96308 Sidewinder-v2.indd
owners
manual
with installation
instructions
SIDEWINDER
®
TU R B O
FORD 6.9/7.3L DIESEL VANS
this manual is for use with systemS 21011 and 21019
gale banks engineering
546 duggan avenue • azusa, ca 91702
(626) 969-9600 • fax (626) 334-1743
Product Information & Sales: (800) 438-7693
www.bankspower.com
©2009 gale banks engineering
02/03/09
p.n. 96308 V.2.0
BANKS SIDEWINDER® TURBO
FORD 6.9/7.3L DIESEL VANS
Dear Customer:
You have just purchased the finest, most technologically advanced turbocharging system
available for light truck diesel engines. GALE BANKS ENGINEERING has utilized the knowledge
and experience gained through more than fifteen years of turbocharged engine design to
combine performance, durability and good looks into a professional quality turbocharger kit. Best
performance and installation of your system will be realized by thoroughly reading and following
the installation instructions before and throughout the installation.
Your Sidewinder turbocharger system operates by utilizing the engine’s exhaust gasses to spin
a turbine wheel, which in turn drives a compressor through a common shaft. The compressor
draws air through the air cleaner and forces it into the engine at a greater density and pressure
than that which the atmosphere would normally provide. This additional air will burn more
completely the available fuel, or additional fuel, resulting in greater performance and efficiency.
The volume and pressure (boost) that the turbocharger puts out is controlled by the size of the
turbocharger in relation to the size of the engine, the position of the accelerator and the load on
the vehicle. A small amount of engine oil is fed to the turbocharger shaft assembly to lubricate
the shaft bearings, and then returned to the engine. Your GALE BANKS ENGINEERING turbo
system is legal in all 50 states when used with the Banks 3” exhaust system — CARB E.O. No.
D-161-2.
We at Gale Banks Engineering are confident that you will be pleased with the performance of
your turbocharged diesel and hope we may be of service in the future.
Thank You,
IMPORTANT
To obtain optimum performance from your BANKS
turbocharger system, it is necessary to make an
adjustment to the fuel injection pump. This adjustment
is easily made by following the enclosed instructions.
However, it is extremely important that the
instructions be followed very carefully. Before starting
the injection pump adjustment procedure, please note
the following:
bolt). Do Not Rotate The Crankshaft
Using The Starter, for any reason. Even
though the fuel solenoid is de-energized, the
engine can still start. This is extremely
hazardous and can result in both severe
personal injury and major mechanical
damage. Again when making the injection
pump adjustment, Do Not Rotate The
Crankshaft Using The Starter.
1.The engine must be Cold (preferably
overnight) before starting the injection pump
adjustment procedure. Do Not attempt to
turn the engine over or adjust the injection
pump while the engine is warm.
3.
If you removed the front crankshaft pulley to
gain access to the vibration damper bolt, be
sure to reinstall the pulley (and belts) before
starting the engine.
2. To gain access to the injection pump adjusting
screw, it is necessary to rotate the engine
crankshaft, so that the screw is properly
positioned. As noted in the instructions, the
crankshaft is rotated by hand, In The
Clockwise Direction Only, by turning
the vibration damper mounting bolt using an
appropriate socket, extension and breaker
bar. (On some late model trucks it may be
necessary to remove the front crankshaft
pulley to gain access to the vibration damper
2
P.N. 96308 V.2.0
FIGURE 1
SEE PAGE 21 FOR PARTS LISTING
3
P.N. 96308 V.2.0
FIGURE 2
SEE PAGE 21 FOR PARTS LISTING
4
P.N. 96308 V.2.0
general Installation practices
The locknuts should be installed as shown in
Figure 3. The nuts will spin on freely and lock only
when tightened.
For ease of installation and trouble-free
1. operation of your BANKS turbocharger
system, PLEASE READ THIS ENTIRE 24-PAGE
INSTRUCTION PACKAGE BEFORE STARTING ANY
WORK. If any pages are missing from this package,
please call GALE BANKS ENGINEERING
immediately for a replacement.)
FIGURE 3
Become thoroughly familiar with all components
and phases of the installation. Determine what
additional tools or materials you may need to
complete the installation, and at what stages you
will require welding, if it is to be done by other
than yourself.
Inspect all components supplied for any
2. foreign material that may have entered
Muffler and exhaust piping are not included
8. with this kit. An exhaust parts kit containing
during shipping and handling. Wash all fuel and oil
hoses with solvent and blow dry with compressed
air before assembly. Inspect all castings for
damage resulting from shipping. Check all
machined surfaces for nicks or other damage.
Clean all castings with solvent and blow dry with
compressed air prior to assembly.
these components is available separately from
GALE BANKS ENGINEERING. The BANKS 3” exhaust
system is required for emissions legal installation.
General assembly diagrams are provided in
9. addition to the specific step or section
diagrams in the text. General assembly diagrams
show relationships of individual components for
reference; however, numbered step-by-step
procedures should be followed for proper
assembly sequence.
Any time the vehicle is raised off its wheels,
3. it should be supported by jack stands or
ramps of adequate capacity for the vehicle’s
weight. NEVER PERFORM ANY WORK UNDER A
VEHICLE SUPPORTED ONLY BY ITS BUMPER OR
HYDRAULIC JACK.
Right-hand and left-hand designations refer
10. to the driver’s right or left, as seated in the
Use the Teflon tape provided on all pipe
vehicle, (i.e.: Right-hand refers to the passenger
side of the vehicle, unless noted otherwise. “FWD”
in illustrations refers to “FORWARD”, or “FRONT
OF VEHICLE”.
4. thread connections. Hold tape back from
the first two threads of the fitting so tape will not
flake off into the fluid. (This is especially critical on
oil lines.)
ALL BANKS components are designed,
11. tested and manufactured to standards far
All threads to be secured with Loctite must
5. be clean, dry and free of any oil or grease.
Clean threads with lacquer thinner as required.
exceeding factory OEM specifications. However,
due to normal variations in production vehicles, it
may be necessary to slightly modify some
exhaust-system components for proper fit.
Pay particular attention to the routing of all
6. hoses and wiring. Keep them away from
NOTE: All parts are furnished in kit unless noted
otherwise.
exhaust heat, moving parts and sharp edges that
may cause cuts or other damage. Route or tie
hoses away from critical areas as required. Keep
all hoses a minimum of 1” from hot exhaust parts;
11⁄ ” or more is recommended whenever possible.
Notification:
The Banks Ram-Air Filter comes preoiled and no piling is necessary for
initial installation. Service the Filter
as specified in the Cleaning and Oiling
the Banks Ram-Air Filter Section of this
manual.
2
7. Collet stainless steel locknuts are used on
the studs in the turbine mounting bracket.
5
P.N. 96308 V.2.0
general Installation
LEVEL 1: Exceeds 30 percent increase in rear
wheel horsepower. Suitable for general use, work
trucks and towing. Recommended for heavy loads
and most applications. (This is the ONLY emissions
legal setting.)
Remove engine cover. Disconnect ground
1. cables from both batteries. Disconnect
electrical connections from top of injection pump.
plastic air inlet duct. Remove air
2. Disconnect
cleaner housing and element. Leave plastic
LEVEL 2: Approximately 50 percent increase in
rear wheel horsepower. For high performance
use. (This setting is NOT emissions legal.)
air inlet duct in place for engine compartment
cooling.
Disconnect wire from oil pressure sender
3. unit, located on rear of engine.
NOTE: Exhaust gas temperature (EGT) must not
exceed 1150°F, as shown on the EGT gauge
(pyrometer) furnished with the kit. If the EGT
approaches this temperature under heavy, uphill
load, the fuel pump capacity adjustment must
be reduced. The level one pump setting will
cause no problem, very rarely approaching this
temperature.
Remove oil pressure sender unit and fitting
4. from rear of engine. Retain sender for later
installation.
Install 1⁄ ” NPT brass pipe plug in hole at rear
5. of
block where oil pressure sender unit and
8
fitting were removed. Use Teflon tape on threads.
Adjust injector pump delivery for desired
8. application, as follows:
Automatic Transmission Vehicles
6. On
Only, remove steel tube connected to
transmission modulator valve.
NOTE: The engine must be COLD before starting
this procedure.
Remove oil fill-pipe from front of engine.
7. (Note: 1987 models use an inspection cover
NOTE: Utmost cleanliness should be exercised.
DO NOT allow any foreign material, including lint
from rags, to enter the injector pump during the
adjustment procedure — the lint from a rag can
clog an injector. Lay any removed parts on a clean
newspaper during the adjustment procedure.
plate, remove cover plate). See Figure 4.
INJECTION PUMP ADJUSTMENT
FIGURE 4
A.Place a drip pan under the rear of the engine,
under the flywheel inspection cover area, to catch
spilled fuel. Clean the area of the pump in the
vicinity of the small access cover, located on the
left side of the pump, as viewed from the front of
the vehicle, with diesel fuel or parts solvent. DO
NOT clean the pump while it is hot; doing so
may damage the pump.
B. Remove the cover plate, retained by two small
screws. Use care not to damage the rubber
gasket; it will be reused during reassembly.
IMPORTANT: Utmost care must be used to
prevent foreign objects and dirt from falling into
the pump to prevent damage.
To obtain the maximum available performance
from your Sidewinder turbo system, it is necessary
to make an adjustment to the fuel injection pump.
The pump adjustment increases the fuel delivery
capacity of the pump. This adjustment is made by
turning an internal screw, found within the pump.
The pump is infinitely adjustable from the standard
setting to an approximately 50% increase in
power. BANKS recommends one of two settings,
as follows:
C. Rotate engine by hand, in a clockwise direction,
using a breaker bar, short extension and suitable
socket on the harmonic balancer retaining bolt.
Align the injector drive pin, as viewed through the
opening for the oil fill pipe, in a straight up (12
o‘clock) position. Using a small mirror, check that
the allen head adjustment screw is visible within
the inspection hole. It may be necessary to rotate
the engine somewhat more to gain access to the
adjusting screw. See Figures 5 and 6. Do Not
Attempt To Rotate The Engine With The
6
P.N. 96308 V.2.0
9. Reroute the injector return hoses. Refer to
Starter.
Figure 7, which shows how the return lines
should be routed. Remove and install necessary
components as required to complete the system
as shown. (Additional hose is provided for the
rerouting.) Note that there should be a minimum
of four inches clearance between the injector
return line and the turbine housing or turbo
mounting bracket when turbo is installed.
D. Using a 5⁄ ” allen wrench (with sharp corners),
rotate the screw to obtain the desired
performance level:
LEVEL 1: 1⁄ turn, clockwise
LEVEL 2: 3⁄ turn, clockwise
32
4
8
NOTE: The allen screw turns fairly tightly and
is self locking. Turning the screw clockwise
increases fuel delivery capacity. Keep track of
your adjustments.
On Automatic Transmission Vehicles Only, also
be sure that the new injector return hose does
not interfere with the transmission kickdown
linkage.
E. Replace access cover on pump. Again exercise
care to prevent foreign material from entering
pump.
10. Remove the engine lifting lug from left rear
of the intake manifold. Replace bolts with
new 3⁄ ”-16 x 21⁄ ” hex head bolts provided, and
original washers. (Do not use original bolts or
reinstall lifting lug.).
8
F. Wipe up any spilled fuel remaining on valley
cover. This completes the pump adjustment
procedure.
2
11. Remove the engine lifting lug from left rear
of the intake manifold. Retain the bolts for
later installation.
FIGURE 5
12. Remove the crankcase anti-depression valve
(the round sheet metal can be attached to
the rear of the intake manifold). Remove standpipe
and grommet from valley cover. (Standpipe may
come out attached to anti-depression valve.) Retain
anti-depression valve and mounting bolts for later
installation. Note, 1987 models: Remove short
length of hose and clamp from anti-depression
valve.
Carefully clean around the hole where the
13. original grommet was installed at the rear
of the valley cover and where the anti-depression
valve was mounted on intake manifold. (Use
acetone, lacquer thinner or other non-oil based
solvent.).
grommet in valley cover as follows.
14. Install
Fill grommet groove with RTV silicone
FIGURE 6
7
P.N. 96308 V.2.0
sealer provided. Press grommet through opening
in valley cover and smooth RTV around grommet.
Remove excess RTV. See Figure 8.
the dipstick tube. Then unbolt the transmission
dipstick tube at the bellhousing and remove the
dipstick tube from the transmission. Retain all
these components for later installation. Cover
the dipstick tube opening with a clean rag, paper
towel or tape to prevent contamination from
entering the transmission. Reinstall bellhousing
bolt.
rubber o-ring in groove in manifold
15. Install
block-off plate. See Figure 8.
Install manifold block-off plate (and o-ring)
16. on intake manifold where anti-depression
valve was removed, using two 5⁄ ”-18 x 1” hex
head bolts and split lockwashers. See Figure 8.
16
19. 1987 models, glow plug relay relocation:
A. On 1987 models, unbolt the glow plug relay from
the rear of the intake manifold (leave wire loom
attached to relay. Remove cable clamps holding
wire loom to rear of engine. Disconnect relay
ground wire from engine.
exhaust head pipes and exhaust
17. Remove
system, including mufflers and tailpipe.
On Automatic Transmission Vehicles
18. Only, remove the transmission dipstick from
FIGURE 7
FIGURE 8
8
P.N. 96308 V.2.0
NOTE: Oil feed line to block must go under injector
tubing loop at rear-most injector.
B. Remove the two intake manifold bolts located
between the third and fourth fuel injector (counting
from the front to the rear) on the right (passenger)
side of the engine. See Figure 9.
Connect oil feed hose to elbow installed in
25. step 21.
C. Mount the glow plug relay to the glow plug relay
bracket (provided) using two 1⁄ ”-20 x 1” hex
bolts, two 1⁄ ” O.D. x 1⁄ ” I.D. washers, and two
1
⁄ ”-20 nylock nuts. Clamp the relay ground wire
under one of the nuts. See Figure 9.
4
2
Lengthen the oil pressure gauge sender
26. wire as follows:
4
4
Cut the plug from the wire loom leaving 2-3
inches of wire attached to the plug. Lengthen the
wire from the loom as required using wire and
connector provided in the kit. Route the wire in
front of the intake manifold air inlet opening to
the gauge sender. Keep wire clear of any moving
parts. Note: Connectors squeeze together onto
the wire with pliers. Re-install plug on sender.
D. Install the bracket and relay on the
intake manifold using the intake bolts
and washers removed in section B.
Route the wiring as shown in Figure 10.
Plastic clips may be removed from wire loom
jacket as required for rerouting wiring.
pipe plug for oil feed connection,
20. Remove
located on lower left side at rear of block,
Tie wrap glow plug wiring and throttle cable
27. at rear of intake manifold (snugly but not
above and to the rear of the oil filter. See Figure
11.
tight enough to cause binding or kinking). See
Figure 13.
Install 1⁄ ” NPT x -4AN turbo oil feed elbow
8
21. in block. Aim elbow at approximately one
one 6 x 14” heat blanket into one piece
28. Cut
6 x 6” and one piece 8 x 6”. Wrap one 8 x
o‘clock position. See Figure 11.
6” piece around the glow plug wiring and throttle
cable near turbine housing. Secure using wire ties
provided (See Figure 14). Save the other pieces
for later installation (to be used around hoses for
rear heater and/or air conditioning where close to
exhaust).
oil feed hoses onto oil feed line tee.
22. Install
Use Teflon tape on threads. See Figure 12.
Install oil pressure sender onto oil feed line
23. tee. Use Teflon tape on threads. See Figure
12.
Cut ear off of right side of transmission bell
29. housing, using a hacksaw. See Figure 15.
oil feedline tee on intake manifold,
24. Install
using rear-most intake manifold mounting
bolt hole, on the left side. Use original bolt and
washer. Replace the other left rear manifold bolt
with one new 3⁄ ”-16 x 21⁄ ” hex head bolt and
original washer.
8
2
FIGURE 9
9
P.N. 96308 V.2.0
FIGURE 10
1987 ONLY
FIGURE 11
Install the pyrometer adapter fitting (from
30. the pyrometer kit) into the 1⁄ ” NPT threaded
4
hole in the turbo mounting bracket.
four 3⁄ x 11⁄ ” studs in the rectangular
31. Install
pad on the turbo mounting bracket. Note
8
2
that the coarse threads on the studs fit into the
turbo mounting bracket.
Install two 3⁄ x 2” studs in the circular pad
8
32. on the turbo mounting bracket. Again note
that the coarse threads on the studs fit into the
turbo mounting bracket.
turbo on turbo mounting bracket,
33. Mount
using four 3⁄ ”-24 stainless steel collet nuts
8
and four 5⁄ ” OD x 3⁄ ” ID flat washers. No gasket
is required (See general notes on collet lock nut
installation, Figure 3).
8
8
Remove the plastic caps
34. IMPORTANT:
from the turbocharger oil inlet and
outlet connections.
Use gasket adhesive (“Gasgacinch” or
35. similar)
to attach the oil drain tube gasket
to the oil drain tube. Place a small bead of RTV
silicone sealer around the oil drain tube about 3⁄ ”
up from the bottom, then insert the oil drain tube
into the grommet in the valley cover.
8
16).
the turbo mounting bracket and
36. Position
turbocharger in place at the rear of the
38
Install the other two bolts in the bolts in the
38. turbo mounting bracket (one 3⁄ ”-16 x 11⁄ ”
8
14
right hand cylinder head. Start one ⁄ ”-16 x 1 ⁄ ”
hex head bolt, two or three turns, through the top
mounting hole in the turbo mounting bracket, into
the head.
4
hex head and one 3⁄ ”-16 x 1” hex head; short bolt
goes through thin corner of bracket). Leave bolts
loose enough to adjust turbo mounting bracket
position to suit.
8
Mount the oil drain tube in position on the
37. turbo, using two 3⁄ ”-16 x 1” hex head bolts
1
⁄ ” NPT x -4AN elbow in the oil inlet
39. Install
connection on the turbocharger. (The oil
4
8
38
and four ⁄ ” I.D. circle lock washers. (Circle lock
washers must be used in pairs as shown in Figure
inlet connection in the only 1⁄ ” NPT port on the
turbocharger). Aim the fitting as shown in Figure
4
10
P.N. 96308 V.2.0
housing bolts and the six compressor housing
bolts and rotating these parts slightly into the
proper position. Be sure to bend the locking
tabs over against the heads of the bolts after
re-tightening.
FIGURE 12
Remove pressure chamber from intake
42. manifold.
up the turbine heat shield and gasket
43. Line
on the turbocharger. You may use 5 ⁄ ”
16
studs, pins or bolts with heads removed to ease
the installation.
turbo down tube on the turbocharger,
44. Install
using six 5⁄ ”-18 x 7⁄ ” stainless steel hex
16
8
head bolts and 9⁄ ” OD x 5⁄ ” ID flat washers. Make
sure gaskets and heat shield are properly in place.
16
16
Y-pipe extension on turbo mounting
45. Install
bracket, using two 3⁄ ”-24 stainless collet
8
lock nuts and two 13⁄ ” O.D. x 3⁄ ” I.D. flat washers.
Leave nuts loose enough to move extension tube
as required for alignment.
16
17. Use Teflon tape on the pipe threads
8
Y-pipe assembly onto engine exhaust
46. Install
manifolds and Y-pipe extension. Do not install
Place air inlet gasket and pressure chamber
40. in position on the intake manifold. Make
U-clamps.
sure the pressure chamber touches and sits
squarely on the gasket.
47. Tighten Y-pipe extension collet lock nuts.
up turbo compressor discharge with
41. Line
pressure chamber hose joint, lifting the
Install two 21⁄ ” exhaust U-clamps on slip
48. connection
joining Y-pipe and Y-pipe
2
turbo slightly for proper alignment. Tighten the
top bolt in the turbo mounting bracket, then the
other two. Scribe the pressure chamber and front
of the intake manifold air inlet opening, across the
gasket joint, for future reference. See Figure 18.
extension, 180° apart. See Figure 1.
holes and mount air cleaner assembly
49. Drill
on bracket on rear lip of hood opening with
four 1⁄ ”-20 nylock nuts. See Figures 2 and 19.
4
NOTE: If the turbocharger needs to be rotated
to correct misalignment, it can be easily aligned
by loosening, but not removing, the six turbine
Trim insulation material from underside of
50. hood, as shown in Figure 20.
FIGURE 13
FIGURE 14
11
P.N. 96308 V.2.0
FIGURE 15
FIGURE 16
FIGURE 17
FIGURE 18
12
P.N. 96308 V.2.0
Install two 3⁄ ”-16 x 1⁄ ” bolts in the top of the
threads.
51. pressure chamber. Use Loctite on threads.
8
2
Install 2” diameter x 2” long silicone hose
See Figure 21.
53. and two #36 hose clamps on turbocharger
If installing optional boost gauge, install
compressor discharge connection. Leave clamps
loose temporarily.
52. boost gauge fitting (supplied in boost gauge
kit) in pressure chamber.
pressure chamber (and gasket) on
54. Install
intake manifold, using one 3⁄ ”-16 x 4” hex
NOTE: Nut on fitting must be removed to allow
installation. Fitting should be aimed toward left
side of vehicle. Refer to Figure 21.
8
head bolt, 5⁄ ” OD x 3⁄ ” ID flat washer and 3⁄ ” ID
sealing washer. Be sure pressure chamber aligns
properly with scribe marks previously made.
8
If boost gauge will not be installed, substitute
1
⁄ ” NPT pipe plug, from kit. Use Teflon tape on
8
8
8
FIGURE 19
FIGURE 20
13
P.N. 96308 V.2.0
FIGURE 21
FIGURE 22
14
P.N. 96308 V.2.0
55. Tighten compressor discharge hose clamps.
in Figure 27. Because of various vehicle/chassis
combinations, the illustration provided is general,
but typical of the exhaust system routing.
Install turbo compressor air inlet elbow and
56. 3 x 13⁄ ” long silicone hose on compressor.
4
See Figure 1. Do not tighten clamps at this time.
NOTE: The factory muffler and exhaust system
are NOT suitable for turbocharged engines. The
entire exhaust system, from the turbo down-pipe
through to the tail pipe, should be three inch
diameter, including the muffler. Use of a smaller
muffler or exhaust piping will result in significantly
inferior performance. A separate 3” high-flow
exhaust system includes a special low restriction
3” core muffler, pre-formed tubing sections and
all components necessary to install the complete
exhaust system. The BANKS 3” exhaust system
is Required for emissions legal applications. Use
of any other exhaust with the turbo system is not
emissions legal.
Mount compressor air inlet elbow brace
57. on rear of left cylinder head, using one
38
⁄ ”-16 x 3⁄ ” hex head bolt and one 3⁄ ” split lock
washer. Install anti-depression valve, with hose
connection facing upward, on the air inlet elbow,
using original bolts and two 9⁄ ” OD x 5⁄ ” ID flat
washers and 5⁄ ”-18 nylock nuts. Be sure original
seal is in place on anti-depression valve mounting
surface. Remove existing o-ring and nylon sleeve
from the anti-depression valve hose connection
(through 1986 models). See Figures 1 and 22.
4
8
16
16
16
Tighten air inlet elbow hose clamps, at
58. turbocharger and elbow.
For those wishing to do their own exhaust system
fabrication, the following recommendations
should be followed (see Figure 28):
Connect oil feed hose to turbocharger oil
59. inlet elbow.
A. Be sure to use a high quality, low restriction 3”
core muffler, designed for turbocharged diesel
applications. (Most 3” mufflers available from
muffler shops are low quality, high restriction
“economy” replacement mufflers, usually based
on a 21⁄ ” or smaller core.)
Install 3” diameter flexible fresh air inlet
60. hose between air cleaner assembly and air
inlet elbow, using two #52 hose clamps.
and discard the hose clamp from
61. Remove
the heater hose connection on the water
2
pump. Hose clamp may be cut with snips to avoid
disconnecting hose.
B. Make all bends as gradual as possible. Align all
weld joints as carefully as possible so the exhaust
flow will not experience “steps” in the tubing.
degrease the oil fill-pipe flange
62. Thoroughly
face (injector pump drive cover flange face
C.Do not “cheat” bends or make miter-weld joints.
These types of bends are too abrupt for proper
exhaust flow.
on 1987 models) using acetone lacquer thinner or
other non-oil based solvent. Install the crankcase
vent hose adapter and oil fill-pipe (inspection
cover on 1987 models) using two 5⁄ ”-18 x 2” hex
bolts and two 5⁄ split lock washers. Use silicone
sealer on both flange surfaces. See Figure 23.
D. Maintain adequate clearance to chassis,
floorboards, driveline, moving suspension parts,
etc. Suspend exhaust tubing in rubber hangers to
allow for engine movement. The original hangers
may be reused if in good condition.
16
16
the hose clamp previously removed
63. Replace
from the heater hose with a No. 10 hose
clamp, provided in the kit. Keep the tail of the
hose clamp clear of the alternator drive belt. See
Figure 23.
Install a 9 x 24” heat blanket on turbo down-
68. pipe. Make sure top of pipe is covered by
the heat blanket. Secure using wire ties provided.
See Figure 24.
crankcase vent hose, from crankcase
64. Install
vent adapter nipple to anti-depression
Install a 7 x 24” heat blanket on Y-pipe
69. extension, sliding it up from the bottom, all
valve, using two #16 hose clamps, as shown in
Figure 23. Be sure that hose is installed with no
low areas that could cause oil puddling in the
hose.
the way up to the pyrometer fitting on the turbo
mounting bracket. Secure, again using wire ties.
See Figure 24.
pyrometer and gauge panel. Refer to
65. Install
manufacturer‘s instructions included with
70. blanket on hoses for rear heater and/or
Install remaining 6 x 8” piece of heat
pyrometer.
air conditioning if these hoses are routed near
exhaust.
accessory instruments, if used. Refer
66. Install
to manufacturer‘s instructions included with
Reroute the fuel injector return hose to the
71. left side of the transmission bellhousing. See
instruments.
Figure 22. Check to be sure the injector return
hose does not rub on any sharp edges.
muffler and exhaust system (not
67. Install
included with the turbo system) as shown
15
P.N. 96308 V.2.0
FIGURE 23
FIGURE 24
16
P.N. 96308 V.2.0
On Automatic Transmission Vehicles
FIGURE 25
72. Only: Bend transmission modulator vacuum
tube as shown in Figure 24, and then reinstall.
Make sure vacuum hose has at least one inch of
clearance to down-pipe heat shield.
Automatic Transmission Vehicles
73. On
Only: Modify and reinstall transmission
dipstick and tube. Attach tube to turbo mounting
bracket with one 3⁄ ”-16 x 1⁄ ” hex bolt and 3⁄ split
lock washer. See Figures 24 and 26.
8
2
8
On Automatic Transmission Vehicles
74. O n l y : R e r o u t e t h e t r a n s m i s s i o n
neutral safety switch wire to the left side
of the transmission bellhousing. Install the
6 x 14” heat blanket on Y-pipe near the neutral
safety switch/back-up light switch and wiring,
located on left side of transmission. See Figure
25.
75. Reconnect battery cables.
FIGURE 26
Loosen oil feed line connection at the
76. turbocharger. Crank engine until oil flows
from connection. Retighten connection and
crank until engine oil pressure gauge reading is
in normal range. Cranking time should be limited
to 20 to 30 seconds, followed by one minute
of cooling. This cycle should be repeated as
required.
77. Reconnect wires to injection pump.
check the installation for any
78. Visually
improperly installed components,
improperly routed wires and hoses, intake air
leaks and any wires or hoses too close to hot
exhaust, turbo components, or sharp edges.
Start engine. It may not start immediately,
79. due to fuel lost when adjusting the injector
pump. Observe the cranking recommendations
noted above. It also may be necessary to depress
the accelerator pedal somewhat.
]
Run engine at idle for a few minutes, to
80. allow it to warm. Check oil feed lines for
leaks. Engine may idle erratically or surge until air
is fully purged from fuel system.
81. Reinstall engine cover.
Drive vehicle. Several short bursts of
82. acceleration are required to completely
purge the fuel system of air. The engine may run
slightly rough until the purge is complete, but
will not in any way cause damage to the engine.
Check injector pump adjustment. See
83. ”CHECKING ENGINE PERFORMANCE“.
17
P.N. 96308 V.2.0
FIGURE 27
18
P.N. 96308 V.2.0
CHECKING ENGINE PERFORMANCE
Use your pyrometer (exhaust temperature gauge)
to monitor your engine’s operation. At idle
exhaust gas temperature (EGT) will be very low,
perhaps only 150°F. As the throttle is opened for
higher speeds and greater loads, the EGT will rise.
The highest EGT will be seen under maximum
load at full throttle, such as climbing a steep
grade with a heavily laden vehicle. Use caution if
your EGT approaches 1100°F, with 1150°F being
the ABSOLUTE MAXIMUM!
We recommend engine oil temperature be below
240°F, as measured in the oil pan, (An optional oil
temperature gauge is available from GALE BANKS
ENGINEERING). Optimum oil temperature is 220°F.
Continuously high oil temperature is indicative
of the need for an additional oil cooler. If you do
not have an oil temperature gauge, watch your oil
pressure. Falling oil pressure under a heavy load
is caused by rising oil temperature. Use caution.
We recommend that coolant temperature, also,
should not exceed 220°F.
If the vehicle approaches those EGT levels under
these conditions, downshift the vehicle to reduce
the load, or back off the throttle. If frequent high
EGT levels are encountered, the fuel delivery of
the injection pump will have to be reduced by
backing out the Allen head screw in the injection
pump as indicated in the Pump Adjustment
section. A high EGT can also be caused by a
restrictive exhaust system.
NOTE: Because the oil pressure gauge sender
is now tapped into a different location on the
engine, your oil pressure gauge readings will be
slightly lower, although your engine oil pump
is still putting out the same pressure. Once the
engine has warmed up, take note of the oil
pressure at various engine speeds and use these
readings as your new standard for normal oil
pressure.
OPERATING CHARACTERISTICS
Your BANKS turbocharged diesel engine should
exhibit the following operating characteristics:
400°F. This lower EGT translates directly to lower
piston and valve temperatures, and significantly
increased engine life.
Cruise Conditions (Constant 60 mph on Level
Road): EGT should be approximately 400°F;
boost gauge, if so equipped, should read 1 to 2
pounds.
It is also important to understand that
turbocharged boost pressures are load related,
that is the turbocharger makes boost only when
called upon to do so (by load requirements). The
turbo will not “make boost” with the transmission
in neutral, but makes boost proportional to the
load. Long uphill grades, with a heavy load, will
result in maximum boost. In other words, the
turbo makes boost only when it is needed. This
characteristic makes turbochargers so attractive
that the vast majority of long haul trucks and offroad earth moving equipment are equipped with
turbochargers. Turbocharging typically results in
more power and torque, better fuel economy and
increased engine life.
High
Load
Conditions
(Uphill
with
Heavy
Load):
EGT should typically be 900 to 1000°F, with
1100 as a maximum; boost levels may approach
9 pounds.
It is important to realize that diesels, unlike
gasoline engines, run cooler with additional
air. It is impossible to run a diesel too “lean”.
Exhaust gas temperature rises as more fuel is
added. Turbocharging a diesel typically lowers the
EGT. Normal cruise condition EGT for a normally
aspirated (non-turbocharged) diesel engine is
typically 600 to 650°F. As noted above, cruise
condition EGT for a turbocharged diesel is typically
19
P.N. 96308 V.2.0
Cleaning and Oiling the banks ram-air Filter
Notification:
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.
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
Fitler.
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 lightweight oils.
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.
7.
1.
spray-on cleaning
Spray Banks air-filter
cleaner liberally onto the
entire element and let
soak for 10 minutes.
2.
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.
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.
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.
10. performance hints
Service every 50-100,000 miles on street-driven
applications. Service more often in offroad or heavy-dust
conditions. If an air-filter restriction gauge is installed,
then change the element when the air-filter restriction
reaches 18”/H2O.
cleaning hints
3. Use only Banks air-filter cleaner. No gasoline
cleaning, No steam cleaning, No caustic cleaning
solutions, No strong detergents, No high-pressure car
wash, No parts cleaning solvents. Any of these Nos
can cause harm to the cotton filter media plus SHRINK
and HARDEN the rubber end caps.
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.
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.
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.
20
P.N. 96308 V.2.0
parts list – 21011/ 21019
Sidewinder Turbo System, Ford 6.9/7.3 Diesel Van
QTYDESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . item # PART #
QTYDESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . item # PART #
1 BRACKET, Turbo Mounting . . . . . . . . . . . . . . . 2
1CHAMBER, Pressure . . . . . . . . . . . . . . . . . . . . 3
4CLAMP, Hose, #16. . . . . . . . . . . . . . . . . . . . . . 1DECAL, Carb. E.O. -D-161-36. . . . . . . . . . . . . . 1DECAL, Fed. Emis. Comp. Turbo. . . . . . . . . . . 1FILTER ELEMENT, Air. . . . . . . . . . . . . . . . . . . . 6
2 HEATSHIELD, Blanket, 6 x 14”. . . . . . . . . . . . . 1 HEATSHIELD, Blanket, 7 x 24”. . . . . . . . . . . . 20
1 HEATSHIELD, Blanket, 9 x 24”. . . . . . . . . . . . 21
1 HOSE, Air Duct, 3” x 3’. . . . . . . . . . . . . . . . . . 32
1 HOSE, Crankcase Vent. . . . . . . . . . . . . . . . . . 28
1 HOSE, Heater, 1” x .58’ . . . . . . . . . . . . . . . . . . 2 HOSE, Splice, 1 x 13⁄ ”. . . . . . . . . . . . . . . . . . . 15
1 KIT, Small Parts . . . . . . . . . . . . . . . . . . . . . . . . 1ADAPTER, Crankcase Vent Hose. . . . . . 18
1ASSEMBLY, Air Inlet Elbow . . . . . . . . . . 16
1 BRACE, Air Inlet Elbow Assembly . . . . . 17
1 BRACKET, Air Filter Mount. . . . . . . . . . . . 5
1 BRACKET, Dip Stick Tube. . . . . . . . . . . . . 1 BRACKET, Glow Plug Relay . . . . . . . . . . 65
2CLAMP, Exhaust, 21⁄ ”. . . . . . . . . . . . . . . 13
1CLAMP, Exhaust, 3”. . . . . . . . . . . . . . . . 12
1DRAIN, Turbo Oil. . . . . . . . . . . . . . . . . . . 8
1 HEATSHIELD, Turbine. . . . . . . . . . . . . . . 19
1 HOSE, Silicone, 2 x 2”. . . . . . . . . . . . . . . 27
1 HOSE, Silicone, 3 x 13⁄ ”. . . . . . . . . . . . . 31
1 KIT, Clamp . . . . . . . . . . . . . . . . . . . . . . . . 1CLAMP, Hose, #10 . . . . . . . . . . . . . . 2CLAMP, Hose, #16 . . . . . . . . . . . . . 33
2CLAMP, Hose, #36 w/Liner. . . . . . . 34
4CLAMP, Hose, #52 w/Liner. . . . . . . 35
8CLAMP, Spring Band. . . . . . . . . . . . . 2CLAMP, Spring Band. . . . . . . . . . . . . 1 KIT, Electrical. . . . . . . . . . . . . . . . . . . . . . 1 KIT, Fastener . . . . . . . . . . . . . . . . . . . . . . 5 BOLT, 1⁄ ” 20 x 3⁄ ” Hex. . . . . . . . . . . 60
2 BOLT, 1⁄ ” 28 x 1” Hex . . . . . . . . . . . 63
2 BOLT, 3⁄ ” 16 x 1⁄ ” Hex. . . . . . . . . . . 48
1 BOLT, 3⁄ ” 16 x 3⁄ ” Hex. . . . . . . . . . . 46
3 BOLT, 3⁄ ” 16 x 1” Hex. . . . . . . . . . . 49
2 BOLT, 3⁄ ” 16 x 11⁄ ” Hex. . . . . . . . . . 50
3 BOLT, 3⁄ ” 16 x 21⁄ ” Hex. . . . . . . . . . . 1 BOLT, 3⁄ ” 16 x 4”. . . . . . . . . . . . . . . 51
2 BOLT, 5⁄ ” 18 x 1” Hex. . . . . . . . . . . 47
6 BOLT, 5⁄ ” 18 x 1” Stainless Hex . . . 53
2 BOLT, 5⁄ ” 18 x 2” Hex. . . . . . . . . . . 64
5NUT, 1⁄ ” 20 Nylock . . . . . . . . . . . . . 66
2NUT, 1⁄ ” 28 Nylock . . . . . . . . . . . . . 59
6NUT, 3⁄ ” 24 Collet Lock, Stainless . 52
2NUT, 5⁄ ” 18 Nylock. . . . . . . . . . . . . 58
4STUD, 3⁄ x 11⁄ ”. . . . . . . . . . . . . . . . . 54
4
2
4
4
4
4
8
2
8
4
8
8
4
8
2
8
16
16
16
4
4
8
16
8
2
52155
42070
92816
96029
96020
41503
26001
26002
26003
94086
94043
94464
94050
21031
94042
42250
42260
42230
35299
60081
52461
52465
24073
26021
94251
94281
92899
92810
92816
92837
92853
92875
92877
62100
91011
91117
91140
91425
91426
91427
91428
91432
91437
91229
91228
91239
91110
91111
91418
91210
91503
21
2STUD, 3⁄ x 2”. . . . . . . . . . . . . . . . . . 55 91505
5 WASHER, 1⁄ ” SAE. . . . . . . . . . . . . . . 61 91102
2 WASHER, 1⁄ ” Stainless AN. . . . . . . . 62 91101
2 WASHER, 3⁄ ” SAE . . . . . . . . . . . . . . 41 91402
8 WASHER, 3⁄ ” Stainless AN . . . . . . . 45 91401
4 WASHER, 3⁄ ” Circle Lock. . . . . . . . . 42 91407
1 WASHER, 3⁄ ” Split Lock. . . . . . . . . . 43 91404
1 WASHER, 3⁄ ” Stat-O-Seal. . . . . . . . . 56 91413
4 WASHER, 5⁄ ” Split Lock. . . . . . . . . . 40 91204
8 WASHER, 5⁄ ” Stainless AN . . . . . . . 44 91201
1 KIT, Fitting . . . . . . . . . . . . . . . . . . . . . . . . 92798
1FITTING, 1⁄ ” NPT x -4 AN Elbow . . . 38 92110
1FITTING, 1⁄ ” NPT x -4 AN Elbow . . . 37 92105
1FITTING, 3⁄ ” Tee, Plastic. . . . . . . . . . 92009
1FITTING, Oil Feed Tee. . . . . . . . . . . 39 92006
2PLUG, 1⁄ ” NPT, Hex Head . . . . . . . . 36 92250
1 KIT, Hose . . . . . . . . . . . . . . . . . . . . . . . . . 94356
1CAP, Rubber, Fuel Ret, 1⁄ ” . . . . . . . . 92027
1 HOSE, Turbo Oil Feed, 131⁄ ”. . . . . . 29 94070
1 HOSE, Turbo Oil Feed, 211⁄ ”. . . . . . 30 94075
1 HOSE, Fuel, 1⁄ ” x 21⁄ ’. . . . . . . . . . . . . 94134
1 HOSE, Fuel, 3⁄ ” x 21⁄ ’ . . . . . . . . . . . . 94095
1 KIT, Pyrometer. . . . . . . . . . . . . . . . . . . . 14 64001
1 MOUNT, Air Filter. . . . . . . . . . . . . . . . . . . 4 42220
1 MOUNTING PANEL, One-Gauge. . . . . . . . 63001-01
2NUT, Machine Screw, . . . . . . . . . . . . . . . 91833
1PLATE, Block Off, Intake Manifold. . . . . . 7 42130
2SCREW, Machine. . . . . . . . . . . . . . . . . . . 91834
1SET, Gasket . . . . . . . . . . . . . . . . . . . . . . . 93315
1GASKET, Oil Drain. . . . . . . . . . . . . . 23 93040
1GASKET, Pressure Chamber. . . . . . 22 93061
2GASKET, Turbine Outlet . . . . . . . . . 24 93001
1GROMMET, Oil Drain. . . . . . . . . . . . 26 93043
1 O-RING, Manifold Block-off Plate . . 25 93150
1SILICONE, Blue Gasket. . . . . . . . . . . . . . . 90023
1TAPE, Teflon, 1⁄ x 100”. . . . . . . . . . . . . . . 91099
1THREADLOCKER, Blue, 6 mil . . . . . . . . . . 90001
1TIE, Cable, 11” Black . . . . . . . . . . . . . . . . 62002
12TIE, Wire, Heatshield Blanket, 16”. . . . . . 26013
1 WASHER, . . . . . . . . . . . . . . . . . . . . . . . . . 91832
1 MANUAL, Owners, Ford 6.9/7.3 Diesel Van . . 96308
2PLAQUE, Banks Sidewinder. . . . . . . . . . . . . . . 96003
1PLUG, 1” NPT. . . . . . . . . . . . . . . . . . . . . . . . . . 92267
1PIPE, Turbine Outlet. . . . . . . . . . . . . . . . . . . . 11 52165
1PIPE, “Y” Assembly (for C-6 Trans. only). . . . 10 52170
1PIPE, “Y” Assembly (for E4OD Trans. only). . 10 52171
1PIPE, Extension, Y-Pipe (for C-6 Trans. only). . 9 52175
1PIPE, Extension, Y-Pipe (for E4OD Trans. only).9 52176
1SERVICE KIT, Air Filter. . . . . . . . . . . . . . . . . . . 90094
1TURBOCHARGER, Banks Sidewinder. . . . . . . . 1 24004
1WARRANTY STATEMENT. . . . . . . . . . . . . . . . . 96362
8
4
4
8
8
8
8
8
16
16
4
8
16
8
4
2
4
4
16
2
2
2
P.N. 96308 V.2.0
turbo diesel trouble shooting chart
SYMPTOMCAUSE
REMEDY
High EGTExcessive Fuel DeliveryChange injector pump setting
Faulty injector(s)
Repair injectors
Restricted exhaust system
Modify pipe layout for better flow, check for restrictive mufflers
Excessive fuel smoke (black),Faulty injector(s)
Repair injector
poor performance
Dirty air cleanerClean or replace
Restricted air intakeCheck for collapsed or blocked
air intake hoses
Poor quality or dirty diesel fuel
Replace filters, clean lines,
injectors and tanks as required
Excessive oil smoke (blue)Blocked or restricted turbo
oil drain
Eliminate restriction or low spots
in drain line
Leaking turbo oil seal
Replace turbo, replace seal;
(Seal leakage may be caused by
blocked turbo oil drain)
Excessive engine blowby
being vented into the air intake
Replace worn piston rings or valve
guides. Check engine oil level.
Lack of boost,Damaged turbo bearings and
Rebuild turbo, check oil level;
excessive oil smoke, seal caused by dirty oil or lackChange oil and filter at regular
and poor performance
of lubrication
service intervals
Worn or damaged engineCheck compression, Replace rings
components
or valves
22
P.N. 96308 V.2.0
turbo diesel trouble shooting chart
SYMPTOMCAUSE
REMEDY
Low boost, poor performance,
Restricted exhaust systemEliminate restrictions, modify pipe
sometimes with high EGT
layout for better flow
Muffler too small
Install recommended muffler
Lack of boost or low boost,
Intake system leaks
poor performance
Locate and seal leaks; (Check seal
between pressure chamber and
intake manifold)
Exhaust system leaks ahead
of turbocharger exhaust inlet
Listen for leaks, repair as necessary
Rebuild turbocharger, eliminate
means of foreign objects entry
Broken turbocharger blades
caused by foreign objects
entering intake or exhaust system
Pyrometer not workingCheck that wires are not reversed
Revise Wires
Poor connectionsClean and secure connections
Wiring connections shorted
together
Gradual loss of performance,Clogged (or partially clogged)
and possibly boost
fuel filter
(“Flatten out” at higher RPM)
23
Insulate connections
Replace fuel filter(s)
P.N. 96308 V.2.0
gale banks engineering
546 duggan avenue • azusa, ca 91702
(626) 969-9600 • fax (626) 334-1743
Product Information & Sales: (800) 438-7693
www.bankspower.com
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement