IMPORTANT

DEAR CUSTOMER:

To obtain o p ti mu m performance f r om your BANKS turbocharger s y s t e m , it is necessary to make an a d j u s t m e n t to the fuel injection p u m p . This a d j u s t m e n t is easily made by following the enclosed instructions. H o w e v e r , it is extremely important that the instructions be followed very c a r e f u l l y . Before starting the injection pump a d j u s t m e n t p r o c e d u r e , please note the following:

The engine must be C.OL_D (preferably o v e r n i g h t ) before starting the injection pump a d j u s t m e n t p r oc e du re . DO NOT_ attempt to turn the engine over or a d j u s t the i n j e c t i o n p u m p while the engine is w a r m .

To gain access to the i n j e c t i o n pump ad ju st i ng s c r e w , it is necessary to rotate the engine c r a n k s h a f t , so that the screw is properly p o s i t i o n e d . As noted in the i n s t r u c t i o n s , the crankshaft is rotated by h a n d , IN THE CLOCKWISE DIRECTION O N L Y , by turning the vibration damper mounting bolt using an appropriate s o c k e t , extension and breaker b a r . ( O n some late m o d e l trucks it may be ne ce s sa ry to r e m o v e the front crankshaft pulley to gain a c c e s s to the vibration damper b o l t . ) DO NOT ROTATE THE CRANKSHAFT USING THE S T A R T E R , for any r e a s o n . Even though the fuel solenoid is d e - e n e r g i z e d , the engine can still s t a r t . This is extremely hazardous and can result in both severe personal i n j u r y and m a j o r mechanical d a m a g e . Again when making the i n j e c t i o n pump a d j u s t m e n t , DO NOT ROTATE THE CRANKSHAFT WITH THE S T A R T E R .

3 .

If you r e m o v e d the f r o n t c r a n k s h a f t pu l ley to g a i n access to the v i b r a t i o n d a m p e r b o l t , be s u r e to r e i n s t a l l the pulley ( a n d b e l t s ) b e f o r e s t a r t i n g the e n g i n e .

GALE BANKS E N G I N E E R I N G

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 WE HAVE SUBSTITUTED ( 2 ) YOUR BILL OF

BOLTS TO MOUNT THE OIL DRAIN TUBE.

3/8" 16 X 3/4." HEX BOLTS IN THEIR PLACE. MATERIALS WILL NOT HAVE THESE BOLTS LISTED.

IMPORTANT

DEAR CUSTOMER:

To obtain o p ti mu m performance f r om your BANKS turbocharger s y s t e m , it is necessary to make an a d j u s t m e n t to the fuel injection p u m p . This a d j u s t m e n t is easily made by following the enclosed instructions. H o w e v e r , it is extremely important that the instructions be followed very c a r e f u l l y . Before starting the injection pump a d j u s t m e n t p r o c e d u r e , please note the following:

The engine must be C.OL_D (preferably o v e r n i g h t ) before starting the injection pump a d j u s t m e n t p r oc e du re . DO NOT_ attempt to turn the engine over or a d j u s t the i n j e c t i o n p u m p while the engine is w a r m .

To gain access to the i n j e c t i o n pump ad ju st i ng s c r e w , it is necessary to rotate the engine c r a n k s h a f t , so that the screw is properly p o s i t i o n e d . As noted in the i n s t r u c t i o n s , the crankshaft is rotated by h a n d , IN THE CLOCKWISE DIRECTION O N L Y , by turning the vibration damper mounting bolt using an appropriate s o c k e t , extension and breaker b a r . ( O n some late m o d e l trucks it may be ne ce s sa ry to r e m o v e the front crankshaft pulley to gain a c c e s s to the vibration damper b o l t . ) DO NOT ROTATE THE CRANKSHAFT USING THE S T A R T E R , for any r e a s o n . Even though the fuel solenoid is d e - e n e r g i z e d , the engine can still s t a r t . This is extremely hazardous and can result in both severe personal i n j u r y and m a j o r mechanical d a m a g e . Again when making the i n j e c t i o n pump a d j u s t m e n t , DO NOT ROTATE THE CRANKSHAFT WITH THE S T A R T E R .

3 .

If you r e m o v e d the f r o n t c r a n k s h a f t pu l ley to g a i n access to the v i b r a t i o n d a m p e r b o l t , be s u r e to r e i n s t a l l the pulley ( a n d b e l t s ) b e f o r e s t a r t i n g the e n g i n e .

GALE BANKS E N G I N E E R I N G

I M P O R T A N T

In order to protect your engine from water d a m a g e , Ford Motor Company recommends that the air inlet duct be disconnected from the air filter housing when fording s t r e a m s . This warning can be found on both ends of the air inlet duct ( i t does not appear on some very early m o d e l s ) . Removing this duct allows the engine to draw air into the air filter from a higher e l e v a t i o n , reducing the risk of water entering the e n g i n e . The duct should be replaced when fording is completed. This air inlet duct is reused with your BANKS 6 . 9 / 7 - 3 L turbo k i t . You should continue to follow the fording instructions after the turbo kit is installed. -G B E 1/25/89

GALE BANKS ENGINEERING

INSTALLATION INSTRUCTIONS

GENERAL INSTALLATION PRACTICES 1. For ease of installation and trouble-free operation of your BANKS turbocharger s y s t e m , PLEASE READ THIS ENTIRE INSTRUCTION PACKAGE BEFORE STARTING ANY W O R K . ( T h i s package contains 15 pages of i n s t r u c t i o n s , 12 sheets of illustrations, and two sheets of parts l is t in g. If any pages are missing from this p a c k a g e , please call GALE BANKS ENGINEERING immediately for a r e p l a c e m e n t . ) Become thoroughly familiar with all components and phases of the installation before starting any w o r k . Inspect all components supplied for any foreign material that may have entered during shipping and handling. Wash all fuel and oil hoses with solvent and blow dry with c o m p r e s s e d air before assembly. Inspect all castings for damage resulting from s h i p p i n g . Check all machined surfaces for nicks or other d a m a g e . Clean all castings with solvent and blow dry with compressed air prior to a s s e m b l y . Any time the vehicle is raised off its w h e e l s , it should be supported by j a c k stands or ramps of adequate capacity for the v e h i c l e ' s w e i g h t . NEVER PERFORM ANY WORK UNDER A VEHICLE SUPPORTED ONLY BY ITS BUMPER OR A HYDRAULIC J A C K . Use the Teflon tape p r o v i d e d on all pipe thread c o n n e c t i o n s . Hold tape back from the first two threads of the fitting so tape will not flake off into the f l u i d . ( T h i s is especially critical on oil l i n e s . ) Any threads to be secured with Loctite m u s t be c l e a n , dry and free of any oil or g r e a s e . Clean t h r e a d s w i th lacquer thinner as required. Pay particular a t t e n t i o n to the r o u t i n g of all hoses and w i r i n g . Keep them away from exhaust h e a t , moving parts and sharp edges that may cause cuts or other d a m a g e . Route or tie hoses away from critical areas as r e q u i r e d . K e e p all hoses a minimum of 1" from hot e x h a us t, p a r t s , 1 - 1 / 2 " or more is recommended whenever possible.

2.

3-

4-

5-

6.

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7 .

Collet stainless steel l o c k n u t s a r e used on the st ud s in the turbine m o u n t i n g b r a c k e t . The l o c k n u t s s h o u l d be i n s ta l led as shown in f i g . 3- The nuts will spin on f r e e l y and lock only when tightened. M uf fl er and e x h a u s t piping are not included w i t h this k i t . An exhaust parts kit c o n t a i n i n g these c o m p o n e n t s is a v a i l a b l e separately f r o m GALE BANKS E N G I N E E R I N G , or you may h av e a local m u f f l e r shop fabricate the exhaust s y s t e m . The B A N K S 3" e x h a u s t s y s te m is R E Q U I R E D for e m i s s i o n s legal installations. N O T E : If you ha v e a muffler sh op fabricate the exhaust s y s t e m , or if you c o m p l e t e the s ystem y o u r s e l f , it is h ig hly r e c o m m e n d e d that you install a B A N K S 3" core mu ff le r to realize the full benefits of your BANKS turbo s y s t e m .

8.

9-

General a s s e m b l y diagrams are p r o v i d e d in a d d i ti o n to the specific step or section dia gr am s in the t e x t . Ge neral assembly d i a g r a m s show relationships of i n d i v i d u a l c o m p o n e n t s for r e f e r e n c e ; h o w e v e r , numbered step-by-step procedures should be followed for proper assembly s e q u e n c e .

1 0 . Right-hand and left-hand designations refer to the d r i v e r ' s right or l e f t , as seated in the v e h i c l e , ( i . e . : Right-hand refers to the passenger side of the v e h i c l e , unless noted otherw i s e . " F W D " in sketches refers to " f o r w a r d " , or front of vehicle. 1 1 . All BANKS components are d e s i g n e d , tested and m anufactured to standards far exceeding factory OEM s p e c i f i c a t i o n s . However due to normal v a r i a t i o n s in p r o d u c t i o n v e h i c l e s , it may be necessary to slightly m o d i f y s o m e exhaust c o m p o n e n t s for proper fit. N O T E : All parts are furnished in kit unless noted otherwise.

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INSTALLATION PROCEDURE 1. Disconnect ground cables from both b a t t e r i e s . connections from t o p of i n j e c t i o n pump . Disconnect electrical

2 .

D i s c o n n e c t p l a s t i c a i r inlet d u c t from a i r c l e a n e r - h o u s i n g and r e m o v e air c l e a n e r h o u s i n g and e l e m e n t . D i s c o n n e c t w i r e f rom oil p ress u re s e n d e r u n i t , l o c a t e d on top-rear of e n g i n e . ( O n some m o d e l s , the o i l p r e s s u r e sender is mou nte d on the f i r e w a l l . ) R e m o v e oil p r e s s u r e s e n d e r u n i t a n d i t s c o n n e c t i o n s f r o m rea r of engine b l o c k . ( F i t t i n g s , h o s e , and b r a c k e t , e t c . , if firewall m o u n t e d ) . Retain sender for l a t e r i n s t a l l a t i o n . Install 1 / 8 " NPT brass pipe plug in hol e at r e a r of blo ck w h e r e oil p r e s s u r e s e n d e r unit and f i t t i n g w e r e r e m o v e d . Use Teflon tape on t h r e a d s .

3-

4-

5-

6.

Remove steel tube connected to transmission modulator v a l v e .

7. Remove oil fill-pipe from front of engine. ( N o t e : 1 987 and later models use an inspection cover p l a t e , remove cover p l a t e ) . See fig- U O N P U M P ADJUSTMENT
To obtain the m a x i m u m available performance from your BANKS 6 9 / 7 - 3 L diesel turbo s y s t e m , and to comply with emissions r e q u i r e m e n t s , it is necessary to make an a d j u s t m e n t to the fuel i n j e c t i o n p u m p . The pump a d j u s t m e n t increases the fuel delivery capacity of the p u m p . This a d j u s t m e n t is made by turning an internal s c r e w , found within the p u m p . The p um p a d j u s t m e n t will provide a 30 percent or greater increase in rear wheel h o r s e p o w e r , suitable for general u s e , work trucks and t o w i n g . ( T h i s is the ONLY emissions legal s e t t i n g ) . N O T E : Exhaust gas temperature ( E G T ) must NOT exceed 1150 degrees F, as shown on the EGT gauge ( p y r o m e t e r ) furnished w i t h the k i t . If the EGT approaches this temperature under h e a v y , uphill l o a d , the fuel pump capacity a d j u s t m e n t must be r e d u c e d . The recommended pump setting should cause no problem, very rarely approaching this temperature.

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8. A d j u s t injector pump delivery as f o l l o w s : N O T E : The engine m u s t be COLD before starting this p r o c e d u r e . R e v i e w warnings at the beginning of instruction b o o k l et . N O T E : U t m o s t cleanliness should be e x e r c i s e d . DO NOT allow any foreign m a t e r i a l , including lint from r a g s , to enter the injector p u m p during the a d j u s t m e n t procedure - the lint f r o m a rag can clog an i n j e c t o r . Lay any r e m o v e d parts on a clean newspaper during the a d j u s t m e n t p r o c e d u r e . a. Place a d r i p pan u n d e r the rear of the e n g i n e , u n de r the flywheel inspection cover a r e a , to catch spilled f u e l . Cl ea n the area of the p u m p in the v i c i n i t y of the small access c o v e r , located on the left side of the p u m p , as viewed from the .f:rp_n_t, of the v e h i c l e , with diesel fuel or parts s o l v e n t . DO NOT clean the p u m p while it is h o t ; doing so may damage the p u m p . b. R e m o v e the cover p l a t e , retained by two small s c r e w s . Use care not to d a m age the rubber g a s k e t ; it will be reused during reassembly. IMPORTANT: Utmost care must be used to prevent foreign o b j e c t s and dirt from falling into the pump to prevent d a m a g e . c. Rotate engine slowly by h a n d , in a clockwise d i r e c t i o n , u s i n g a breaker b a r , short extension and suitable socket on the harmonic balancer retaining b o l t , to align the i n j e c t o r drive p i n , as viewed through the opening for the oil fill pipe or inspection c o v e r , in a straight up ( 1 2 o ' c l o c k ) position. Using a small m i r r o r , check that the Alien head a d j u s t m e n t screw is visible within the i n s p ec ti on hole on the p u m p . It may be necessary to rotate the engine s o me w ha t m o r e to gain access to the a d j u s t i n g s c r e w . See f i g s . 5 and 6. DO NOT ATTEMPT TO ROTATE THE ENGINE WITH THE S T A R T E R ! ! . d. Using a 5 / 3 2 " Alien wrench ( w i t h sharp c o r n e r s ) , rotate the screw 1/4 t u r n , clockwise. NOTE : The Alien screw turns fairly tightly and is self l o c k i n g . Turning the screw clockwise increases fuel delivery capacity. Keep track of your adjustments! e. Replace access c o v e r on p u m p . A g a i n exercise care to prevent foreign material from entering p u m p . W i p e up any spilled fuel remaining on valley c o v e r . This completes the pump adjustment p r oc ed ur e .

f .

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R e r o u t e the i n j e c t o r return h o s e s . Refer to f i g - 7 A . w h i c h shows how the return lines should be r o u t e d . R e m o v e a n d install necessary c o m p o n e n t s as r e q u i r e d to c o m p l e t e t h e s y stem as shown. ( A d d i t i o n a l hose is p r o v i d e d for the r e r o u t i n g . ) N o t e that t h e r e should be a m i n i m u m of f o u r inches clearance between the i n j e c t o r return line a r : d t, h e ; t u r b i n e h o u s i n g or turbo m o u n t i n g b r a c k e t . Be su re t h a t the new i n j e c t o r return hose does not i n t e r f e r e w i t h the t rans mis s ion kickdown linkage. 1989 and later models - if the injector return fittings on the injector nozzles have the late style " o f f c e n t e r " nipples, see f i g . 7, the injector return lines do not need to be rerouted. Go to step 1 0 .

1 0 . Remove the engine lifting lug from right front of the intake manifold. Retain the bolts for later installation. 11. Remove the engine lifting lug from right rear of the intake manifold. Replace bolts with new 3 / 8 " - l 6 x 2-1/2" hex head bolts p r o v i d e d , and original washers. ( D o not use original bolts or reinstall lifting l u g . )

1 2 . R e mo v e the engine lifting lug from left rear of the intake manifold. Retain the bolts for later installation. 1 3 - Remove the crankcase anti-depression valve ( t h e round sheet metal can attached to the rear of the intake m a n i f o l d ) . Remove standpipe and grommet from valley c o v e r . (Standpipe may come out attached to anti-depression v a l v e . ) Retain antidepression valve and mounting bolts for later installation. N o t e , 1987 and later models: Remove short length of hose and clamp from anti-depression v a l v e . 1-4- Carefully clean around the hole where the original g r o m m e t was installed at the rear of the valley cover and where the anti-depression valve was mounted on intake manifold. ( U s e acetone, lacquer thinner or other non-oil based s o l v e n t . ) 1 5 - Install grommet in valley cover as follows. Fill grommet groove with RTV silicone sealer pr ovid ed. Press grommet through opening in valley cover and smooth RTV around grommet. Remove excess R T V . See fig- 8. 1 6 . Install rubber o-r i n, i n groove in manifold block-off plate See f i g . 8. 1 7 . Install manifold block-off plate ( a n d o - r i n g ) on intake manifold where anti-depression valve was r e m o v e d , using two 5/16" - 1 8 x 1" hex head bolts and split lockwas h e r s . See Fig. 8.

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1 8 . 1987 and later m o d e l s , glow plug relay r e l o c a t i o n : A. U n b o l t the glow plug r e l a y f r o m the r e a r of the i n t a k e m a n i f o l d ( l e a v e wire loom a tt ac he d to r e l a y . R e m o v e cable cl am ps holding wire loom to rear of e n g i n e . D i s c o n n e c t relay ground wire from e n g i n e . If v e h i c l e has the E 4 0 D tr an sm is si on (4 speed a u t o m a t i c / o v e r d r i v e ) save one of the cable c l a m p s for step 4 9 B. R e m o v e the two intake m a n i f o l d bolts l o c a t e d b e t w e e n the third and fourth fuel i n j e c t o r ( c o u n t i n g f ro m the front to the r e a r ) on the right ( p a s s e n g e r ) side of the e n g i n e . See f i g - 9M o u n t the glow plug relay to the glow p l u g relay b r a c k e t ( p r o v i d e d ) using two 1 / 4 " - 2 8 x 1" hex b o l t s , two 1 / 2 " O . D . x 1 / 4 " I . D . w a s h e r s , and two 1/4"-28 nylock n u t s . C l a m p the relay ground w i re u nd er one of the n u t s . See f i g . 9 Install the bracket and relay on the intake manifold using the intake bolts and washers r e m o v e d in section B. Ro ut e the wiring as shown in f i g - 1 0 . Plastic clips ma y be r e m o v e d from wire loom j a c k e t as r e q u i r e d for rerouting wiring.

C.

D.

1 9 - R e m o v e the screws holding the v a c u u m hose j u n c t i o n b l o c k , located on upper right portion of f i r e w a l l , and lift block upward as far as p o s s i b l e . ( D o not d i s c o n n e c t any v a c u u m h o s e s . ) Temporarily retain the v a c u u m block u p , out of the w a y , by tying with heavy string or other m e a n s . 2 0 . R e m o v e exhaust head pipes and exhaust s y s t e m , including muffler and t a i l p i p e . 2 1 . R e m o v e the transmission dipstick from the d i p s t i c k t u b e . Then u n b o l t , the transmission dipstick tube at the b e l l h o u s i n g and r e m o v e the dipstick tube from the t r a n s m i s s i o n . R e t a i n all these co mp on en ts for later i n s t a l l a t i o n . C o v e r the d i p s t i c k tube o p e n i n g with a clean r a g , paper towel or tape to prevent contamination from entering the t r a n s m i s s i o n . Reinstall bellhousing b o l t . 2 2 . R e m o v e 1 / 8 " NPT pipe plug for oil feed c o n n e c t i o n , located on lower left s i d e at rear of b l o c k , a b o v e and to the rear of the oil filter. See f i g . 1 1 . 2 3 - Install 1 / 8 " NPT x -4AN turbo oil feed elbow in b l o c k . A i m elbow at approximately one o ' c l o c k p o s i t i o n . See f i g - 1 1 2 ^ . In st al l oil feed hoses onto oil feed line t e e . tape on t h r e a d s . See f i g - 1 2 . Use Teflon

2 5 . I n s t a l l oil pressure s en de r onto oil feed l i n e t e e . Teflon tape on t h r e a d s . See f i g - 1 2 .

Use

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2 6 . Install oil feedline tee on intake m a n i f o l d , using rear-most intake manifold mounting bolt h o l e , on the left s i d e . Use original bolt and w a s h e r . R e pl ace the other left rear manifold bolt with one new 3 / 8 " - l 6 x 2 - 1 / 2 " h e x head bolt and original w a s h e r . N O T E : Oil feed line to block m u s t go u n d e r i n j e c t o r tubing loop at rear-most i n j e c t o r . 2 7 . Connect oil feed hose to elbow installed in step 232 8 . Lengthen the oil pressure gauge sender wire as f o l l o w s : Cut the plug from the wire loom leaving 2-3 i n c h e s of w i r e attached to the p l u g . Lengthen the wire fr o m the l o o m as required using wire and connectors provided in the k i t . Route the wire in front of the intake m a n i f o l d a i r i n l e t opening to the gauge s e n d e r . Keep wire clear of any m o v i n g p a r t s . N o t e : Connectors squeeze together onto the wire wi t h p l i e r s . Reinstall plug on s e n d e r . 2 9 - Tie wrap glow plug wiring and throttle cable at rear of intake manifold ( s n u g l y but not tight enough to cause b i n d i n g or k i n k i n g ) . See f i g . 1 3 3 0 . If vehicle is equipped with a plastic acoustic shield on the f i r e w a l l , cut and remove a section as shown in f i g - 1 4 3 1 . Cut one 9" x 2 4 . " 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 h o u s i n g . Secure u s i n g wire ties p r o v i d e d . Save the other pieces for later installation. On 1 9 89 and later m o d e l s , wrap i n j e c t o r return hose together with glow plug wiring and throttle cables near turbine housing. 3 2 . Bend firewall lip back as far as p o s s i b l e , on b o t h s i d e s , for installation of exhaust p i p i n g . Use a d j u s t a b l e w r e n c h to grip lip as deeply as possible and bend e n t i r e s e a m back parallel with bell h o u s i n g . A 3 '-4 ' piece of pipe or m e t a l bar may be used as a lever against the seam to f l a t t e n the m e t a l . It may also be necessary to slightly r e s h a p e the floorpan heat shields for proper exhaust system c l e a r a n c e . See fig. 1 5 33- Install the pyrometer adapter fitting and probe ( f r o m the pyrometer k i t ) into the 1 / 4 " NPT t h re ad ed hole in the turbo mounting bracket. 34- Install four 3 / 8 " x 1 - 1 / 2 " studs in the r e c t a n g u l a r pad on the turbo mounting b r a c k e t . Note that the coarse t h r e a d s on the studs fit into the turbo m o u n t i n g b r a c k e t . 3 5 - Install two 3 / 8 " x mounting bracket. studs fit into the 2" studs in the c i r c u l a r pad on th e t u r b o Again note that the coarse t h re ad s or. the turbo mounting b r a c k e t .

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36

Mount turbo on turbo mounting b r a c k e t , using four 3 / 8 " - 2 4 stainless steel collet lock nuts and four 5 / 8 " O . D . x 3 / 8 " I . D . flat washers. No gasket is r e q u i r e d . ( S e e general notes on collet locknut installation, F i g . 3 ) -

3 7 IMPORTANT: R e m ov e the plastic caps from the turbocharger oil inlet and outlet c o n n e c t i o n s . 38 Use gasket adhesive ( " G a s g a c i n c h " or s i m i l a r ) to attach the oil drain tube gasket to the oil d r a i n t u b e . Place a small bead of RTV silicone sealer around the o i l d r a i n p i p e about 3 / 8 " up from the b o t t o m , then insert the oil d r a i n pipe into the g r om me t in the valley c o v e r . Position the turbo mounting bracket and t ur boc h ar ge r in place at the rear of the right hand c y l i n d e r h e a d . Start one 3 / 8 " - l 6 x 1 - 1 / 4 . " hex head b o l t , two or three t u r n s , through the top mounting hole in the turbo m o u n t i n g b r a c k e t , into the cylinder head. Mount the oil drain tube in position on the t u r b o , using two 3 / 8 " - l 6 x 1" hex head bolts and four 3 / 8 " I . D . circle lock w a s h e r s . ( C i r c l e lock washers must be used in pairs as shown in f i g . 1 7 . ) Carefully smooth the RTV around the oil drain pipe at the g r o m m e t with a r a g , to assure a good s e a l . An additional bead of RTV sealant may be added if d e s i r e d . Install the other two bolts in the turbo mounting bracket ( o n e 3 / 8 " - l 6 x 1-1/4-" hex head and one 3 / 8 " - l 6 x 1" hex h e a d ; short bolt goes through thin corner of b r a c k e t . ) Leave bolts loose enough to a d j u s t turbo m o u n t i n g bracket position to suit. Install 1 / 4 " NPT x -4AN elbow in the oil inlet c o n n e c t i o n on top of the tur b oc ha rge r . A i m the fitting as shown in fig - 1 6 . Use Teflon tape on the pipe t h r e a d s . Place air inlet gasket and intake casting in p o s i t i o n on the intake m a n i f o l d . Make sure the intake casting touches and sits squarely on the g a s k e t . Line up turbo compressor discharge connection w i t h the intake casting hose j o i n t , lifting the turbo slightly if needed for proper a l i g n m e n t . Tighten the top bolt in the turbo m o u n t i n g b r a c k e t , then the other t w o . NOTE_ If the turbocharger needs to be rotated to c o r r e c t m i s a l i g n m e n t , it can be easily aligned by l o o s e n i n g , but not r e m o v i n g , 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 l o c k i n g tabs over against the heads of the bolts after re-t i g h t e n i n g .

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R e m o v e intake casting from intake m a n i f o l d . Modify the transmission dipstick tube as shown in f i g - 1 9 Lower turbo down-tube in p l a c e , but do not m o u n t . ON C - 6 AUTOMATIC TRANSMISSION VEHICLES O N L Y , install transmission dip stick t u b e , using one 3/8 " - 1 6 x 1 / 2 " hex head bolt and 3 / 8 " split l o c k w a s h e r . It may be necessary to bend the tube slightly to f i t . Tube m o u n ts to turbo m o u n t i n g bracket. On E40D (4 SPEED O V E R D R I V E ) AUTOMATIC MODELS O N L Y , install transmission di ps t ic k tube using a cable clamp retained from step 1 8 , a 9 0 b r a ck et , a 5/16-18 x 1" hex b o l t , two 1 1 / 1 6 O . D . x 5/16 I . D . washers, and a 5/16-18 Nylock nut. 9 0 bracket mounts under belIhousing-to-engine b o l t . See f i g s . 1 9 and 21 . Line up the turbine heat shield and gaskets on the turbocharger. You may use 5 / 1 6 " s t u d s , pins or bolts with heads removed as guides to ease the installation.

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50

5 1 Bolt the turbo down-tube to the turbocharger, using six 5 / l 6 " - 1 8 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 p l a c e , and that the heat shield does not touch the firewall. N o t e : Heat shield may be crushed slightly to provide clearance. 52 ON E40D (4 SPEED O V E R D R I V E ) AUTOMATIC MODELS O N L Y , use hacksaw to remove aproximately 1 / 2 " of the corners of the boss indicated in fig- 2 7 . This is necessary for the Y - p i p e assembly to clear the transmission-bellhousing a r e a . Install exhaust " Y - p i p e " assembly to engine exhaust manifolds 'under the v e h i c l e . Bolt the extension tube flange to the turbo mounting bracket using two 3/8-24 stainless collet lock nuts and two 1 3 / 1 6 O . D . x 3/8 I. D. flat w a s h e r s . Leave nuts loose enough for a l i g n m e n t . Do not install U - cl a mp at this time .

53

N O T E : ON E40D (4 SPEED O V E R D R I V E ) A U T O M A T I C MODELS O N L Y , u n b o l t the shift linkage p i v o t b rac k et f r o m the left s i d e of the t r a n s m i s s i o n to allow the e x t e n s i o n half of the Y - p i p e to be m o u n t e d in place bet wee n the linkage and the t r a n s m i s s i o n . It is not n e c e s s a r y to c o m p l e t e l y r e m o v e the l i n k a g e . W h e n the Y p i p e a s s e m b l y is in p l a c e , r ein st all the l i n k a g e . See fig. 27. 54 T igh t en Y - p i p e c o l l e t lock n u t s .

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55

I nstall exhaust U -clamp on slip connection j o i n i n g Y- pipehalve s. N O T E : Both 2 1 / 1. and 2 1/2 inch U- c l a m p : ; are i n c l u d e d , use the p r op e r size c l a m p for the t u b e s i z e s u p p l i e d . See f i g . 1.

5 6 C o n n e c t oil feed hose to t u r b o c h a r g e r oil i n l e t e l b o w . 57 If i n s t a l l i n g optional boost g a u g e , install b oos t g a u g e fitting ( s u p p l i e d in boost gauge k i t ) in the 1/8 N . P . T . boss on the intake c a s t i n g . N O T E : Nut on f i t t i n g m a y be r e m o v e d to allow i n s t a l l a t i o n . F i t t i n g should be a i m e d t o w a r d l e f t side of v e h i c l e . Refer to f i g . 2 0 . If boost g a u g e w i l l n o t be i n s t a l l e d , substitute 1 / 8 " NPT pipe p l u g , from k i t . Use Teflon tape on p i p e t h r e a d s .

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Install 2" d i a m e t e r x 2" long silicone hos e and two # 3 6 h o s e clamps on the intake casting compressor c o n n e c t i o n . T i g h t e n the c l a m p nearest the intake c a s t i n g , leave the o t h e r c l a m p l o o s e . Position the clamps as shown in F i g . 2 to p r o v i d e acc es s for tightening and pr ev en t clamp from t o u c h i n g ki ck-down rod . Install t u r b o c h a r g e r co mp re s sor air inlet elbow and c l a m p s on t u r b o c h a r g e r . N^OT_E: Large end uses #56 c l a m p , small end uses #52 c l a m p . Do not tighten clamps at this t i m e . Install intake casting ( a n d g a s k e t ) on intake m a n i f o l d , u s i n g one 3 / 8 " - l 6 x L, 1 / 2 " hex head b o l t , and 1 3 / 1 6 " O . D . x 3 / 8 " I . D . flat w a s h e r . Guide the intake casting and t u r b o c h a r g e r hose j o i n t s together as the casting is set in p l a c e . Make sure all loose clamps are in position on the h o s e s . Torque the mounting bolt to aproximately 1 2 - 1 5 f t . I b s . NJDT E : On s ome m o d e l s , fuel return line tube may hav e to be bent slightly so fuel hose will not be kinked by the u n d e r s i d e of the intake c a s t i n g . Check for c l e a r a n c e . Tighten r em ain in g turbocharger compressor discharge hose clamp . WARNING_!_ Make sure transmission kick-down rod has clearance thru its entire t r a v e l . Improperly located c l a m p s , bent throttle l e v e r s , h o s e s , e t c . may rub or push against the kick -down rod and interfere with transmission shif ti ng a n d / o r throttle o p e r a t i o n . Check this before starting e n g i n e . Tighten air inlet elbow hose c l a m p s , at t u r b o c h a r g e r and a i r filter b o d y .
Install air f i l t e r e l e m e n t in the i n t a ke c a s t i n g . e l e m e n t is p r o p e rl y s ea t ed in g r o o v e . Check that

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NOTE Be s u r e y o u h a v e the 3 1 / 2 " h i g h a i r f i l t e r e l e m e n t . The o l d e r 3 " h i g h e l e m e n t , if I n s t a l l e d , w i l l n o t f i l t e r in t h i s c a s ti n g . R e v . 8 Pa g e 10 of 1 5

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Install air filter c o v e r , i n c l u d i n g g a s k e t , , u s i n g eight 5/1 6"-18 x 2" h e x head b o lt s a n d 9 / 1 6" O . D . x 5/1 6" l . D . f J .-i washers. M a k e sure t h at a i r f i l t e r e l e m e n t is p r o p e r l y e n g a g e d in g r o o v e on u n d e r s i d e of c o v e r b e f o r e t i g h t e n i n g b o l t s . Use a l i gh t coat of grease on body g a s k e t , s u r f a c < - ! . . , hold gasket in place d u r i n g assembly and to f a c i l i t a t e { ' u t i l i se r v i c e . Install a i r f i l t e r body s u p p o r t b r a c k e t , u s i n g two o r i g i n a] i n t a k e m a n i f o l d bolts and w a s h e r s and two 3/8" - 1 6 x 1" h e x head bolts and 1 3 / 1 6 " O . D . x 3 / 8 " l . D . flat w a s h e r s . S t a r t all b o lt s be fo r e t i g h t e n i n g . See f i g - 2 2 . R e m o u n t v a c u u m block on f i r e w a l l , r e l o c a t i n g u p w a r d as

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required to provide maximum clearance to turbo system. D r i 1 new mounting holes to suit and use original sheet metal screws.

68

Install anti-depression valve on the intake casting b o d y , using original bolts, with hose connection facing u p w a r d . Be sure original seal is in place on anti-depression v a l v e mounting surface. Remove existing o-ring and nylon sleeve from the anti-depression valve hose connection, if still in place. See fig. 22. Remove and discard the hose clamp from the heater hose connection on the water p u m p . Hose clamp may be cut w i t h snips to avoid disconnecting h o s e . See f i g . 23Thoroughly degrease the oil fill-pipe flange face ( i n j e c t o r pump drive cover flange face on 1987 and later m o d e l s ) using acetone, lacquer thinner or other non-oil based s o l v e n t . Install the crankcase vent hose adapter and oil fill-pipe (inspection cover on 1987 and later m o d e l s ) using two 5 / l 6 " 1 8 x 2" hex bolts and two 5/16 split lock w a s h e r s . Use silicone sealer on both flange surfaces. See fig- 23Replace the hose clamp previously removed from the heater hose with a N o . 10 hose clamp, provided in the k i t . Keep thetail of the hose clamp clear of the alternator d r i v e b e l t . See fig. 23
Install crankcase v e n t h o s e , from crankcase v e n t a d a p t o r

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nipple to anti-depression v a l v e , using two # 1 6 hose c l a m p s , as shown in fig- 23- Be sure that hose is i n s t a l l e d w i t h no low areas that could cause oil puddling in the h o s e ; .
73 74 Reinstall flexible fresh air inlet hose on i n t a k e e a s t i n g . Install pyrometer and gauge panel. with p y r o m e t e r . Refer to Instructions included

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Install accessory i n s t r u m e n t s , if u s e d . Refer to m a n u f a c t u r e r ' s instructions included with instruments. Install muffler and exhaust system ( n o t included with the turbo s y s t e m ) as shown in f i g - 2 6 . Because of various v e h i c l e / chassis c o m b i n a t i o n s , the illustration provided is g e n e r a l , but typical of the exhaust system r o ut in g. N O T E : The factory muffler and exhaust system are NOT s u i t a b l e for turbocharged e n g i n e s . The entire exhaust s y s t e m , f r o m the turbo down-pipe through to the tail p i p e , should be three inch_diam eter_, including the muffler. Use of a s m a l l e r muff ler or exhaust piping will result in significantly inferior performance. A separate 3" high-flow exhaust system is available from GALE BANKS ENGINEERING. This e x h a u s t s y st em includes a special low restriction 3" core m u f f l e r , pre-formed tubing sections and all components n e c e s s a r y to install the complete exhaust s y s t e m . The B A N K S 3" exhaust system is REQUIRED for emissions legal a p p l i c a t i o n s . Use of any other exhaust with the turbo system is not emissions l e g a l . For those wishing to do their own exhaust system f a b r i c a t i o n , the following r eco m me nd ati o ns should be fol lowed: a. Be sure to use a high q u a l i t y , low restriction 3" core m u f f l e r , designed for turbocharged diesel applications. ( M o s t 3" mufflers available from muffler shops are low q u a l i t y , high restriction " e c o n o m y " replacement mufflers, usually based on a 2 - 1 / 2 " or smaller c o r e . ) b. Make all bends as gradual as p o s s i b l e . j o i n t s as carefully as possible so the not experience " s t e p s " in the tubing. Align all weld exhaust flow will See f i g . 2 6 A .

76

c. Do not " c h e a t " bends or make miter-weld j o i n t s . These types of bends are too abrupt for proper exhaust f l o w . d. Maintain adequate clearance to c hass is, floorboards, d r i v e l i n e , moving suspension p a r t s , e t c . Suspend exhaust t u b i n g in rubber hangers to allow for engine m o v e m e n t . The original hangers may be reused if in good c o n d i t i o n . 7 7 . Install a 9" x 24 heat blanket on turbo d o w n - p i p e . Slide b l an ke t up f r o m b o t t o m as far as p o s s i b l e . Wrap top of pipe w i t h the remaining part of the other 9" x 2 4 . " heat b l a n k e t . Secure using wire ties p r o v i d e d . 7 8 . Install a 7" x 24" heat blanket on Y-pipe e x t e n s i o n , ( t h a t p o r t i o n of exhaust piping connected to the turbo m ounting b r a c k e t ) s l i d i n g it up from the b o t t o m , all the way up to the pyrometer fitting on the' turbo mounting bracket. S e c u r e , again using wire t i e s .

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CHECKING ENGINE PERFORMANCE Use your pyrometer ( e x h a u s t temperature g a u g e ) to monitor your e n g i n e ' s operation. At i d l e , EGT (exhaust gas temperature) will be v e r y l o w , perhaps only 150 degrees F. As the t h r o t t l e is opened for higher speeds and greater l o a d s , the EGT will r i s e . The h i g h e s t EGT will be seen under m a x i m u m load at full t h r o t t l e , such as climbing a steep grade with a heavily laden v e h i c l e . Use caution if your EGT approaches 1100 d e g re es F, with 1 1 5 0 degrees F being the A BSD LUT E_M A X I_ MUM ! If the v e h i c l e approaches those EGT level under these c o n d i t i o n s , d o w n s h i f t the vehicle to reduce the l o a d , or back off the t h r o t t l e . If frequent high EGT levels are e n c o u n t e r e d , the fuel d e l i v e r y of the i n j e c t i o n p u m p will have to be reduced by backing o u t the Alien-head screw in the i n j e c t i o n pump as indicated in the P u m p A d j u s t m e n t s e c t i o n . A high EGT can also be caused by a restrictive exhaust system. We r e c o m m e n d engine oil temperature be below 24.0 degrees F, as m e a s u r e d in the oil p a n . ( A n optional oil temperature gauge is available from GALE BANKS E N G I N E E R I N G ) . Optimum oil temperature is 230 degrees F. Continuously high oil temperature is i n d i c a t i v e of the need for an additional oil c o o l e r . If you do not have an oil temperature g a u g e , watch your oil p r e s s u r e . Falling oil pressure under a heavy load is caused by rising oil temperature. Use caution. We r e c o mm e nd that coolant t e m p e r a t u r e , a l s o , should not exceed 220 degrees F.

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OPERATING CHARACTERISTICS Your BANKS turbocharged diesel engine following operating characteristics: shou ld e x h i b i t the

Cruise Conditions ( C o n s t a n t 60 mph on Level R o a d ) : EGT should be approximately 4 0 0 degrees F; boost g a g e , if so e q u i p p e d , should read 1 to 2 p o u n d s . High Load Conditions ( U p h i l l with Heavy L o a d ) : EGT should typically be 900 to 1000 d e g r e e s F, with 1100 as a m a x i m u m ; boost levels may approach 9 p o u n d s .

It is important to realize that d i e s e l s , unlike gasoline e n g i n e s , run cooler with additional a i r . It is impossible to run a diesel too " l e a n " . Exhaust gas temperature rises as more fuel is a d d e d . Turbocharging a diesel typically lowers the E G T . Normal cruise condition EGT for a normally aspirated (non-turbocharged) diesel engine is typically 600 to 650 degrees F. As noted a b o v e , 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 r e l a t e d , that is the turbocharger makes boost only when called upon to do so ( b y load r e q u i r e m e n t s ) . The turbo will not " m a k e b o o s t " with the transmission in neutral, but makes boost proportional to the l o a d . Long uphill g r a d e s , with a heavy l o a d , will result in maximum b o o s t . In other w o r d s , the turbo makes boost only when it is n e e d e d . This characteristic makes turbochargers so attractive that the vast majo rit y 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 l i f e . - G B E GBE/1000
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GALE BANKS ENGINEERING Bill of Materials F o r

AUTOMATIC TRANSMISSION

ITEM # 1 2

3 5 7
8 10 11 12

QTY / KIT 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 2 1 1 1 1 1 1 1 1 1 2 2 1 1 1

DESCRIPTION Banks Turbocharger Turbo Mounting Bracket Intake Casting Air Filter Cover Air Filter Element, 3 - 1 / 2 " tall Air Filter Support Bracket Intake Manifold Block-off Plate Turbo Oil Drain Tube Y - p i p e , left half Y-pipe, right half Turbo Down Pipe Bracket, dipstick tube 2-1/ 4" Exhaust U-clamp 2-1/2" Exhaust U-clamp Pyrometer Adapter and Probe Turbine Heat Shield 7" x 2 4 " Heat Blanket 9" x 2 4 " Heat Blanket Air Inlet Gasket Air Filter Cover Gasket Turbo Oil Drain Gasket Turbine Outlet Gasket 0-ring Grommet 2" I . D . x 2" Silicone Hose Compressor Air Inlet Elbow Crankcase Vent Hose Crankcase Vent Hose Adaptor Turbo Oil Feed H o s e , 1 3 - 1 / 2 " Long Turbo Oil Feed H o s e , 2 1 " Long Glow Plug Relay Bracket N o . 16 Hose Clamp N o . 36 Hose Clamp No . 52 Hose Clamp N o . 56 Hose Clamp N o . 10 Hose Clamp

13 U --17 18
20 21 22 23 24 25 26 27 28 29 30 31 32

33 34 35 36 37 38 39 40

R E V . 5/19/89 1001/KN

Sheet 1 of 2

ITEM 41 42 43 44 47 48

QTY/KIT 2 1 1 1 4 8 4 1 14 4

1/8" 1/8" 1/4" 1/4"

DESCRIPTION NPT Brass Hex Head Pipe Plug NPT x -4AN 90-degree Elbow NPT x -4AN 90-degree Elbow NPT Tee with Tab

5 / 1 6 " Split Lock Washer 1 3 / 1 6 " O . D . x 3 / 8 " I . D . Flat Washer 3 / 8 " Circle Lock Washer 3 / 8 " Split Lock Washer 9 / 1 6 " O . D . X 5 / 1 6 " I . D . Flat Washer 5/8" O . D . x 3 / 8 " I . D . Flat Washer 5 / l 6 " - 1 8 x 1 " Hex Head Bolts 5 / l 6 " - 1 8 x 1 - 3 / 4 " Hex Head Bolts 3 / 8 " - l 6 x 1 / 2 " Hex Head Bolt 3 / 8 " - l 6 x 1 " Hex Head Bolt 3/8"-1 6x1-1 /4" Hex Head Bolt 3/8"-l6x2-1/2" Hex Head Bolt 3/8"--l6x4 1 / 2 " Hex Head Bolt 3/8"-24 Collet Locknut 5 / l 6 " - 1 8 x 1 " Stainless Hex Head Bolt 3/8"x1-1/2" Stud 1 1 / 1 6 " 0. D. x 5/16 flat washer 3/8"x2" Stud 5 / 1 6 " - 18 Nylock Nut 5 / l 6 " - 1 8 x 2 " Hex Head Bolt K&N Air Filter Cleaner K&N Air Filter Oil 1/4" -28 x1" Hex Head Bolt 1/4"-28 Nylock Nuts 1/2" O . D . x l / 4 " I - D . Flat Washers "Banks Turbo" Emblems

49 50 51 52 53 54 55 56 57 58 59 61 62 63 -65 -68 -69

70 71 --

3 8 1 5
2

3 1 6 6 4
2 2 1 2 1 1 2 2 2 2

NOTE:

SOME ITEMS IN KIT ARE NOT SHOWN IN ILLUSTRATIONS.

RE V. 5/19/89 1001/ K N

S h e e t 2 of