x 3⁄ ” Hex
1
25
91228 BOLT, 5 ⁄ ” 18 x 1” Hex
3
1
4
26
91450 BOLT, ⁄ ” 16 x 3 ⁄ ” Hex
8
27
91117 BOLT, 1⁄ ” 20 x 3⁄ ” Hex
2
28
91789 BOLT, 8mm 1.25 x 30mm Hex
8
29
91831 BOLT, 10 32 x 1” Hex Washer Head
2
30
25930 ISOLATOR BUSHING, Rubber
5
5
31
91210 NUT, ⁄ ” 18 Nylock
1
32-39 25970-5 FASTENER KIT
3
4
32
91415 NUT, ⁄ ” 16 Nylock
4
33
91110 NUT, 1⁄ ” 20 Nylock
8
34
91910 NUT, 10-32 Nylock
2
35
91803 LOCKNUT, 8mm 1.25 Hex with Washer
5
12
36
91202 WASHER, ⁄ ” SAE
3
8
37
91403 WASHER, ⁄ ” USS
4
16
8
16
8
16
4
16
8
4
4
4
16
8
4
16
8
Continued on page 26
23
P.N. 96322 V.7.0
24
P.N. 96322 V.7.0
25
P.N. 96322 V.7.0
BILL OF MATERIALS
Item #
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
Part #
91102
91857
90001
41509
90094
24450
93604
93605
52124
52123
52465
26001
26013
52142
52467
64001
63025
63033
63002
62001
62010
6280162825
96322
96392
96363
96009
96004
96005
Description
WASHER, 1 ⁄ ” SAE
WASHER, #10 SAE
THREAD-LOCKER, 6 ml
BANKS RAM-AIR FILTER
FILTER SERVICE KIT
QUICK-TURBO TURBINE HOUSING
O-RING, Oil Feed
O-RING, Oil Drain
TURBINE OUTLET PIPE, Lower
TURBINE OUTLET PIPE, Upper
U-CLAMP, 3”
HEATSHIELD BLANKET, 6 x 14”
WIRE TIE, Heatshield Blanket
MONSTER TAILPIPE*
U-CLAMP, 31⁄ ”
DYNAFACT PYROMETER GAUGE KIT
DYNAFACT BOOST GAUGE, 30 PSI
BOOST GAUGE INSTALLATION KIT
TWO-GAUGE MOUNTING PANEL
CABLE TIE, 5”
CABLE TIE, 8”
OTTOMIND ENGINE CALIBRATION MODULE
4
2
OWNERS MANUAL
PRODUCT REGISTRATION CARD
WARRANTY STATEMENT
BANKS POWER DECAL, UroCal
BANKS POWER DECAL, Large
BANKS POWER DECAL, Small
PowerPack Stinger-Plus Stinger
8
8
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
4
1
1
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
4
4
4
4
4
4
1
1
1
1
1
1
2
-
1
1
1
2
-
1
1
1
2
2
*Stinger systems 48401, 48403 and 48405 use tailpipe p/n 52129
*Stinger-Plus systems 48451, 48453 and 48455 use tailpipe p/n 52129
*PowerPack systems 48501, 48503 and 48404 use tailpipe p/n 52129
26
P.N. 96322 V.7.0
FIGURE 6
27
P.N. 96322 V.7.0
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28
P.N. 96322 V.7.0
FIGURE 7
29
P.N. 96322 V.7.0
Gale Banks Engineering
546 duggan avenue • azusa, ca 91702
(626) 969-9600 • fax (626) 334-1743
Product Information & Sales: (800) 438-7693
Customer Support: (888) 839-5600
Installation Support: (888) 839-2700
www.bankspower.com
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