banks manual

8/2/2019 Banks Manual

1/27

IMPORTANT

DEAR CUSTOMER:

To obtain optimum performance from your BANKS turbocharger

system, it is necessary to make an ad ju st me nt to the fuel

injection pu mp . This adj ust me nt is easily made by following the

enclosed instructions. However, it is extremely important that the

instructions be followed very ca re fu ll y. Before starting the

injection pump adjustment procedure, please note the following:

The engine must be C.OL_D (preferably overn ight ) before starting

the injection pump adjustment procedure. DO NOT_ attempt to

turn the engine over or adju st the injection pump while the

engine is w a r m.

To gain access to the injection pump adjusting screw, it is

necessary to rotate the engine cr ankshaft, so that the screw

is properly positioned. As noted in the instructio ns, the

crankshaft is rotated by h a n d , IN THE CLOCKWISE DIRECTION

ONLY , by turning the vibration damper mounting bolt using an

appropriate so ck et , extension and breaker bar . ( O n some late

model trucks it may be necessary to remove the front

crankshaft pulley to gain access to the vibration damper

b o l t . ) 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

da ma ge . Again when making the injection pump adju stme nt, DO

NOT ROTATE THE CRANKSHAFT WITH THE STARTER.

3 . If you r e m o v e d the fron t crank sha ft pulley to gain access to the

vibration da mpe r b o l t , be sure to reinstall the pulley ( an d

be lt s) before starting the en gin e.

GALE BANKS ENGINE ERIN G


2/27

JUNE 1 2 , 1989

ATTENTION

THIS IS AN ADDENDUM TO ALL GALE BANKS TURBOCHARGER SYSTEM

INSTRUCTIONS. THE INSTRUCTIONS SHOW ( 2 ) 3/8" 16 x 1" HEX

BOLTS TO MOUNT THE OIL DRAIN TUBE. WE HAVE SUBSTITUTED ( 2 )

3/8" 16 X 3/4." HEX BOLTS IN THEIR PLACE. YOUR BILL OF

MATERIALS WILL NOT HAVE THESE BOLTS LISTED.


3/27

IMPORTANT

DEAR CUSTOMER:

To obtain optimum performance from your BANKS turbocharger

system, it is necessary to make an ad ju st me nt to the fuel

injection pu mp . This adj ust me nt is easily made by following the

enclosed instructions. However, it is extremely important that the

instructions be followed very ca re fu ll y. Before starting the

injection pump adjustment procedure, please note the following:

The engine must be C.OL_D (preferably overn ight ) before starting

the injection pump adjustment procedure. DO NOT_ attempt to

turn the engine over or adju st the injection pump while the

engine is w a r m.

To gain access to the injection pump adjusting screw, it is

necessary to rotate the engine cr ankshaft, so that the screw

is properly positioned. As noted in the instructio ns, the

crankshaft is rotated by h a n d , IN THE CLOCKWISE DIRECTION

ONLY , by turning the vibration damper mounting bolt using an

appropriate so ck et , extension and breaker bar . ( O n some late

model trucks it may be necessary to remove the front

crankshaft pulley to gain access to the vibration damper

b o l t . ) 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

da ma ge . Again when making the injection pump adju stme nt, DO

NOT ROTATE THE CRANKSHAFT WITH THE STARTER.

3 . If you r e m o v e d the fron t crank sha ft pulley to gain access to the

vibration da mpe r b o l t , be sure to reinstall the pulley ( an d

be lt s) before starting the en gin e.

GALE BANKS ENGINE ERIN G


4/27

I M P O R T A N T

In order to protect your engine from water damage, Ford Motor

Company recommends that the air inlet duct be disconnected from

the air filter housing when fording streams. This warning can

be found on both ends of the air inlet duct ( i t does not appearon some very early models). Removing this duct allows the

engine to draw air into the air filter from a higher

elevation, reducing the risk of water entering the engin e.

The duct should be replaced when fording is completed.

This air inlet duct is reused with your BANKS 6.9/7-3L turbo

kit. You should continue to follow the fording instructions

after the turbo kit is installed.

-G B E -

1/25/89


5/27

GALE BANKS ENGINEERING

INSTALLATION INSTRUCTIONS

GENERAL INSTALLATION PRACTICES

1. For ease of installation and trouble-free operation of your

BANKS turbocharger s ystem, PLEASE READ THIS ENTIRE INSTRUCTION

PACKAGE BEFORE STARTING ANY WORK. (This package contains 15

pages of instr uc tions, 12 sheets of illustrations, and two

sheets of parts listing. If any pages are missing from this

package, please call GALE BANKS ENGINEERING immediately for a

repl ac em en t. ) Become thoroughly familiar with all components

and phases of the installation before starting any wo rk.

2. Inspect all components supplied for any foreign material thatmay have entered 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.

3- Any time the vehicle is raised off its wh eels, it should be

supported by jack stands or ramps of adequate capacity for the

ve hi cl e's weight. NEVER PERFORM ANY WORK UNDER A VEHICLE

SUPPORTED ONLY BY ITS BUMPER OR A HYDRAULIC J A C K .

4- Use the Teflon tape provided on all pipe thread co nnections.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.)

5- Any threads to be secured with Loctite must be clean, dry and

free of any oil or grease. Clean threads with lacquer thinner

as required.

6. Pay particular attention to the rou ti ng of all hoses and

wiring. Keep them away from exhaust heat, moving parts and

sharp edges that may cause cuts or other damage. Route or tie

hoses away from critical areas as re quired. Keep all hoses a

minimum of 1" from hot exhaust, pa rts, 1 - 1 / 2 " or more is

recommended whenever possible.

5/18/89 73TA01 Rev.8 Page 1 of


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7 . Collet stainless steel locknu ts a re used on the studs in the

turbine mounti ng bra cke t. The locknuts should be installed as

shown in f i g . 3- The nuts will spin on fre ely and lock only when

tightened.

8. Muffler and exhaust piping are not included wit h this k i t .

An exhaust parts kit cont ain ing these components is ava ila ble

separately from GALE BANKS EN GI NE ER IN G, or you may have a localmuffler shop fabricate the exhaust sy s t e m . The BANKS 3"

exhaust system is REQUIR ED for emissions legal installations.

NO TE : If you have a muffler shop fabricate the exhaust

s y s t e m , or if you comple te the system your se lf , it is highly

re comm ende d that you install a BANKS 3" core muffler to realize

the full benefits of your BANKS turbo sy s t e m .

9- General assembly diagrams are provided in addition to the

specific step or section diagrams in the text. General

assembly diagrams show relationships of individual componen ts

for ref ere nce ; h ow ev er , numbered step-by-step procedures should

be followed for proper assembly s eq uenc e.

1 0 . Right-hand and left-hand designations refer to the d r i v e r ' s

right or le ft , as seated in the ve hi cl e, ( i . e . : Right-hand

refers to the passenger side of the vehicle , unless noted

otherwi se . " F W D " in sketches refers to " f o r w a r d " , or front of

vehicle.

1 1 . All BANKS components are de si g ne d, tested and manufactured to

standards far exceeding factory OEM specifi catio ns. However due

to normal variations in production v e h ic le s , it may be

necessary to slightly modify some exhaust comp onents for proper

f i t .

NOTE: All parts are furnished in kit unless noted otherwise.

3/18/89 73TA01 Rev.8 Page 2 of 1


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INSTALLATION PROCEDURE

1. Disconnect ground cables from both batteries. Disconnect electrical

connections from to p of in je ct io n pump .

2 . Disconnect plastic air inlet duc t from air cleaner- ho us in g

and remove air cleaner housing and e l em e n t .

3- Disconnect wire from oil pressure sender u n i t , loca ted on

top-rear of eng ine . ( O n some m o d e l s , the oil pressure sender

is mounted on the fi r e w a l l . )

4- Re mo ve oil pressure sender unit and it s conne ctio ns from rear of

engine block. (F it ti ng s, ho se , and brack et, e t c . , if firewall

m o u n t e d ) . Retain sender for later inst alla tion .

5- Install 1 / 8 " NPT brass pipe plug in hole at rear of block where

oil pressure sender unit and fitt ing were re m o v e d . Use

Teflon tape on thr ea ds .

6. Remove steel tube connected to transmission modulator va lve.

7. Remove oil fill-pipe from front of engine. (Note: 1 987

and later models use an inspection cover plate, remove

cover plate). See fig- U

ONPUMP ADJUSTMENT

To obtain the maximum available performance from your BANKS 6-

9/ 7- 3L diesel turbo system, and to comply with emissions

requirements, 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 pumpadjustment will provide a 30 percent or greater increase in

rear wheel horsepower, suitable for general u s e , work trucks

and towing. (This is the ONLY emissions legal setting).

NOTE: Exhaust gas temperature ( E G T ) must NOT exceed 1150

degrees F, as shown on the EGT gauge (pyrometer)

furnished with the k i t . If the EGT approaches this

temperature under heavy, uphill lo ad, the fuel pump

capacity adjustment must be reduced. The recommended

pump setting should cause no problem, very rarely approaching

this temperature.

R e v . 8 Page 3 of 15


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8. Ad ju st injector pump delivery as follows:

NOTE: The engine must be COLD before starting this pro cedure.

Review warnings at the beginning of instruction booklet.

NOT E: Utmost cleanliness should be ex er ci se d. DO NOT allow any

foreign mat eri al , including lint from ra gs, to enter the

injector pump during the adjustment procedure - the lintfrom a rag can clog an injector. Lay any removed parts on a

clean newspaper during the adjustment procedure.

a. Place a drip pan under the rear of the engine, under the

flywheel inspection cover ar ea, to catch spilled fuel. Clean

the area of the pump in the vici nity of the small access

cover, located on the left side of the p ump, as viewed from

the .f:rp_n_t, of the vehicle, with diesel fuel or parts

so lv en t. DO NOT clean the pump while it is h o t ; doing so may

damage the pump.

b. Remove the cover p late, retained by two small screws . Use

care not to damage the rubber g asket; it will be reusedduring reassembly. IMPORTANT: Utmost care must be used to

prevent foreign obje cts and dirt from falling into the pump to

prevent dama ge.

c. Rotate engine slowly by hand, in a clockwise direc ti on , using

a breaker b a r , short extension and suitable socket on the

harmonic balancer retaining bo lt, to align the injector

drive p in, as viewed through the opening for the oil fill pipe

or inspection c o ver, in a straight up ( 1 2 o' clo ck )

position. Using a small mirror, check that the Alien head

adjustment screw is visible within the inspection hole on the

pump. It may be necessary to rotate the engine somewhat

more to gain access to the adjusting sc re w. See figs. 5 and6. DO NOT ATTEMPT TO ROTATE THE ENGINE WITH THE S T A R T E R ! ! .

d. Using a 5/32" Alien wrench (wit h sharp corners), rotate the

screw 1/4 turn, clockwise.

NOTE : The Alien screw turns fairly tightly and is self

locking. Turning the screw clockwise increases fuel delivery

capacity. Keep track of your adjustments!

e. Replace access cover on pump. Again exercise care to

prevent foreign material from entering pump.

f . Wipe up any spilled fuel remaining on valley cover.

This completes the pump adjustment procedure.

73TA01 R e v . 8 Page 4 of 1


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Reroute the in jec tor return ho se s. Refer to fig- 7 A . whic h

shows how the return lines should be ro ut ed . Re mo v e and install

necessary comp one nts as required to com ple te th e system as

sho wn. (A dd it ion al hose is provided for the r er ou ti ng .)

Note that there should be a m i n i m u m of four inches clearance

between the inje ct or return line ar:d t, he ; turbine hou sin g or

turbo moun ting br ac ke t. Be sure th at the new injec tor return

hose does not inte rfere w it h the transmission kickdown

linkage.

1989 and later models - if the injector return

fittings on the injector nozzles have the late style " o f f

center" nipples, see fig. 7, the injector return lines do not

need to be rerouted. Go to step 10 .

engine lifting lug from right front of the intake

Retain the bolts for later installation.

10. Remove the

manifold.

1 1 . Remove the engine lifting lug from right rear of the intake

manifold. Replace bolts with new 3/8"-l6 x 2-1/2" hex headbolts provided, and original washers. (Do not use original

bolts or reinstall lifting l u g . )

1 2 . Remove the engine lifting lug from left rear of the intake

manifold. Retain the bolts for later installation.

13- Remove the crankcase anti-depression valve (the round sheet

metal can attached to the rear of the intake manifold).

Remove standpipe and grommet from valley cover. (Standpipe

may come out attached to anti-depression v al v e. ) Retain anti-

depression valve and mounting bolts for later installation.

Note, 1987 and later models: Remove short length of hose and

clamp from anti-depression valve.

1-4- Carefully clean around the hole where the 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 so lvent.)

15- Install grommet in valley cover as follows. Fill grommet

groove with RTV silicone sealer provided. Press grommet

through opening in valley cover and smooth RTV around

grommet. Remove excess RTV. See fig- 8.

1 6 . Install rubber

See fig. 8.

groove in manifold block-off plate

17. Install manifold block-off plate (and o-ring) on intake

manifold where anti-depression valve was removed, using two

5/16" - 18 x 1" hex head bolts and split lockwas hers. See Fig.

8.

o-r i n, i n

5/18/89 73TA01 R e v . 8 Pagerj of 15


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1 8 . 1987 and later mo de ls , glow plug relay rel oca tio n:A. Un bo lt the glow plug relay fr om the rear of the intake

manifold (l ea ve wire loom attached to re la y. Remo ve cable

clamps holding wire loom to rear of e n g i ne . Disconn ect

relay ground wire from engine. If vehicle has the E 4 0 D

transmission (4 speed automat ic / o v e r d r i v e ) save one of the

cable clamps for step 49-B. Re mo ve the two intake man ifold bolts located betwee n the

third and fourth fuel in je ct or ( co unti ng from the front to

the rea r) on the right (p a ss e ng e r) side of the en gi ne .

See fig- 9-C. Mou nt the glow plug relay to the glow plug relay brac ket

( p r o v i d e d ) using two 1/4"-28 x 1" hex bol ts , two 1/ 2 "

O . D . x 1/ 4" I . D . washers, and two 1/4"-28 nylock nut s.

Clamp the relay ground wire under one of the nu t s . See fig.

9 -D. Install the bracket and relay on the intake manifold

using the intake bolts and washers rem ove d in section B.Route the wiring as shown in fig- 1 0 . Plastic clips may be

rem oved from wire loom ja ck et as required for rerouting

wiring.1 9 - Remove the screws holding the vacuum hose junct ion b lock,

located on upper right portion of fire wa ll , and lift block upward

as far as pos sib le. ( D o not disconnect any vacuum h o s e s . )

Temporarily retain the vacuum block u p , out of the wa y , by tying

with heavy string or other me ans.20 . Remove exhaust head pipes and exhaust sy s t e m , including

muffler and tailpipe. 2 1 . Remove the transmission dipstick from the dipstick t u b e .

Then unb olt , the transmission dipstick tube at the bellho using

and rem ove the dipstick tube from the transm iss ion. Ret ain all

these components for later insta lla tio n. Cover the dipstick

tube opening with a clean r a g , paper towel or tape to prevent

contamination from entering the transmi ssi on. Reinstall

bellhousing bol t. 22 . Re mo ve 1 / 8 " NPT pipe plug for oil feed c on ne ct io n, located on

lower left side at rear of b l o c k , ab ove and to the rear ofthe oil filter. See fi g. 1 1 .

23- Install 1/ 8 " NPT x -4AN turbo oil feed elbow in b l o c k . A i m

elbow at approximately one o' cl oc k position. See fig- 1 1 - 2 ^ . Install oil feed hoses onto oil feed line t e e . Use Teflon

tape on th re ad s. See fig- 1 2 . 2 5 . I nsta ll oil pressure sender onto oil feed line te e . Use

Teflon tape on th re ad s. See fig- 1 2 .

5/18/89 73TA01 R e v . 8 Page 6 of 15


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2 6 . Install oil feedline tee on intake ma nifold, using rear-most

intake manifold mounting bolt hole, on the left side. Use

original bolt and wa sher . Replace the other left rear manifold

bolt with one new 3/ 8"-l6 x 2- 1/ 2" hex head bolt and original

wa sh er . NO TE : Oil feed line to block must go under injector

tubing loop at rear-most injector.

27. Connect oil feed hose to elbow installed in step 23-

28. Lengthen the oil pressure gauge sender wire as follows:

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 connectors provided in the k i t . Route

the wire in front of the intake manifold air inlet opening to

the gauge sender. Keep wire clear of any mo vin g parts. Note:

Connectors squeeze together onto the wire with pliers. Re-

install plug on se nder.

29- Tie wrap glow plug wiring and throttle cable at rear of

intake manifold (snugly but not tight enough to cause binding or

kinking). See fig. 13-

30. If vehicle is equipped with a plastic acoustic shield on the

firewall, cut and remove a section as shown in fig- 1 4-

3 1 . Cut one 9" x 24." heat blanket into one piece 9" x 1 2 " and two

pieces 9" x 6 " . Wrap one 9" x 6" piece around the glow plug

wiring and throttle cable near turbine housing. Secure using

wire ties provided. Save the other pieces for later

installation. On 1989 and later models, wrap injector return

hose together with glow plug wiring and throttle cables near

turbine housing.

32. Bend firewall lip back as far as po ssible, on both s i d e s , forinstallation of exhaust pi ping . Use adjustable wrench to grip

lip as deeply as possible and bend entire seam back parallel with

bell housing. A 3 '-4 ' piece of pipe or metal bar may be used as

a lever against the seam to flatten the me tal. It may also be

necessary to slightly reshape the floorpan heat shields for

proper exhaust system clea ra nc e. See fig. 15-

33- Install the pyrometer adapter fitting and probe ( f r o m the

pyrometer kit) into the 1/4" NPT threaded hole in the turbo

mounting bracket.

34- Install four 3/8" x 1- 1 / 2 " studs in the rectangular pad on

the turbo mounting bracket. Note that the coarse threads on

the studs fit into the turbo mounting bracket.

35- Install two 3/ 8" x 2" studs in the circular pad on the turbo

mounting bracket. Again note that the coarse threads or. the

studs fit into the turbo mounting bracket.

5/18/89 73TA01 Rev.8 Page 7 of 15


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36 Mount turbo on turbo mounting br ac ke t, using four 3/8"-24

stainless steel collet lock nuts and four 5/ 8" O . D . x 3/8"

I . D . flat washers. No gasket is requ ired. (See general

notes on collet locknut installation, Fig. 3 ) -

37 IMPORTANT: Remove the plastic caps from the turbocharger oil

inlet and outlet connections.

38 Use gasket adhesive ( "Gasg acinch" or 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 pipe about 3/8" up

from the bottom, then insert the oil drain pipe into the

grommet in the valley co ver.

39 Position the turbo mounting bracket and turbocharger in place at

the rear of the right hand cylinder h ead. Start one 3/8" -l 6 x

1-1/4." hex head bolt, two or three turns, through the top

mounting hole in the turbo mounting b racket, into the cylinder

head.

40 Mount the oil drain tube in position on the turbo, using two

3/ 8" -l 6 x 1" hex head bolts and four 3/8" I . D . circle lock

washers. (Circle lock washers must be used in pairs as shown

in fig. 1 7 . ) Carefully smooth the RTV around the oil drain

pipe at the grommet with a r a g , to assure a good se al. An

additional bead of RTV sealant may be added if desired.

41 Install the other two bolts in the turbo mounting bracket

(one 3/8"-l6 x 1-1/4-" hex head and one 3/8"-l6 x 1" hex head;

short bolt goes through thin corner of br ac ke t. ) Leave bolts

loose enough to adjust turbo mounting bracket position to suit.

42 Install 1/ 4 " NPT x -4AN elbow in the oil inlet connection on topof the turbocharger. Aim the fitting as shown in fig-1 6 . Use

Teflon tape on the pipe threads.

43 Place air inlet gasket and intake casting in position on the

intake man ifold. Make sure the intake casting touches and sits

squarely on the gasket .

44 Line up turbo compressor discharge connection with the intake

casting hose j o i n t , lifting the turbo slightly if needed for

proper al ignmen t. Tighten the top bolt in the turbo mounting

bracket, then the other two.

NOTE_ If the turbocharger needs to be rotated to correct

misalignment, it can be easily aligned by lo os en in g, but not

remo vi ng, the six turbine housing bolts and the six compressor

housing bolts arid rotating these parts slightly into the proper

position. Be sure to bend the locking tabs over against the

heads of the bolts after re-tigh te nin g.


13/27

45 Remove intake casting from intake manifold.

4 6 Modify the transmission dipstick tube as shown in fig- 1 9 -

47 Lower turbo down-tube in place, but do not mo un t.

48 ON C-6 AUTOMATIC TRANSMISSION VEHICLES ONLY, install

transmission dip stick tub e, using one 3/8 " - 1 6 x 1 / 2 " hex headbolt and 3/8" split lockwasher. It may be necessary to bend

the tube slightly to fit. Tube mounts to turbo mounting

bracket.

4 9 On E40D (4 SPEED OVE RDR IV E) AUTOMATIC MODELS ONLY, install

transmission dipstick tube using a cable clamp retained from

step 18 , a 90 bracket, a 5/16-18 x 1" hex bol t, two 1 1 / 1 6

O . D . x 5/16 I . D . washers, and a 5/16-18 Nylock nut. 90

bracket mounts under belIhousing-to-engine bolt. See figs. 1 9

and 21 .

50 Line up the turbine heat shield and gaskets on the

turbocharger. You may use 5 / 1 6 " studs, pins or bolts with

heads removed as guides to ease the installation.

5 1 Bolt the turbo down-tube to the turbocharger, using six

5/l6"-18 x 7/8" stainless steel hex head bolts and 9 / 1 6 " O . D . x

5 / 1 6 " I . D . flat washers. Make sure gaskets and heat shield are

properly in place, and that the heat shield does not touch the

firewall. Note: Heat shield may be crushed slightly to provide

clearance.

52 ON E40D (4 SPEED OVERDRIVE) AUTOMATIC MODELS ONLY, use

hacksaw to remove aproximately 1 / 2 " of the corners of the boss

indicated in fig- 27. This is necessary for the Y-pipeassembly to clear the transmission-bellhousing area.

53 Install exhaust "Y -pipe " assembly to engine exhaust manifolds

'under the vehicle. Bolt the extension tube flange to the turbo

mounting bracket using two 3/8-24 stainless collet lock nuts and

two 13/1 6 O . D . x 3/8 I. D. flat washers. Leave nuts loose

enough for alignment. Do not install U-clamp at this time .

N O T E : ON E40D (4 SPEED OV ER DR IV E) AUTOM ATIC MODELS ON L Y , unbolt the

shift linkage pivot bracket from the left side of the

transmission to allow the extensi on half of the Y- pipe to be

mounted in place between the linkage and the tra ns mi ss io n. It is

not necessary to completely rem ove the li nk ag e. When the Y-pipe assembly is in p l a c e , reinstall the l i n k a g e . See fig. 27.

54 Tighten Y-pipe co ll et lock nu ts .

5/18/89 73TA01 R e v . 8 Page 9 of 15


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55 Install exhaust U -clamp on slip connection jo i n i n g Y- pipe-

halve s. NOTE: Both 2 1 / 1. and 2 1/2 inch U- clamp:; are

i n c l u d e d , use the proper size clamp for the tube size

su ppl ied . See f i g . 1.

5 6 Connect oil feed hose to turbocharger oil inlet e l b o w .

57 If installing optional boost g a ug e , install boost gauge

fitting (su ppl ied in boost gauge ki t ) in the 1/8 N . P . T . boss on

the intake cast in g. NO TE : Nut on fitting may be rem oved to

allow instal lation . Fitting should be aimed toward left side

of v ehicl e. Refer to f ig . 20. If boost gauge will not be

inst alled, substitute 1 / 8 " NPT pipe pl ug , from k i t . Use Teflon

tape on pipe t hr ea ds .

5 8 Install 2" diamete r x 2" long silicone hose and two #36 hos e

clamps on the intake casting compressor con ne ct io n. Tighten

the clamp nearest the intake cas ti ng , leave the other clamp

loose. Position the clamps as shown in F i g . 2 to provide

access for tightening and prevent clamp from touching ki ck-down

rod .

5 9 Install turbocharger compressor air inlet elbow and cla mps on

turbocharger. N^OT_E: Large end uses #56 clamp, small end

uses #52 clamp. Do not tighten clamps at this t i m e .

6 0 Install intake casting ( an d gas ket) on intake ma ni fo ld , using

one 3 /8 " -l 6 x L, 1/ 2" hex head bolt, and 1 3 / 1 6 " O . D . x 3/8"

I . D . flat wa sh er . Guide the intake casting and turboc harger

hose jo int s together as the casting is set in p l a c e . Make sure

all loose clamps are in position on the hos es. Torque the

mounting bolt to aproximately 1 2 - 1 5 f t . Ib s. NJDT E : On some

m o d e l s , fuel return line tube may have to be bent slightly so

fuel hose will not be kinked by the undersid e of the intakecas tin g. Check for cle ar anc e.

6 1 Tighten remaining turbocharger compressor discharge hoseclamp .

6 2 WARNING_!_ Make sure transmission kick-down rod has clearance thru

its entire trave l. Improperly located cl am ps , bent throttle

l e v er s , ho se s, e t c . may rub or push against the kick -down rod

and interfere with transmission shifting and/or throttle

opera tion. Check this before starting en gi ne .

6 3 Tighten air inlet elbow hose cl am ps , at turbocharge r and ai r

filter body .

6 4 Install air filter element in the intake ca st in g. Check that

element is properly seated in groo ve.

NOTE Be sure you have the 3 1 / 2 " hi gh ai r fi lt er e l e m e n t . The

older 3 " high e l e m e n t , if In st al le d, wil l not fi lt er in t h i s

c a s ting.

R e v . 8 Pa g e 10 of 1 5


15/27

6 5 Install air filter co ve r, including gask et, , usi ng eight5/1 6"-18 x 2" hex head bolts a nd 9 /1 6" O . D . x 5/1 6" l . D . f J .-i

was her s. Make sure that a i r filter element is pro per ly engaged

in groove on und ersi de of cover before ti gh te n in g bolt s. Use a

light coat of grease on body ga sk et , su rf ac


16/27

75 Install accessory instruments, if used. Refer to

manufacturer's instructions included with instruments.

76 Install muffler and exhaust system (not included with the

turbo system) as shown in fig- 2 6 . Because of various

vehicle/chassis combinations, the illustration provided is

general, but typical of the exhaust system routing.

NOT E: 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_diam

eter_, including the muffler. Use of a smaller muffler or exhaust

piping will result in significantly inferior performance. A separate

3" high-flow exhaust system is available from GALE BANKS

ENGINEERING. This 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.

For those wishing to do their own exhaust system fabrication,

the following recommendations should be followed:

a. Be sure to use a high quality, low restriction 3" core

muffler, designed for turbocharged diesel applications.

( M o s t 3" mufflers available from muffler shops are low

quality, high restriction "economy" replacement mufflers,

usually based on a 2-1/2" or smaller c o r e . )

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. See fig. 26A.

c. Do not " c h e a t " bends or make miter-weld joints. These

types of bends are too abrupt for proper exhaust flow.

d. Maintain adequate clearance to chassis, floorboards,

dr iv el ine , 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.

7 7 . Install a 9" x 24 heat blanket on turbo down-pipe. Slide

blanket up from bottom as far as possible. Wrap top of pipe

with the remaining part of the other 9" x 24." heat blanket.

Secure using wire ties provided.

78. Install a 7" x 24" heat blanket on Y-pipe extension, (that

portion of exhaust piping connected to the turbo mounting

bracket) sliding it up from the bott om , all the way up to the

pyrometer fitting on the' turbo mounting bracket. Secure,

again using wire ti es.

5/18/89 73TA01 R e v . 8 Page 12 of 15


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CHECKING ENGINE PERFORMANCE

Use your pyrometer (exhaust temperature gauge) to monitor your

en gi ne 's operation. At id le , EGT (exhaust gas temperature) will

be very l o w , perhaps only 150 degrees F. As the throttle is opened

for higher speeds and greater load s, the EGT will ri se. 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 ifyour EGT approaches 1100 degrees F, with 1150 degrees F being the A BSD

LUT E_M A X I_ MUM !

If the vehicle approaches those EGT level under these conditions,

downshift the vehicle to reduce the load, or back off the

thr ot tle . If frequent high EGT levels are en countere d, the fuel

delivery of the injection pump will have to be reduced by backing

out the Alien-head screw in the injection pump as indicated in the

Pump Ad ju st me nt section. A high EGT can also be caused by a

restrictive exhaust system.

We recommend engine oil temperature be below 24.0 degrees F, as

measured in the oil pan. ( A n optional oil temperature gauge isavailable from GALE BANKS ENGINEERING). Optimum oil temperature is

230 degrees F. Continuously high oil temperature is indicative of

the need for an additional oil cooler. If you do not have an oil

temperature gaug e, watch your oil pressure. Falling oil pressure

under a heavy load is caused by rising oil temperature. Use caution.

We recommend that coolant temperature, al so, should not exceed

220 degrees F.

5/18/89 73TA01 Rev.8 Page U of 15


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OPERATING CHARACTERISTICS

s h o u l d e x h i b i t t heYour BANKS turbocharged diesel engine

following operating characteristics:

Cruise Conditions (Constant 60 mph on Level R o a d ) : EGTshould be approximately 4 0 0 degrees F; boost gage, if so

equi pped, should read 1 to 2 pounds.

High Load Conditions (Up hill with Heavy Lo a d ) : EGT should

typically be 900 to 1000 degrees F, with 1100 as a m a x i m u m ;

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 " l e a n " . 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) dieselengine is typically 600 to 650 degrees F. As noted above, cruise

condition EGT for a turbocharged diesel is typically /i.OO degrees

F. This lower EGT translates directly to lower piston and valve

temperatures, and significantly increased engine life.

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 ( b y 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 makesturbochargers so attractive that the vast majority of long haul

trucks and off-road earth moving equipment are equipped with

turbochargers. Turbocharging typically results in more power and

torque, better fuel economy and increased engine life.

- G B E -

GBE/1000

5/18/89 73TA01 Rev. 8 Page 15 of 15


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GALE BANKS ENGINEERING

Bill of Materials For

AUTOMATIC TRANSMISSION

ITEM # QTY / KIT DESCRIPTION1 1 Banks Turbocharger

2 1 Turbo Mounting Bracket

3 1 Intake Casting

5 1 Air Filter Cover

7 1 Air Filter Element, 3-1/2" tall

8 1 Air Filter Support Bracket

10 1 Intake Manifold Block-off Plate

11 1 Turbo Oil Drain Tube12 1 Y-pipe, left half

13 1 Y-pipe, right half

U 1 Turbo Down Pipe-- 1 Bracket, dipstick tube-- 1 2-1/4" Exhaust U-clamp17 1 2-1/2" Exhaust U-clamp

18 1 Pyrometer Adapter and Probe

20 1 Turbine Heat Shield

21 1 7" x 24" Heat Blanket

22 2 9" x 24" Heat Blanket

23 1 Air Inlet Gasket

24 1 Air Filter Cover Gasket25 1 Turbo Oil Drain Gasket

26 2 Turbine Outlet Gasket

27 1 0-ring

28 1 Grommet29 1 2" I . D . x 2" Silicone Hose

30 1 Compressor Air Inlet Elbow

31 1 Crankcase Vent Hose32 1 Crankcase Vent Hose Adaptor

33 1 Turbo Oil Feed Hose, 13- 1/2 " Long34 1 Turbo Oil Feed Hose , 2 1 " Long

35 1 Glow Plug Relay Bracket

36 2 N o. 16 Hose Clamp37 2 No. 36 Hose Clamp38 1 No . 52 Hose Clamp39 1 N o . 56 Hose Clamp

40 1 N o . 10 Hose Clamp

REV. 5/19/89 Sheet 1 of 21001/KN


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ITEM QTY/KIT DESCRIPTION

41 2 1/8" NPT Brass Hex Head Pipe Plug

42 1 1/8" NPT x -4AN 90-degree Elbow

43 1 1/ 4" NPT x -4AN 90-degree Elbow

44 1 1/4" NPT Tee with Tab

47 4 5/16" Split Lock Washer

48 8 13/16" O.D.x3/8" I. D . Flat Washer

49 4 3/8" Circle Lock Washer50 1 3/8" Split Lock Washer

51 14 9/16" O.D.X5/16" I.D . Flat Washer52 4 5/8" O.D.x3/8" I.D. Flat Washer

53 3 5/l6"-18 x1" Hex Head Bolts54 8 5/l6"-18x1-3/4" Hex Head Bolts55 1 3/8"-l6x1/2" Hex Head Bolt56 5 3/ 8" -l6x 1" Hex Head Bolt57 2 3/8"-1 6x1-1 /4" Hex Head Bolt

58 3 3/8"-l6x2-1/2" Hex Head Bolt59 1 3/8"--l6x4 1/2" Hex Head Bolt

61 6 3/8"-24 Collet Locknut

62 6 5/l6"-18x1" Stainless Hex Head Bolt63 4 3/8"x1-1/2" Stud

-- 2 11 / 16 " 0. D. x 5/16 flat washer65 2 3/8"x2" Stud-- 1 5/16" - 18 Nylock Nut

68 2 5/l6"-18x2" Hex Head Bolt

-- 1 K&N Air Filter Cleaner - 1 K&N Air Filter Oil69 2 1/4"-28x1" Hex Head Bolt

70 2 1/4"-28 Nylock Nuts71 2 1/2" O.D.x l/4" I-D. Flat Washers

-- 2 "Banks Turbo" Emblems

NOTE: SOME ITEMS IN KIT ARE NOT SHOWN IN ILLUSTRATIONS.

R E V . 5/1 9/8 9 Sheet 2 of

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