Banks Power 2001-2005 Chevy_GMC 6.6L Duramax Turbo-Diesel Pickups - Manual (Page 17)

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1.
The thermocouple monitors
the temperature of the exhaust
gases entering the turbocharger
at the turbine housing. Installation
requires that the exhaust manifold
be drilled near the manifold outlet.
It is recommended that the manifold
be removed from the engine to
thoroughly clean out all metal chips
from drilling. If manifold is not
removed from the vehicle, all chips
must be removed from the manifold.
This may be accomplished by using
a magnet to extract the chips after
drilling. The tap should be greased
before use and the chips again
removed with a magnet. All metal
shavings must be cleaned from the
manifold to avoid turbine damage.
2.
To access the exhaust manifold,
remove front passenger wheel well by
removal of plastic retainers.
3.
On the passenger side, remove the
hardware retaining the turbine inlet
exhaust pipe to the exhaust manifold
using a 12mm, 12pt socket along with
a 12mm, 12pt wrench, then remove
the exhaust manifold from vehicle. Pay
special attention to the orientation of
the manifold outlet gasket. Retain the
hardware and gaskets for re-assembly.
4.
center punch and drill through the
passenger side exhaust manifold into
the rear passage at the location shown
(see Figure 13). Use a 7 ⁄
16
” drill,
keeping the drill perpendicular to the
manifold surface.
5.
Tap the drilled hole with a 1 ⁄
4
” NPT
pipe tap. check the thread depth as
you tap by periodically removing the
tap and screwing the thermo-couple
insert into the tapped hole.
6.
Install the thermocouple insert
into the manifold using anti-seize
compound on the threads. Install the
probe in the thermocouple insert.
7.
Make sure to remove all shavings
from inside the exhaust manifold.
Reinstall the exhaust manifold. Torque
to 28 ft-lb in the sequence shown
Figure 13.
8.
Attach the thermocouple to the
supplied thermocouple leadwire
extension with the supplied nuts and
bolts. cover this joint with the supplied
heat shrink tubing and heat until the
tubing conforms to the joint. Make
sure the entire joint is insulated.
9.
Route the thermocouple leadwire
extension along the factory harness
to the driver’s side and connect it to
Section 4
OPTIONAL THERMOCOUPLE INSTALLATION (REqUIRED FOR
OPTIONAL BANKS POWERPDA OR SPEED-LOADER MODULE)
Figure 13