Banks Power Ford Trucks: (Diesel ’03 - 07 6.0L Power Stroke) Interface- PowerPDA Ford (03-09), Chevy (01-08), Dodge (03-07) - Manual (Page 18)

18
96801 v.9.0
The installation of the EgT
thermocouple needs to be
completed on trucks that currently
do not have a previously installed
thermocouple. Check to see that
a thermocouple is installed by
locating it on the exhaust manifold
as shown in the following figures:
Figure 26 – chevy/GMc (2001-2008)
Figure 27 – Dodge (2003-2007)
Figure 29– Ford 6.0L (2003-2007)
If a thermocouple is installed
then skip to Section 5.
Thermocouple is not required for
the Ford 6.4L (08-09). All Ford 6.4L
(08-09), skip to Section 5.
Note: Once the Six-Gun Diesel Tuner
is powered up at key-on, it will ‘learn’
that a thermocouple is installed and
automatically enable the EGT limiting
function. The thermocouple must
be installed in combination with the
Banks PowerPDA. If the thermocouple
is not installed, the Banks PowerPDA
will NOT add power, resulting in stock
power level and a Six-Gun tuner
fault error.
Chevy/gMC 6.6L Duramax
(LB7, LLY & LBZ) 2001-2007
ThERMoCoUPLE INSTALLATIoN
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 in Figure 26. 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 thermocouple
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
in Figure 26.
8.
Attach the thermocouple to the
supplied thermocouple leadwire
extension with supplied nuts and bolts.
Section 4
EgT ThERMoCoUPLE INSTALLATIoN
Notice: A Pyrometer (EgT) probe must be installed in conjunction with
the Six-gun Diesel Tuner in order to enable the Six-guns EgT limiting
function. Using the Six-gun Tuner without a pyrometer probe can lead
to detrimental damage to the engine due to excessive Exhaust gas
Temperature (EgT).