Banks Power Pack® System
Banks Power Pack®
System
For use with Palm® Tungsten™ E2 only
Including Stinger® System
and EconoMind
2001-2005 Chevy/GMC 6.6L Duramax
Turbo-Diesel Pickups
THIS MANUAL IS FOR USE WITH SYSTEM
48950-48994, 61073-61079, 63713-63715, 63762-63765
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
©2009 Gale Banks Engineering
12/14/09 PN 96776 v.11.0
General Installation Practices
5. Route and tie wires and hoses
Dear Customer, If you have
any questions concerning
the installation of your Banks
EconoMind Diesel Tuner, please
call our Technical Service
Hotline at (888) 839-2700
between 7:00 am and 5:00 pm
(PT). If you have any questions
relating to shipping or billing,
please contact our Customer
Service Department at (888)
839-5600.
Thank you.
1. For ease of installation of your
Banks system, familiarize yourself
with the procedure by reading the
entire manual before starting work.
This manual contains 44 pages of
copy, illustrations and parts listing.
If any pages are missing from this
manual please call Gale Banks
Engineering immediately for a
replacement.
2. The exploded illustrations 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’s side, and the right-side to the
passenger’s side.
4. Disconnect the ground cable from
the battery before beginning work. If
there are two batteries, disconnect
both.
2
96776 v.11.0
a minimum of 6 inches away from
exhaust heat, moving parts and sharp
edges. Clearance of 8 inches or more
is recommended where possible.
6. During installation, keep the
work area clean. If foreign debris
is transferred to any Banks system
component, clean it thoroughly before
installing.
7. 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; put the transmission in
park; set the parking 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.
8. The Palm Tunsten E2 will need
to be charged for a minimum of 1-2
hours before the Banks software
can be installed. Locate the supplied
AC-outlet wall charger, also located
in your kit and plug the charging cord
into the Tungsten E2. Please refer
to the Banks PowerPDA Software &
Installation Kit, Owners Manual for
additional instruction.
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.
Notification
The Banks Ram-Air Filter comes
pre-oiled and no oiling is
necessary for initial installation.
Service the filter as specified in
the Filter maintenance Section of
this manual.
Tools Required:
• 1⁄ 4” and 3⁄ 8” drive ratchets
• Inch and metric deep sockets
• Ratchet extension
• Metric combination or open-end
wrenches
• Phillips and flat blade screwdrivers
• Standard and needle-nose pliers
• Pocket or X-Acto knife
• Clean shop towels or rags
• Drill bit set
• Drill motor
• Tap Handle
• 1⁄ 4” NPT tap
•
5⁄ 16
nut driver
• Pliers
• Torx bits
• Pry-bar
Highly recommended tools and
supplies:
Table of Contents
• Multimeter or 12-volt test light
General Assembly Diagram . . . . . . 4
Banks Power Pack System
• Heat gun
• Foot-pound torque wrench
• Penetrating oil or light lubricant
spray
• Reciprocating saw
• Inch-pound torque wrench
Section 1 . . . . . . . . . . . . . . . . . . . . . . 6
Installation of Banks Monster Exhaust
System
Section 2 . . . . . . . . . . . . . . . . . . . . . 13
Techni-Cooler Assembly Installation
Section 3 . . . . . . . . . . . . . . . . . . . . . 24
Thermocouple Installation
Section 4 . . . . . . . . . . . . . . . . . . . . . 25
Banks Ram-Air Intake System
Section 5 . . . . . . . . . . . . . . . . . . . . . 31
Banks EconoMind Diesel Tuner
Installation
Section 6 . . . . . . . . . . . . . . . . . . . . . 33
Mounting the Docking Station and
Connecting the Banks PowerPDA Vehicle
Command Center
Section 7 . . . . . . . . . . . . . . . . . . . . . 35
Installation of the Power Level Selector
Switch
Section 8 . . . . . . . . . . . . . . . . . . . . . 38
Optional Gauge Cluster Installation
Section 9 . . . . . . . . . . . . . . . . . . . . . 39
Automatic Transmission Learning
Section 10 . . . . . . . . . . . . . . . . . . . . 40
Troubleshooting, EconoMind
Section 11 . . . . . . . . . . . . . . . . . . . . 42
Clearing Learned Parameters
Section 12 . . . . . . . . . . . . . . . . . . . . 42
Updating Your Banks PowerPDA Software
& Banks EconoMind Diesel Tuner
Firmware
Section 13 . . . . . . . . . . . . . . . . . . . . 42
Removal of the EconoMind Diesel Tuner
Section 14 . . . . . . . . . . . . . . . . . . . . 43
Filter Maintenance
Section 15 . . . . . . . . . . . . . . . . . . . . 44
Placement of the Banks Power Decals
96776 v.11.0
3
General Assembly Diagram
Banks Power Pack System
4
96776 v.11.0
96776 v.11.0
5
Section 1
Installation of Banks Monster Exhaust System
Figure 1a
General Assembly
Banks Monster Exhaust (Single Tailpipe)
Description
1
Monster muffler
Part #
Qty.
Ext./Crew Cab Short Bed/Std Cab Long Bed
53800
1
Ext./Crew Cab Long Bed
53801
2
Intermediate pipe
1
Standard Cab Long Bed
53718
1
Ext./Crew Cab Short Bed
53719
1
Ext./Crew Cab Long Bed
53720
1
3
Tailpipe Ext./Crew Cab Short Bed/Std Cab Long Bed
53708
1
Ext./Crew Cab Long Bed
53709
1
4
Flanged intermediate pipe
Standard Cab Long Bed
53713
1
Ext./Crew Cab Short Bed/Ext./Crew Cab Long Bed
53717
1
5
Polished 5-inch exhaust tip with clamp
52383
1
6
4” Exhaust hanger/clamp (saddle type) Ext./Crew Cab Long Bed
53707
1
7
4” Band clamp 52471
1
8
4” Exhaust clamps (saddle type)
52470
2*
9
Exhaust gasket 93210
1
10
Head pipe assembly (non-cat models)
53716
1
11
7⁄ 16-20
x 1.5” bolts (non-cat models)
91629
4
12
7⁄ 16-20
Crimplock nuts (non-cat models)
91619
4
13
7⁄ 16
91601
8
AN washers (non-cat models)
*Ext./Crew Cab Long Bed only receive (1)
6
96776 v.11.0
96776 v.11.0
7
Figure 1b
General Assembly
Banks Split-Dual Monster Exhaust, Split-Dual
Description
Part #
Qty.
1
Monster muffler
53800
1
2
Intermediate pipe
Standard Cab Long Bed
53721
1
Ext. Crew Cab Short Bed/Crew Cab Short Bed
53724
1
Ext. Crew Cab Long Bed/Crew Cab Long Bed
53725
1
3
Passenger side tailpipe
53743
1
4
Driver side tailpipe
53744
1
53727
1
5Y-pipe, Split dual
6
Flanged Intermediate extension pipe
Standard Cab Short Bed/Ext. Crew Cab Short Bed/Crew Cab Long Bed/Crew Cab Short Bed
53717
1
Standard Cab Long Bed
53713
1
7
Rear muffler hanger/clamp
53726
1
8
4” Saddle clamp
52476
1
9
3.5” Saddle clamp
52467
2
10
4” Band clamp
52471
1
11
4-bolt gasket 93210
1
12
Driver side frame hanger bracket
53731
1
13
Driver side rubber insulator
53732
1
14
1⁄ 2-13
91930
2
15
1⁄ 2
91902
4
16
1⁄ 2-13
Nylock nut 91823
2
17
5” Black cable tie
62001
3
18
Head pipe assembly (non-cat models)
53716
1
19
7⁄ 16-20
x 1.5” bolts (non-cat models)
91629
4
20
7⁄ 16-20
Crimplock nuts (non-cat models)
91619
4
21
7⁄ 16
91601
8
x 1.0” Bolt
SAE washer
AN washers (non-cat models)
20
21
19
8
21
2
10
6
11
18
8
96776 v.11.0
13
14
12
15
9
16
3
4
9
5
7
18
1
17
96776 v.11.0
9
Exhaust System Installation
Use the Bill of Materials Chart
and Figure 1a or 1b to reference
component nomenclature and
location. Use caution when working
in the engine compartment. Make
sure the engine has been OFF for
several hours and cool.
Figure 2
1. Disconnect the ground of the
battery (if there is more than one
battery, disconnect both).
2. Raise the vehicle and support it
with 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; place the
transmission in park; set the parking
brake and place blocks behind the
rear wheels.
Figure 3
CAUTION: DO NOT WORK UNDER
ANY VEHICLE SUPPORTED ONLY
BY A JACK. SEVERE INJURY MAY
RESULT.
CAUTION: The following step
involves cutting a stainless steel
tube. Safety glasses should
be worn during any cutting
operation and care should be
taken to avoid injury due to sharp
edges and burrs.
3. Removal of the factory exhaust
can be simplified by cutting the
factory exhaust pipe behind the
muffler. This will allow the tailpipe to
be removed as a separate piece.
4. Remove the four (4) nuts from the
factory exhaust flange located at the
back side of the factory head pipe
(retain for re-use).
5. Remove the factory tailpipe
from the vehicle by disengaging the
exhaust system hanger pins from
the rubber grommets using a large
screw-driver or pry bar.
Note: Lubricating the rubber hangers
with WD-40 or similar lubricant will
ease removal of the hanger pins.
6. Remove the factory muffler
from the vehicle by disengaging
the hanger pins from the rubber
grommets using a large screwdriver
or pry bar.
Step 7 thru 10 for vehicles with no
catalytic converters only.
7. Spray penetrating oil such as WD-40
on the T-bolt of the factor V-band
10
96776 v.11.0
clamp to prevent galling. Remove
factory
V-band clamp and save for re-use.
8. Remove factory head pipe from
the vehicle by disengaging the
exhaust system hanger pins from
the rubber hangers using a large
screwdriver or pry bar.
9. Install Banks head pipe in vehicle
and insert the hanger pin in the
rubber exhaust hanger.
NOTE: Be sure to install the hanger
pin in the same location as the
previously removed factory head
pipe.
10. Loosely install V-band clamp on
head pipe flange and only tighten
the T-bolt on the clamp to the point
that the pipe is snug but can still be
rotated in the clamp for adjustment/
alignment.
NOTE: Do not completely tighten the
V-band clamp at this point.
11. If the system is being installed
on an extended-cab vehicle, the
Banks flanged intermediate pipe
(53717) must be trimmed prior
to installation in the vehicle. For
extended-cab models, trim 9-1⁄ 2”
from the outlet of the intermediate
pipe such that 10” including the
flange is remaining. Once the cut has
been performed, debur the cut end
with a file or sandpaper. (See Figure
2).
12. Install the Banks flanged
intermediate pipe and 4-bolt gasket
onto the headpipe. Loosely assemble
with the four (4) factory nuts. Slide
the Banks 4-inch band clamp on
the outlet of the Banks 4-bolt flange
pipe.
1⁄ 4”
Figure 4
away from its original position.
Step 14 thru 21 applies only to
single tailpipe systems.
Skip to Step 22 if installing Banks
Split-Dual Monster Exhaust System.
Single Tailpipe System (Step 14
thru 21)
14. Slide one (1) of the supplied
4-inch exhaust clamps over the
Banks intermediate pipe.
Note: On extended cab long-bed
and crew-cab long-bed vehicle, the
clamp that is used between the
intermediate pipe and muffler is a
combination hanger/clamp. When
this hanger clamp is installed the
hanger pin should be inserted into
the factory rubber hanger and the
clamp should be rotated until the
hanger pin is parallel with the framemounted pin before being torqued.
15. Install the muffler onto the end
of the intermediate pipe outlet. Be
sure that the inlet side of the muffler
(see markings on muffler body)
is facing toward the front of the
vehicle. Orient the muffler such that
the “Banks Monster” logo is facing
towards the frame and is level with
the ground. Verify that the muffler
and intermediate pipe are completely
engaged.
Figure 5
16. Slide one (1) of the supplied
4” exhaust clamps onto the Banks
Monster muffler outlet.
17. Install the tailpipe into the outlet
of the muffler. Be sure that the two
pipes are completely engaged. Insert
the front and rear tailpipe hanger
pins into the factory rubber hangers.
Rotate the tailpipe until the hanger
pins are parallel with the frame
mounted pin.
NOTE: Minimum distance between
exhaust tip and body a half (1⁄ 2) inch.
18. Adjust each of the pipes to
13. Insert the intermediate pipe
inlet onto the flanged intermediate
pipe outlet. Install the intermediate
pipe hanger pin(s) into the vehicle
rubber grommets.
NOTE: Once the pipe has been
completely engaged in the slip
joint, it should be marked with a
marker, scribe or tape for reference
when tightening clamps later in the
installation. Each slip joint in the
system should be marked in this
fashion. When the exhaust system is
being adjusted to align the hangers,
the slip joints can be adjusted so that
the reference mark is no more than
ensure that all of the hanger pins
are parallel with the frame-mounted
pins and that the rubber hangers are
all positioned slightly forward (See
Figure 3). The amount of forward
angle on the rubber hangers should
increase the farther downstream the
hanger is positioned. This allows the
hangers to be properly positioned
once the exhaust system reaches
operating temperature.
19. Tighten the head pipe V-band
clamp to 12 ft-lbs (if previously
loosened).
96776 v.11.0
11
20. Tighten the exhaust clamp at
each of the three (3) joints. Figure
4 illustrates the proper location of
an exhaust clamp on a tubing joint.
Torque the nuts on each of the
exhaust clamps to 35 ft-lb. Note: If a
combination hanger/clamp is utilized,
evenly torque nuts to 35 ft-lb. The
clamps only need to be tight enough
to form a seal and hold the pipes
together. Over tightening the clamps
may cause the system to leak due to
the pipe being crimped. Torque the
four (4) factory flange nuts, previously
removed, to 30 ft-lbs.
Figure 6 Short-bed model shown
21. Install exhaust tip by sliding
it over the outlet of the tailpipe.
The tip should be positioned so
that the outlet of the exhaust tip
is approximately one (1) inch past
the outlet of the tailpipe or where
aesthetically pleasing.
NOTE: On vehicles with dual rear
wheels, the outlet of the tip should
be placed approximately 3.5 inches
past the outlet of the tailpipe.
Torque the band clamp to 35 ft-lb.
Skip to Step 34 to complete Banks
Monster Exhaust System.
Banks Split-Dual Monster
Exhaust System (Step 22 thru
33)
22. Install a 4”saddle clamp onto
the Monster muffler inlet. Install
the Monster muffler inlet onto the
Banks intermediate pipe outlet. Be
sure that the inlet side of the muffler
(see markings on muffler body)
is facing toward the front of the
vehicle. Orient the muffler such that
the “Banks Monster” logo is facing
towards the frame and is level with
the ground. Verify that the muffler
and intermediate pipe are completely
engaged.
23. Install the muffler hanger clamp
onto the muffler outlet. Insert the
hanger pin into the vehicle’s rubber
grommet.
24. Install the Banks Y-pipe into the
muffler outlet such that the outlets
are pointing up. Install a 3-1⁄ 2” saddle
clamp onto each y-pipe outlet (See
Figure 5).
25. Install the driver-side hanger
bracket into the rear of the driverside frame rail. If a hitch is installed,
remove the hitch hardware on the
driver-side, install the frame bracket
and reinstall the existing hitch
hardware.
12
96776 v.11.0
For Long bed models, use one (1) bolt
on the flat of frame rail and one (1)
bolt on the side of the frame rail.
NOTE: Minimum distance between
exhaust tip and body is a half (1⁄ 2)
inch.
For Short bed models, use two (2)
bolts on the flat of the frame rail (no
bolts on the side). See Figure 6.
31. Tighten the head pipe V-band
26. Install the supplied rubber
32. Align the saddle clamps on the
grommet onto the Banks hanger
bracket.
27. Install the driver-side tailpipe
(longer) into the top Y-pipe outlet.
Install the driver-side tailpipe hanger
into the Banks rubber grommet.
28. Install the passenger-side
tailpipe (shorter) into the lower
Y-pipe outlet. Install the passengerside tailpipe hanger into the vehicle
rubber grommet.
29. Adjust each of the pipes to
clamp to 12 ft-lbs (if previously
loosened).
radius of the corresponding pipe
slots. Figure 4 illustrates the proper
location of an exhaust clamp on a
tubing joint. Torque the nuts on each
of the exhaust clamps to 35 ft-lbs.
Torque the four (4) factory flange
nuts, previously removed, to 30 ftlbs. Torque the hanger bracket 1⁄ 2”
hardware to 65 ft-lbs.
33. Using the three (3) supplied wire
ties, tie any hoses, brake lines or
harnesses a minimum of four inches
away from the exhaust/tail pipes.
ensure that all of the hanger pins
are parallel with the frame mounted
pins and that the rubber hangers are
all positioned slightly forward (See
Figure 3). This allows the hangers
to be properly positioned once the
exhaust system reaches operating
temperature.
34. Remove the protective covering
30. Be sure that the two (2) tailpipes
installation is now complete.
are completely engaged into the
Y-pipe. Rotate the tailpipe until the
hanger pins are parallel with the
frame-mounted pin. Be sure both
tailpipe tips look symmetrical.
from the tailpipe tip.
Caution: the protective covering
may ignite and burn if not
removed prior to running the
engine.
35. The Banks Monster Exhaust
-end, section 1-
Section 2
Techni-Cooler Assembly Installation
Figure 7
General Assembly
Banks Techni-Cooler Intercooler System
Item Description
1
Techni-Cooler Intercooler
P/N
Qty
25537
1
2
Boost Tube, Right (2001)
42326
1
Boost Tube, Right (2002-2004)
42327
1
Boost Tube, Right (2004.5-2005)
42329
1
3
Boost Tube, Left (2001-2004)
42325
1
Boost Tube, Left (2004.5-2005)
42328
1
1
4
Hose, Compressor Outlet to Boost Tube (2001, 2004.5-2005)
94291
Hose, Compressor Outlet to Boost Tube (2002-2004)
94291
2
5
Hose, Intake Manifold to Boost Tube (2001)
94274
1
Hose, Intake Manifold to Boost Tube (2004.5-2005)
94295
1
6
Hose, Boost Tube to CAC (2001, 2004.5-2005)
94294
1
7
Hose Clamp 3.0”
92860
2
8
Stock Hose —
*
9
Stock Hose Clamp
—
*
* These are stock components that will be re-used with the Banks Techni-Cooler System
7
4
3
5
8
9
7
1
9
2
9
6
96776 v.11.0
13
Figure 8 Air box mounting tray
REMOVE STOCK COMPONENTS
1. Make sure the previously removed
ground cables from both batteries
are still disconnected.
2. Disconnect the mass airflow
(MAF) sensor’s connector at the
air box assembly. Note: MAF will
be installed after Ram-Air intake
installation.
Loosen the hose clamp that joins the
inlet air transfer tube to the molded
plastic compressor inlet duct. Pull the
air box out of the vehicle. It’s held in
place by plastic fasteners that snap
in place. Cover the turbocharger inlet
with a clean rag to prevent debris
from entering the turbocharger that
could result in damage upon start-up
3. Remove the air box mounting tray
from the vehicle shown in Figure 8..
If installing a Banks Stinger
System, Skip ahead to Section 3.
4. Remove the upper grill baffle
that mounts between the grill and
radiator cross brace. The baffle is
held in place by 7 push-in retainers.
The retainers are removed by pulling
up on the center pin, then prying the
retainer out of it’s hole as shown in
Figure 9.
14
96776 v.11.0
Figure 9 Removal of push-in retaining pins
Figure 10a Headlamp assembly removal, Chevy
5. Remove the grill
a. 2001 to 2002 vehicles: The grill is
retained by (4x) 1⁄ 4 turn fasteners,
(1x) screw at the latch support, and
(2x) snaps at the outboard ends of
the grill. Depress the snaps at the
ends of the grill before attempting to
remove the grill from the vehicle.
b. 2003 to 2005 vehicles: Disengage
the snaps at the outboard ends
of the grill. Pull the grill from the
vehicle.
6. Rotate the headlamp-retaining
pin, then remove the pin as shown in
Figure 10a.
Figure 10b Headlamp assembly removal, GMC
Note: Some GMC models depending
on model year may have a two
headlamp-retainer pin. Remove the
two retainer pins from headlamp
assembly as shown in Figure 10b.
7. Disconnect the connectors
from the backside of the headlamp
assembly, and remove from the
vehicle. Repeat for the driver and
passenger side headlamp assemblies.
8. Remove the park/turn signal
lamp assembly by depressing the
outboard retaining clip, then rotating
the assembly outward as shown in
Figure 11. The headlamp is easily
disengaged and does not require
force to be removed once the
outboard clip has been depressed.
Figure 11 Parking lamp assembly removal
96776 v.11.0
15
9. Remove the bulbs from the turn
Figure 12 Removal of headlamp/parking lamp assembly support structures
signal lamp assembly by turning
the lamp sockets a quarter turn
counterclockwise.
10. Remove the plastic headlamp
mounting structure on the driver
and passenger side of the vehicle
shown in Figure 12. There are (6)
bolts, (2) torx head bolts, (1) pushin retainer and (1) large clip that
must be disconnected to remove
the piece from the vehicle, per side.
The plastic piece that resides by
the bumper must be detached from
the headlamp mounting structure,
but will remain on the vehicle. The
retaining clip that attaches the hood
latch cable to the support structure
must also be removed on the driver’s
side.
11. Remove the four bolts that
secure the upper fan shroud to the
upper radiator cross brace. Remove
the four push-in retainers (2 per side)
that attach the upper section to the
lower section of the fan shroud.
These retainers are removed by
pulling up on the center pin then
prying the entire retainer assembly
out as shown in Figure 9.
12. Remove the upper section of
the fan shroud from the vehicle. Take
care not to damage the face of the
radiator when removing the shroud.
13. Remove the two upper
condenser mounting bolts that attach
to the radiator cross brace.
14. Mark the location of the hood
latch, then remove the hood latch
from the latch support. The latch is
held in place by three bolts. The latch
support is shown in Figure 12. It is
not necessary to remove the cable
from the latch, just place the latch
and cable assembly out of the way.
16
96776 v.11.0
Figure 13 Oil cooler line retaining clip
Figure 14 Latch support moved out of the way
15. Remove the two bolts that
attach the latch support to the
radiator cross brace and the 4 lower
attachment bolts (2 per side). The
two bolts that attach the upper
support to the radiator cross brace
are accessed from the engine
compartment side of the vehicle.
16. Remove the oil-cooler-line
retaining clip as shown in Figure 13.
17. Swing the latch support forward
as shown in Figure 14.
18. Pull the air conditioning
condenser out of it’s lower mounts,
and place it against the latch support.
19. Remove the two upper Charge
Air Cooler (CAC) mounting bolts and
unfasten the fender support rod from
the radiator cross brace as shown in
Figure 15.
Figure 15 Upper Charge Air Cooler (CAC) attachment bolt
96776 v.11.0
17
Figure 16 Air box support bracket
TRIM BRACKETS
20. Remove the 6 bolts (3 per side)
that secure the radiator cross brace.
The bolts are on the bottom side at
each end of the support. Remove the
cross brace from the vehicle.
21. Remove the air box support
bracket shown in Figure 16. There is
an a/c condenser line retaining clip
and a plastic fastener that attaches
to the inner fenderwell that must be
removed before the bracket can be
liberated from the vehicle.
22. Trim the air box support bracket
per the template in Figure 18.
Figure 17 shows the bracket before
and after trimming.
Figure 17 Before and after removing material from the air box support bracket.
18
96776 v.11.0
Figure 18 Trim template for the air box-mounting bracket.
96776 v.11.0
19
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20
96776 v.11.0
Figure 19 Radiator attachment bolt and lower clamp
26. Lift the radiator out of it’s
lower saddle mounts and position it
towards the engine so that it is no
longer attached to the charge air
cooler. Take care not to damage the
radiator cooling fins.
27. Remove the charge air cooler
from the vehicle. Check that the
lower mounting peg grommets
remained in the vehicles frame.
Return them to their home on the
vehicles frame, if they came out with
the charge air cooler.
28. Remove the metal sleeve from
the upper CAC isolation grommets.
Remove the grommets from the
stock charge air cooler and place
them on the Banks Techni-Cooler.
Reinstall the metal sleeves in the
grommets in the same orientation as
they were removed from the stock
CAC.
29. Remove the lower radiator
Figure 20 Gap between the CAC hose stop and radiator end tank
saddle mount grommets from the
stock CAC and install them on the
Banks CAC.
banks technicooler
instalation
30. Place the Banks CAC in the
vehicle. Align the lower CAC
mounting pegs with the rubber
mounts in the vehicle’s frame. There
is a significant amount of play in
the rubber mounts that can allow
them to be aligned with the CAC as
required.
31. Reinstall the radiator into the
lower saddle mounts of the Banks
CAC.
32. Reinstall the radiator cross
brace. Leave the attachment bolts
loose to aid in aligning the CAC with
the support.
33. Install the upper CAC
23. Remove the 8 pushpin
fasteners and 2 large head plastic
fasteners that attach the driver’s
side fenderwell. The fasteners are
accessed through the wheel arch
opening. Pull the fenderwell down
approximately 6 inches once the
fasteners are removed. Disconnect
the wire harness retaining clips on
top of the fenderwell, then remove
the fenderwell from the vehicle.
24. Loosen the driver and passenger
side boost tube attachment hoses.
Do not damage the hoses that attach
to the charge air cooler (CAC), the
driver’s side hose will be re-used.
Remove the boost tubes and hoses
from the vehicle. The driver side
boost tube should be removed
through the fenderwell and the
passenger side upward through the
engine compartment. Cover the
intake manifold and turbocharger
discharge to prevent foreign debris
from entering during the installation.
25. Remove the radiator attachment
bolts and the lower retaining clamps
shown in Figure 19.
attachment bolts that were
previously removed. There is enough
play in the lower mounting pads, that
the CAC can be positioned to align
with the upper cross brace. Tighten
the bolts.
34. Position the radiator so that
it’s centered on the CAC. Check the
gap between the hose stops on the
CAC and the radiator end tanks on
each side of the CAC. Reposition
the radiator relative to the CAC until
the gap is equal on each side. The
location to check is shown in
Figure 20.
96776 v.11.0
21
35. Check that the engine cooling
Figure 21 Lower fan shroud fitment with the radiator
fan can freely spin without contacting
the lower fan shroud. If the fan
contacts the shroud, the shroud must
be realigned with the radiator. The
correct alignment is shown in
Figure 21. Each side of the shroud
should overlap the radiator headers,
and the mounting tabs should fit into
their respective bosses as shown in
Figure 21.
36. Secure the radiator to the Banks
CAC with the 5⁄ 16”-18 by 1.0” long
bolts and large OD washers that were
supplied with the Banks system.
Tighten to 10-12 ft-lbs.
37. Install the lower driver side
radiator-retaining clamp that was
removed from the stock CAC and
secure with the 5⁄ 16”-18 by 0.5” long
bolts and the smaller OD washers
that were supplied with the Banks
system. Tighten to 10-12 ft-lbs. The
passenger side clamp will contact
the battery support bracket, and is
optional to reinstall.
38. Tighten the 6 radiator cross
brace bolts to 80 in-lbs. Install the
diagonal fender support brace and
tighten the bolts.
39. Insert the supplied round metal
spacers into the rubber shroud
gasket as shown in Figure 22. The
spacers should be inserted so that
the step mates with the cross brace.
22
96776 v.11.0
Figure 22 Metal spacers installed in the shroud gasket
40. Install the upper fan shroud. The
supplied gasket is used to fill the gap
between the shroud and the cross
brace. The push-in retainers that
secure the upper shroud to the lower
shroud are secured by inserting the
retainer with the center pin pulled
out. Once the retainer is inserted,
press the center pin down to secure
the retainer. Install the gasket and
upper fan shroud bolts. The stock
upper fan shroud bolts are reused
and should be tighten to 80 in-lbs.
41. Install the a/c condenser and
tighten it’s upper mounting bolts to
80 in-lbs
42. Install the latch support. Tighten
it’s six attachment bolts to 80 in-lbs.
Install the oil-cooler-line retaining clip
shown in Figure 13.
43. Install the hood latch. Position it
so that it aligns with the marks that
were previously made on the latch
support prior to it’s removal. Tighten
it’s bolts to 80 in-lbs.
44. Install the driver and passenger
side plastic headlamp support
structures. Tighten the screws to 80
in-lbs.
45. Install the light bulbs into the
park/turn signal lamp assemblies.
These are held in place by turning
them clockwise. Install the park/
turn signal lamp assembly onto
the vehicle for both the driver and
passenger side.
46. Install the electrical connectors
to the headlamp assembly. Install
the headlamp assemblies and secure
them with their retaining pins.
47. Install the grill:
a. 2001 to 2002 vehicles: The grill is
retained by (4x) 1⁄ 4 turn fasteners,
(1x) screw at the latch support, and
(2x) clips at the outboard ends of the
grill. Tighten the screw at the latch
support to 75 in-lbs.
b. 2003 to 2005 vehicles: The grill is
held in place by retaining clips, and
can be snapped in place.
48. Install the upper grill baffle
and secure with the seven pushin retainers that were previously
removed. The push-in retainers that
secure the grill baffle are secured by
inserting the retainer with the center
pin pulled out. Once the retainer is
inserted, press the center pin down
to secure the retainer.
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.
49. Install the driver and passenger
side boost tubes. New clamps are
provided for the intake manifold
hose to boost tube connection
and the turbo hose to boost tube
connection. All other locations reuse
the factory clamps. Tighten the
clamps to 75 in-lbs. The following
hoses are used at each location:
2001 vehicles:
Turbocharger outlet: 3 inch to 23⁄ 8
inch ID straight reducer
CAC inlet (driver side): Re-use factory
hose
CAC outlet (passenger side): Uniform
3 inch ID with 145-degree bend
Intake manifold: 3 inch to 23⁄ 8 inch ID
with 120-degree bend
2002 to 2004 LB7 vehicles:
Turbocharger outlet: 3 inch to 23⁄ 8
inch ID straight reducer
CAC inlet (driver side): Re-use factory
hos
CAC outlet (passenger side): Re-use
factory hose
Intake manifold: 3 inch to 23⁄ 8 inch ID
straight reducer
2004.5 to 2005 LLY vehicles:
Turbocharger outlet: 3 inch to 23⁄ 8
inch ID straight reducer.
CAC inlet (driver side): Re-use factory
hose.
CAC outlet (passenger side): Uniform
3 inch ID with 145-degree bend.
Intake manifold: 3 inch to 23⁄ 8 inch ID
with 120-degree bend.
50. Install the driverside wheel well.
Install the lower air cleaner support
bracket. Tighten the bolts to 80
in-lbs. Do not reinstall the air cleaner
mounting tray. It will not be reused.
However, the fasteners will be used
for installation of the Ram-Air filter
housing.
-end, section 2-
96776 v.11.0
23
Section 3
Thermocouple Installation
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 manifold outlet.
It is recommended that the manifold
be removed from the engine to
thoroughly clean out all metal chips
from drilling. If manifold is not
removed from the vehicle, all chips
must be removed from the manifold.
This may be accomplished by using
a magnet to extract the chips after
drilling. The tap should be greased
before use and the chips again
removed with a magnet. All metal
shavings must be cleaned from the
manifold to avoid turbine damage.
2. Remove passenger side wheel
well.
3. On the passenger side, remove
the hardware retaining the turbine
inlet exhaust pipe to the exhaust
manifold using a 12mm, 12pt socket
along with a 12mm, 12pt wrench,
then remove the exhaust manifold
from vehicle. Pay special attention to
the orientation of the manifold outlet
gasket. Retain the hardware and
gaskets for re-assembly.
4. Center punch and drill through
the passenger side exhaust manifold
into the rear passage at the location
shown Figure 23. Use a 7⁄ 16” drill,
keeping the drill perpendicular to the
manifold surface.
24
96776 v.11.0
5. 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 thermocouple insert into the tapped hole.
6. Install the thermocouple insert
into the manifold using anti-seize
compound on the threads. Install the
probe in the thermocouple insert.
7. Make sure to remove all shavings
from inside the exhaust manifold.
Reinstall the exhaust manifold.
Torque to 28 ft-lb in the sequence
shown see Figure 23.
8. Attach the thermocouple to the
supplied thermocouple leadwire
extension with the supplied nuts
and bolts. 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.
9. Route the thermocouple leadwire
extension along the factory harness to
the driver’s side.
Note: The thermocouple will be
connected to the EconoMind harness
in Section 5, Step 5.
-end, section 3-
Figure 23
14
13
1
3
7
2
11
42138
SCREW, TRUSS HEAD, PHILLIPS, 6-32 X 3⁄ 8
12
* These are stock components that will be re-used with the Banks Ram-Air System.
STOCK MAF SENSOR
SCREW, TRUSS HEAD, PHILLIPS, 5⁄ 16-18 X 3⁄ 4
11
15
O-RING, 50A DUROMETER BUNA, -121 size
10
STOCK GROMMET, FILTER MINDER
HOSE CLAMP, #56 w/LINER
9
STOCK FILTER MINDER
HOSE CLAMP, #72 w/LINER
8
13
91226
91718
HOSE CLAMP, #128
7
14
93740
HOSE, COMPRESSOR INLET
6
42140
*
*
*
92857
92872
92928
94298
94300
INTAKE TUBE, Ram-Air SYSTEM FOR LB7 (2001-2004)
HOSE, BELLOWS, 4.50 I.D. 4B
42139
5
AIR FILTER ELEMENT, Ram-Air SYSTEM
INTAKE TUBE, Ram-Air SYSTEM FOR LLY (2004-2005)
3
42137
2COVER, Ram-Air HOUSING
4A
42136
P/N
6
HOUSING, Ram-Air FILTER
9
12
Description
15
1
8
10
Item
8
5
4A
4B
9
2
4
1
2
2
1
1
1
1
1
1
1
1
Qty
Section 4
Banks Ram-Air Intake System
Figure 24
General Assembly
Banks Ram-Air Intake System
96776 v.11.0
25
RAM-AIR INSTALLATION
Figure 25
Use the Bill of Materials Chart and
the General Assembly Drawing to
reference component nomenclature
and location. See Figure 24. Use
caution when working in the engine
compartment. Make sure the engine
has been OFF for several hours and
cool. Make sure to complete
Steps 1 thru 3 of Section 2 before
proceeding.
2001 thru 2004 LB7 Duramax engine
1. You will have either a decorative
cover or a resonator covering the
intake manifold. The decorative cover
may need to be removed in order to
facilitate installation and alignment
of the Banks Ram-air intake system.
Remove the decorative cover by
removing the screw securing the
rubber grommet. Once the rubbe
grommet is removed, lift up and
unhinge the decorative cover from
its mount. Reinstall decorative cover
after the installation of the Banks
Ram-air system is complete. See
Figure 25
If you have the resonator with
attached decorative cover then th
resonator and attached decorative
cover will be removed from the
engine and will not be used in
conjunction with the Banks Ram-Air
intake system. See Figure 26.
26
96776 v.11.0
Figure 26
Figure 27
2. Locate your Banks Ram-Air filter
housing from your kit and install as
shown in Figure 27. The cutout on
Banks Ram-Air filter housing must
face passenger side fender. Align
the Banks Ram-Air filter housing
holes with bolt holes in engine
compartment. Install the previously
removed stock air box bolts to
secure the Banks Ram-Air filter
housing. Do not tighten the bolts at
this time.
3. Locate your Banks Torx tool,T20H
in your Banks Ram-Air kit. Use the
Torx tool bit to remove the two (2)
screws securing the MAF sensor to
the stock air box cover.
Note: When removing the MAF
sensor, grasp its body and pull up
and out. Do not twist or bend when
removing.
4. Locate the Banks MAF sensor
Figure 28
o-ring supplied in your kit. Install
Banks o-ring as shown in Figure 28.
Ensure o-ring is flush to MAF sensor
edge as shown.
Note: Retain stock o-ring. Keep stock
o-ring in place, you will be installing
the Banks o-ring while retaining the
original o-ring on the MAF sensor.
96776 v.11.0
27
5. Locate your Banks Ram-Air intake
Figure 29
tube in your kit. Install the stock MAF
sensor (with the additional Banks
o-ring) to MAF sensor mounting
boss as shown in Figure 29. Tighten
screws to 3 in/lbs.
Note: Ensure correct alignment as
shown otherwise screw holes will not
align with screw holes in the Banks
Ram-Air intake tube.
Caution: DO NOT OVER TIGHTEN
SCREWS
6. Locate the Banks compressor
inlet hose and hose clamps from
your Banks Ram-Air kit. Loosely fit
the hose clamp onto your Banks inlet
hose. Install the Banks inlet hose
and hose clamp and tighten it to the
compressor inlet.
7. Install Banks Ram-Air intake tube
to Banks inlet hose and hose clamp.
Lightly tighten the hose clamp. Note:
leave the clamps snug to allow
movement of the inlet hose to allow
correct alignment.
8. Locate the previously removed
stock air box and remove the stock
air filter Minder. Make sure to remove
the stock air filter Minder rubber
grommet as well. See Figure 30.
28
96776 v.11.0
Figure 30
Figure 31
9. Locate the Banks Ram-Air filter
housing cover. Install the previously
removed air filter minder rubber
grommet into the Banks Ram-Air
filter housing cover. Once rubber
grommet is installed flush into the
Banks Ram-Air cover, then locate the
previously removed air filter minder
and install into the rubber grommet.
Make sure air filter minder is installed
flush to rubber grommet.
10. Locate the Banks Ram-Air filter
and the Banks filter hose clamp.
Loosely fit the Banks Ram-Air filter
clamp to the Banks Ram-Air filter.
Note: See Figure 31 to reference the
correct alignment locater grove to
the Banks Ram-Air filter.
11. After verifying the correct
Figure 32
alignment between the Banks
Ram-Air filter and the Banks RamAir cover, snap fit the two pieces
together until an audible snap is
heard. This process will ensure that a
correct seal has been established.
12. Tighten the Banks Ram-Air filter
hose clamp to the Banks Ram-Air
filter cover.
13. Place the Banks Ram-Air filter
cover onto the Banks Ram-Air housing.
Locate the screws for the Banks RamAir housing cover in your kit. Align and
loosely fit the Banks Ram-Air cover
onto the Banks Ram-Air housing.
Figure 33
Note: Use the Banks Ram-Air cover
and Banks Ram-Air housing to fine
tune alignment between Banks RamAir intake tube and Banks Ram- Air
filter cover. The Banks Intake Tube can
be rotated to facilitate in alignment.
See Figure 32 and Figure 33.
CAUTION: Ensure Intake tube
is not touching any engine
components, specifically the
boost tube and intake manifold
hose clamps.
14. Tighten the upper (top) hose
clamp intake tube.
15. Remove the Banks Ram-Air
housing cover screws and remove
the Banks Ram-Air housing cover.
Note: Be careful not to disturb the
alignment.
96776 v.11.0
29
16. Tighten the Banks Ram-Air filter
Figure 34
housing bolts to vehicle frame.
17. Install the Banks bellows hose
and hose clamp onto the Banks RamAir intake tube.
18. Loosely fit the hose clamp to the
other end of the bellows.
19. Install the Banks Ram-Air cover
into bellows.
20. Install Banks Ram-Air cover w/
filter into the Banks Ram-Air filter
housing.
Note: a slight resistance in pressing
in the Banks bellows is normal.
21. Now with the Banks Ram-
Air filter housing cover and Banks
bellows fully seated flush, fasten the
Banks cover to the Banks housing
using the Banks cover screws and
tighten.
22. Make sure that the Banks
bellows is flush with the Banks cover
connection bead and tighten the
Banks bellows hose clamp.
Note: Bellows will need to be
compressed slightly.
23. Connect MAF sensor connector
to intake tube.
Note: you may have to loosen wire
harness clips, to increase slack in
length of wire harness available to
connect to intake air tube See
Figure 34.
24. Re-install the passenger side
wheel well.
25. You have successfully
completed the installation of the
Banks Ram-Air Intake system. See
Figure 35. Make sure to go over
all hose clamps for tightness and
connectors for a sure fit. Make sure
that the intake tube is not touching
any engine components, specifically
the boost tube and intake manifold
hose clamps.
-end, section 4-
30
96776 v.11.0
Figure 35
Section 5
Banks EconoMind Diesel Tuner Installation
Figure 36
General Assembly
Banks EconoMind Diesel Tuner
INSTALLATION OF WIRING
HARNESS, CONNECTIONS AND
EconoMind DIESEL TUNER
1. From the engine compartment,
locate the rubber grommet high
on the driver’s side of the vehicle
firewall. The grommet is about 3”
in diameter. Make a 1” x 1” crossshaped incision in the grommet (see
Figure 37).
2. From the engine compartment,
feed the grey three-connector cable
through the incision made in the
firewall grommet and into the cab.
From inside the cab, remove the
lower dash panel under the steering
column to allow access to these
three connectors.
Figure 37
96776 v.11.0
31
3. Locate the two black wire harness
locking connectors between the
brake fluid reservoir and the air
conditioning compressor. Lift the gray
connector locks and disconnect the
38-pin connector pair and the 24-pin
connector pair (see Figure 38).
Figure 38
4. Insert the male 38-pin connector
on the EconoMind harness into the
female 38-pin connector on the
factory harness. Insert the female
38-pin connector on the EconoMind
harness onto the male 38-pin
connector of the factory harness.
Repeat this process with the 24-pin
connectors (see Figure 38).
5. Connect the thermocouple
leadwire to the EconoMind harness
with the supplied nuts and bolts.
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.
Mounting The Banks
EconoMind Diesel Tuner
6. The EconoMind is to be installed
under the hood on the outside of
the fuse box, with the wire harness
facing towards the rear of the vehicle
(see Figure 39). Make sure the
outside of the fuse box is free of oil,
grease and dirt.
7. With the Banks EconoMind Diesel
Tuner positioned next to the fuse
box, peel the protective backing
from the hook and loop interlocking
fasteners attached to the Banks
EconoMind Diesel Tuner. Position the
bottom edge of the Banks EconoMind
Diesel Tuner approximately a half
inch above the main wiring harness
exiting the fuse box, then press the
adhesive onto the outside of the
fuse box. Apply light pressure to
the Banks EconoMind Diesel Tuner
by hand for 60- seconds to create
a strong bond between the fuse
box and hook & loop interlocking
fasteners. Using the supplied cable
ties, secure the wire harness away
from any heat sources or moving
components.
-end, section 5-
32
96776 v.11.0
Figure 39 Driver’s side of engine compartment
Section 6
Mounting the Docking Station and Connecting the Banks PowerPDA
Vehicle Command Center
Section 6 not needed if installing
the Power Level Selector Switch.
Please proceed to Section 7.
Note: This system has been
designed for use with the Palm
Tungsten E2 PDA.
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
Figure 40
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. For mounting location see
Figure 40.
Note: In cold climates, best
results will be obtained if the
vehicle’s heater is run to bring the
inside temperature up to “room
temperature” (at least 68°F).
1. Clean mounting area with
supplied alcohol swab to prepare the
surface for the adhesive tape.
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 40. 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. Locate the two self-drilling screws
supplied in your kit.
6. Install the screws through the
two access holes in the right side
of the Docking Station. Doing this
will put two permanent holes in the
dashboard panel. Be certain of the
location of the Docking Station before
installing the screws.
7. Two push-in plastic plugs are
provided to cover the two screw
access holes in the Docking Station.
Install the plugs at this time.
8. Locate the Banks OBD II Interface
Figure 41
Cable in your kit. This cable has
three connection points. Connect
the RED OBD II connector on the
Banks interface cable to the vehicle
OBD II connector. Use a cable tie as
shown in Figure 41 to secure the
Banks interface cable to the vehicle
OBD II connector. Next, connect the
6-pin connector on the Banks OBD II
interface cable to the 6-pin connector
on the EconoMind Tuner harness.
9. Finally, unclip the dashboard
panel, starting with the lower right
hand corner. (See Figures 42 thru
44) Pry and unclip as needed to
gain enough clearance to route the
RJ12 cable (simular to a telephone
connecter) behind the panel, along
its lower edge.
10. Locate the RJ12 connector
portion on the Banks interface cable
and pull enough cable through to
reach the bottom of the Docking
Station.
96776 v.11.0
33
11. Connect the RJ12 cable into the
Figure 42
left-most receptacle on the bottom of
the Docking Station.
Warning: The charging cable on
the Docking Station is designed
to supply a constant lowvoltage power source (+5VDC)
to the Banks PowerPDA Vehicle
Command Center 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.
Figure 43
12. Refit the dash panel by carefully
snapping it back into place. Tuck any
excess cable behind it for a clean
appearance.
13. Your Docking Station is now
installed and is ready for the Banks
PowerPDA Vehicle Command Center.
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. Reconnect the
ground cables to the vehicle batteries.
NOTE: There may be a snug fit when
installing the Banks PowerPDA into
the Docking Station. Take care not to
force this process.
-end, section 6-
34
96776 v.11.0
Figure 44
Section 7
Installation of the Power Level Selector Switch
Section 7 not needed if Banks
PowerPDA will be installed. Please
proceed to Section 8.
Figure 45
CAUTION: Do not use force
when working on plastic parts.
Permanent damage to the part
might result.
1. The Power Level Selector switch
will be installed on the driver’s side
of the instrument panel (IP) next to
the steering column (see Figure
45). Carefully remove the IP from
the dashboard by slowly pulling
outwards from the dashboard
around the edges of the IP, allowing
the mounting pins to pull free from
their dashboard sockets. Automatic
transmission equipped vehicles will
need to set the parking brake and
move the shift lever down to the
lowest gear to allow clearance for
instrument panel removal.
Figure 46 Power level selector switch template
�
96776 v.11.0
35
2. Cut out the supplied template (see
Figure 46) and align the template
onto the rear of the IP, squarely
seating it on the top of the IP
mounting pin (see Figure 47).
3. Using a 3⁄ 8” Uni-bit, 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.
4. On the front side of the IP, align
the Power Level Selector Switch label
onto the previously drilled hole (see
Figure 48).
36
96776 v.11.0
Figure 47
Figure 48
5. Remove the nut and internal
tooth washer from the Power Level
Selector Switch. Rotate the shaft
counter clockwise until the shaft
stops. Verify the locating washer tab
is inserted into the #6 position on the
switch (see Figure 49).
NOTE: If the washer is in any position
other then the #6, your EconoMind
Tuner will not select power levels
properly.
6. After confirming the locating
Figure 49
washer is in the #6 location, install
the switch through the 3⁄ 8” hole
on the backside of the instrument
panel. 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 washer; be careful not to
over torque the nut and damage the
plastic threads.
7. Install the knob onto the shaft
facing the #1 Level on the Power
Level Selector Switch label. On the
knob, snug the two (2) set screws
with the supplied 0.050” hex key
wrench.
8. Route the Power Level Selector
Switch cable down to the EconoMind
Tuner’s three-connector cable
underneath the dashboard, and
reinstall the IP to the dashboard.
9. Connect the Power Level Selector
Switch Cable’s 2-pin receptacle to
the 2-pin plug on the EconoMind
Tuner’s grey three-connector cable.
-end, section 7-
96776 v.11.0
37
Section 8
Optional Gauge Cluster Installation
If not installing optional gauges,
Skip to next section.
1. Choose a suitable location under
the lower edge of the dash for the
mounting of the instrument panel
provided where the driver can
conveniently view it.
Note: Molded pillar mount and
additional gauges are available
through Gale Banks Engineering.
2. Using the panel as a template,
drill two 3⁄ 16” diameter holes in the
dash and mount the panel with the
supplied machine screws, nuts and
star washers provided.
3. Locate the supplied EconoMind
wire loom with the 4-pin connector.
Connect the 4-pin connector on
the EconoMind wire loom to the
connection labeled DYNAFACT
Gauges on the EconoMind wiring
harness. See Figure 36.
4. Install the DynaFact boost and
pyrometer gauges in the mounting
panel using the clamps and
thumbnuts provided. Plug the BLACK
wire lead to the male spade terminal
on the BLACK wire of each gauge
wire harness. Plug the YELLOW wire
into the Yellow wire of the boost
gauge wire harness and the RED wire
into the RED wire of the pyrometer
gauge wire harness. The ORANGE
wire remains unused.
5. Connect the 4-pin connector
of each gauge into the back of its
corresponding gauge.
a.Crimp the remaining Black and
RED wires from each 4-pin
connector gauge harness to the
butt connectors as shown in
Figure 50.
b. Strip one end of the RED wire and
crimp it to the butt connector
containing the RED wires from
step ‘a’.
c. Strip one end of the BLACK wire
and crimp it to the butt connector
containing the BLACK wires from
step ‘a’.
d. Route the RED wire to the fuse
box. Locate the appropriate
fuse for instrument lighting in
the owner’s manual. Cut the
RED wire as required and strip
the end. Crimp the push on
connector to the RED wire and
connect to the fuse as shown in
Figure 50. Alternatively, locate
power wire to dimmer switch and
install T-tap. Cut the RED wire as
38
96776 v.11.0
required and strip the end. Crimp
the push on T-tap connector to
the RED wire and connect to
T-tap on dimmer power wire.
e. Locate a metal surface that will
serve as an acceptable chassis
ground. Cut the BLACK wire to a
sufficient length that will allow
it to reach the chassis ground
and strip the end. Crimp the ring
terminal to the BLACK wire as
shown in Figure 50.
Figure 50
f. Drill a 1⁄ 8” hole, if required, to
attach the ring terminal to the
chassis ground. Caution: If
drilling, check the backside
to make sure there are no
components that may be
damaged by drilling.
g. Use the supplied self-tapping
screw to secure the ring terminal
to the chassis ground
-end, section 8-
Section 9
Automatic Transmission Learning
NOTE: Please refer to the Banks
PowerPDA Software & Installation
Kit, Owners Manual for software
installation and operation instruction
before beginning Section 9,
Automatic Transmission Learning.
The 6.6L GM Duramax Trucks
equipped with the Allison 1000
5-speed automatic overdrive
transmission use adaptive shift
control logic. This will require
the transmission to adapt to the
additional power created by the
Banks Power products before it will
shift properly. Failure to follow the
sequence can result in damage to the
transmission. Perform the following
sequence at a location where it is
safe to accelerate without exceeding
the posted speed limit.
1. With the power selector on level
one, start the truck and allow the
engine to reach normal operating
temperature.
2. Switch to power level two.
3. Drive vehicle in power level two
for 5 to 10 miles ensuring a complete
shift cycle though each gear. (The
transmission shift adaptation learning
process requires 15 to 30 complete
shift cycles to learn new shift
program.)
4. Repeat step 3 for each power
level.
WARNING: Take particular care
not to do wide open runs in
5th gear when in Automatic
transmission Learning Mode. The
Allison 1000 5-speed automatic
transmission will continually
adapt to the power output of
the engine to optimize shift
quality. The transmission will
quickly adapt to the power
setting if the driving cycle
includes regular gear changes
at high loads. The transmission
learning procedure will need to
be repeated when switching back
to the higher power settings once
the transmission adapts to the
lower power settings. It will be
apparent when the transmission
adapts to the lower settings
by monitoring the feel of the
gearshift. Gear changes will be
noticeably harder when initially
switching from a higher to lower
power setting. This will soften as
the transmission adapts to the
new setting.
-end, section 9-
96776 v.11.0
39
Section 10
Troubleshooting, EconoMind
Using The Banks PowerPDA
Vehicle Command Center
Check the Banks PowerPDA’s
Status Indicator for the “OK” icon.
Any EconoMind Tuner fault will be
indicated by the “Banks Engine” icon
(see Figure 51) and its cause can
be investigated by going to the ‘Self
Diagnostics’ screen and scrolling
through the list of logged tuner
events.
that event is highlighted. Each key
cycle of the vehicle produces a
minimum of two logged events.
Figure 53
• No LEDs will illuminate if the fuse
on the EconoMind wiring harness is
blown or the wiring harness is not
properly connected. If the fuse and
all connections are okay, contact
Banks Technical Service.
Figure 51
EconoMind
TUNER icon
1. Press the center button on the 5way navigator to take you to the
System Menu screen.
2. Touch the button labeled ‘More>’
to move to the second screen of the
System Menu.
3. Next, touch the ‘Self Diagnostics’
button. (See Figure 52)
Figure 52
5. Touch the button labeled ‘Down’
to scroll down through the recorded
events.
6. Touch the button labeled ‘Up’
to scroll up through the recorded
events.
7. Touch the ‘Back’ button to return
to the System Monitor screen.
Diagnosing EconoMind error
codes without the PowerPDA.
If you feel that your Banks EconoMind
Diesel Tuner is not functioning
properly, some diagnostics can be
performed. Your EconoMind Diesel
Tuner is equipped with diagnostic
features that will detect and display
certain errors.
4. The ‘Self Diagnostics’ screen
displays a log of diagnostic events
related to the EconoMind tuner (See
Figure 53). 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
40
96776 v.11.0
• The GREEN LED will flash if all wire
connections are correct, the engine
is running, but the engine coolant
temperature is not within its normal
operating range. The GREEN LED will
stop flashing once the engine coolant
temperature is within its normal
operating range.
Remove the Banks EconoMind Diesel
Tuner from its mounting location
while keeping all connectors plugged
in, and position it in such a way
that you can view the end of the
EconoMind housing that contains
the LEDs from the driver’s seat. Turn
the vehicle key to the ON position.
Observe the two LEDs mounted on
the end of the Banks EconoMind
Diesel Tuner:
• A steady GREEN LED will illuminate
if all wire connections are correct,
the engine is running, and the engine
coolant temperature is within its
normal operating range.
• The RED LED will flash in a certain
sequence if a connection is incorrect
of if there is a problem with the
system – this sequence will identify
one or more diagnostic codes. A
Banks EconoMind 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
common diagnostic codes. For
example, if a faulty thermocouple
is detected (code “2,3”) by the
Banks EconoMind Diesel Tuner, the
following red and green LED flashing
sequence is observed when the key
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 light.
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.
-end, section 10-
Table 1 Banks EconoMind Diagnostic Codes
Code
Event
Course of Action
1,1
Fuel Rail Pressure (FPR) Input
Voltage Out of Range
Turn ignition OFF and check the 24-Pin and 38-Pin connectors. Turn
ignition back ON and re-check for presence of code.
1,2
Manifold Absolute Pressure
(MAP) Input Voltage Out of
Range.
Turn ignition OFF and check the 24-Pin and 38-Pin connectors.
Turn Ignition back ON and re-check for presence of code.
1,3
EconoMind Switch Input Value
Out of Range
Turn ignition OFF and make sure either Banks PowerPDA orEconoMind
switch is connected to EconoMind tuner. If EconoMind 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.
1,4
(LB7) Barometric Pressure Input
Voltage Out of Range
(LLY) Barometric Pressure CAN
Signal Not Available
Turn ignition OFF and check the 24-Pin and 38-Pin connectors. Turn
ignition back ON and re-check for presence of code.
2,1
Fuel Rail Pressure (FPR) Output
voltage Out of Range.
Turn ignition OFF and check the 24-Pin and 38-Pin connectors.
Turn ignition back ON and re-check for presence of code.
2,2
Manifold Absolute Pressure
(MAP) Output Voltage Out of
Range.
Turn ignition OFF and check the 24-Pin and 38-Pin connectors.
Turn ignition back ON and re-check for presence of code.
2,3
Exhaust Gas Temperature (EGT)
Sensor Open Circuit.
Turn ignition OFF and check both thermocouple ring-terminal
connections. Turn ignition back ON and re-check for presence of code.
2,4
(LB7) OBD Signal Malfunction
Turn ignition OFF and check OBD connector and cable. Turn ignition back
ON and re-check for presence of code.
3,1
Crankshaft Position (CKP)
Strand Fault or Internal Module
Malfunction.
Turn ignition OFF and check the 24-Pin and 38-Pin connectors.
Turn ignition back ON and re-check for presence of code.
3,2
Power Up Error or Internal
Module Malfunction
Turn ignition OFF and check the 24-Pin and 38 Pin connectors. Turn
ignition back ON and re-check for presence of code.
3,3
Low Battery Voltage or Internal
Module Malfunction.
Turn ignition OFF and check the 24-Pin and 38-Pin connectors. Turn
ignition back ON and re-check for presence of code.
3,4
CAN Communications Error with
Vehicle.
Turn ignition OFF and check the 24-Pin and 38-Pin connectors.
Turn ignition back ON and re-check for presence of code.
4,1
Injection Control Signal Fault or
Internal Module Malfunction
Turn ignition OFF and check the 24-Pin and 38-Pin connectors.
Turn ignition back ON and re-check for presence of code.
4,2
Transmission slippage Detected
Transmission is slipping excessively. Code will automatically clear once
transmission stops slipping (repaired).
5,1
Internal Module Malfunction
Turn ignition off. Turn ignition back ON and re-check for presence of code.
If problem persists, call Gale Banks Engineering Tech Support.
96776 v.11.0
41
Section 11
Clearing Learned Parameters
If the Banks EconoMind Diesel Tuner
has been moved to a different
vehicle, or you are instructed to
do so by Banks Technical Staff,
it is possible to reset all of the
parameters that the EconoMind has
‘learned’.
1. Turn the vehicle key to ON but DO
NOT start the engine.
CAUTION: The following
procedures can only be carried
out with the engine OFF!
3. Turn the key OFF. Wait 30
2. Fully depress the throttle pedal
and then release it completely.
Repeat 5 times. The GREEN LED
will flash when this is completed
successfully.
off and stays off. Turn the key back
to the ON position but DO NOT start
the engine.
4. Fully depress the throttle pedal
and then release it completely.
Repeat 5 times
-end, section 11-
seconds, or until the GREEN LED goes
Section 12
Updating Your Banks PowerPDA Software & Banks EconoMind Diesel Tuner Firmware
The Banks PowerPDA is designed
such that new software updates
can be easily installed. Check the
BanksPower web site at <http://
www.bankspower.com/downloads>
for the latest version of the Banks
PowerPDA software. Once you have
determined that your Banks PowerPDA should be updated, follow the
instructions on the page for the appropriate software update.
The Banks EconoMind Diesel Tuner
is designed such that new firmware
updates can be easily installed. Check
the BanksPower web site at <http://
www.bankspower.com/downloads>
for the latest version of the Banks
EconoMind Diesel Tuner firmware.
Once you have determined that your
Banks EconoMind Diesel Tuner should
be updated, follow the instructions on
the page for the appropriate firmware
update.
END, SECTION 12-
Section 13
Removal of the EconoMind Diesel Tuner
If the Banks EconoMind Diesel Tuner
should ever need to be removed
from the vehicle, perform the
following:
1. Disconnect the EconoMind’s
38-pin connector from the factory
harness.
2. Re-connect the vehicle’s 38-pin
connector back into the factory
harness.
3. Disconnect the EconoMind’s
24-pin connector from the factory
harness.
42
96776 v.11.0
4. Re-connect the vehicle’s 24-pin
connector back into the factory
harness.
5. Disconnect the 2-ring terminals
from the EGT thermocouple.
6. Disconnect the 3 small connectors
on the ‘In-Cab Cable’ and gently pull
the cable back through the firewall.
7. Remove the Banks EconoMind
Diesel Tuner.
Note: Failure to follow the above
instructions when removing the
module 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.
-end, section 13-
Section 14
Filter Maintenance
Notification
The Banks Ram-Air Filter comes
pre-oiled and no oiling is
necessary for initial installation.
Service the filter as specified in
this Section of the manual.
1. Service Banks Ram Air Filter every
50-100,000 miles on street-driven
applications. Service more often in
off-road or heavy-dust conditions.
If an air-filter restriction gauge is
installed, then clean the element
when the air-filter restriction gauge
enters the restrictive red zone. See
Figure 54.
Figure 54 Typical air-filter restriction gauge
AIR-FILTER
RESTRICTION
GAUGE
RESTRICTIVE
RED ZONE
2. Use Banks Ram Air Filter cleaning
system (part # 90094), available from
Gale Banks Engineering to service
the Air Filter. Follow the instructions
included with the cleaning system
to clean and re-oil your Banks Ram
Air Filter. No gasoline cleaning, No
steam cleaning, No caustic cleaning
solutions, No strong detergents, No
high pressure car wash, No parts
cleaning solvents. Any of these No’s
can cause harm to the cotton filter
media plus SHRINK and HARDEN the
rubber end caps.
CAUTION! Extremely fine dust
from agriculture or off-road
use will pull the oil from the
element. Frequent re-oiling of
the element’s clean side might
be required. Completely service
when practicable. For extra
protection use an air-filter sealing
grease on rubber ends of the
element. Service only with Banks
Ram-Air-filter cleaner and Banks
Ram-Air-filter oil.
-end, section 14-
96776 v.11.0
43
Section 15
Placement of the Banks Power Decals
Figure 55
TYPICAL LEFT FENDER PLACEMENT
TYPICAL LEFT FENDER PLACEMENT
TYPICAL RIGHT FENDER PLACEMENT
TYPICAL RIGHT FENDER PLACEMENT
44
96776 v.11.0
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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