Banks Power Dodge Trucks: (Diesel ’03 - 07 5.9L Cummins) Power Systems- Stinger system '03-04 - Manual (Page 5)

Figure 4
21.
Re-install the air filter housing
that was previously removed.
EXHAUST
INSTALLATION
22.
Make sure the mating surface
is clean and free of oil, attach the
supplied T.O.P. gasket to the Banks
T.O.P. Loosely place the factory
V-band clamp on the Banks T.O.P.
Install the Banks T.O.P. to the turbine
housing (note: the factory turbine
outlet elbow will not be used).
Loosely snug the V-band clamp
assuring gasket and T.O.P. is aligned
properly. See Figure
3 on page 6-7 .
For vehicles equipped with catalytic
converter, skip to STEP
24 . For non-
cat vehicle, continue to STEP 23 .
23.
FOR VEHICLES THAT
ARE NOT EQUIPPED WITH A
CATALYTIC CONVERTER: install the
supplied Banks front intermediate
pipe and supplied gasket onto the
previously installed Banks T.O.P.
Place a small amount of anti-seize
onto the four (4)
7 ⁄
16
” bolts. Loosely
install the supplied 7 ⁄
16
” hardware
onto the T.O.P. and intermediate pipe
flange (see Figure
3 on page 6-7 ).
Proceed to Step 27 .
24.
FOR VEHICLES EQUIPPED
WITH CATALYTIC CONVERTER:
IMPORTANT: If the vehicle is
equipped with a catalytic converter, it
should be inspected. Diesel catalysts
may become plugged with soot and
can cause a restriction to exhaust
flow, impeding performance. Shine
a powerful flashlight into the inlet
end of the converter. Observe the
light through the other end of the
converter. The full circle of the
flashlight should be visible without
any blockage in the grid work of the
catalyst. If excessive soot is observed,
the catalyst may need to be cleaned.
TAkE PREcAUTIONS to avoid blowing
soot toward the work area or where
it could be inhaled. ALWAYS use
breathing protection. Also inspect the
catalyst for damage (i.e. chips, bent
corners, etc.) to the grid work. If your
catalytic converter is damaged, it
may be covered under your vehicle’s
emissions warranty.
CAUTION: The following step
involves cutting a stainless steel
tube. Safety glasses should be
worn during any cutting operation,
and care should be taken to avoid
injury due to sharp edges and
burrs.
With the catalytic converter removed
from the vehicle and the headpipe
removed from the converter,
measure 13” inward from the outlet
tubing rim (3-
1 ⁄
2
” of tubing from the
outlet weld should remain). Using
a reciprocating saw or equivalent,
squarely cut and remove 13” from
the converter outlet tubing. See
Figure
4 .
25.
Install the supplied Banks
front intermediate pipe and supplied
gasket onto the previously installed
Banks T.O.P. Place a small amount
of anti-seize onto the four (4)
7 ⁄
16
”
bolts. Loosely install the supplied
7 ⁄
16
” hardware onto the T.O.P. and
intermediate pipe flange.
26.
Install the supplied 3- 1 ⁄
2
” clamp
onto the catalytic converter inlet.
Place the catalytic converter onto
the previously installed intermediate
pipe. Loosely snug the clamp on the
catalytic converter inlet.
27.
Place a supplied 4” clamp onto
the front of the supplied intermediate
pipe. Install the intermediate pipe
onto the catalytic converter outlet or
the front intermediate pipe. Lightly
snug the band-clamp near the rim of
the intermediate pipe.
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