Banks Power Chevy_GMC Trucks: Diesel ’93 - 96 6.5L Power Systems- Stinger System '93-early '94 (non-cat) Pickups w_ factory turbo option - Manual (Page 2)

2 P.N. 96299
GENERAL INSTALLATION PRACTICES
For ease of installation of your Banks Stinger™
System, PLEASE READ THIS ENTIRE INSTRUCTION
PACKAGE BEFORE STARTING ANY WORK. (This package
contains 10 pages of copy, illustrations, & parts listing. If any
pages are missing from this package, please call GALE
BANKS ENGINEERING immediately for a replacement.)
Become thoroughly familiar with all components & phases of
the installation before starting any work.
Inspect all components supplied for any foreign material
that may have entered during shipping and handling.
WARNING! NEVER work under any
vehicle supported only by a jack of
any kind. DO NOT USE concrete blocks or
other masonry items that may collapse under
the vehicle weight.
Pay particular attention to the routing of wires and
hoses. Keep them away from exhaust heat, moving
parts and sharp edges that may cause cuts or other damage.
Route or tie away from critical areas as required. Keep all
wires a minimum of 6” from hot exhaust parts, 8” or more is
recommended whenever possible.
Right-hand and left-hand designations refer to the
driver’s right or left, as seated in the vehicle (i.e.:
Right-hand refers to the passenger side of the vehicle), unless
noted otherwise.
1.
INSTALLATION PROCEDURE
Disconnect both batteries.
Pull crankcase vent hose out of turbocharger air inlet
hose, then loosen air intake hose clamp at turbo compres-
sor. Remove two bolts through inner fender panel above right
front tire, then remove air cleaner assembly from vehicle.
Remove decorative cover from top of engine. Unbolt and
remove heat shield from turbocharger. On models with
support brace between turbocharger and intake manifold, pull
CDR valve out of valve cover and unbolt support brace, then
remove heat shield.
Remove “E” clip from pin on end of wastegate control
rod where pin attaches to wastegate lever on turbo out-
let elbow casting. Use care not to lose “E” clip. See Figure 1.
Unbolt wastegate control bracket from turbo compres-
sor cover, remove wastegate control assembly.
Install high boost lever, provided in kit, over pin on
wastegate control rod (see Fig.
2 ). Install “E” clip on pin.
Attach high boost lever with wastegate control assem-
bly to original wastegate lever on turbo outlet elbow.
Use a 5 /
16
–24 x 3 /
4
hex bolt, 5 /
16
AN washer, 3 /
16
long spacer, and
5 /
16
–24 lock nut as shown in Figure 2. Make sure end of bolt and
lock nut do not rub on outlet elbow when lever is rotated.
Reattach the wastegate control bracket to the tur-
bocharger compressor. Move the wastegate control rod
and lever through their rotation and check that binding does not
occur. Correct as necessary. NOTE: Some resistance is always
present from the wastegate control.
Loosen compressor discharge hose clamp at turbocharg-
er. Remove connecting strap between turbocharger and
air inlet casting.
Unbolt and remove air inlet casting from top of intake
manifold. Cover intake manifold opening to prevent for-
eign objects form falling into engine. WARNING! Any for-
eign object that falls into the intake manifold
can cause serious engine and/or turbocharger
damage upon engine start up.
Measure and mark the air inlet casting as shown in Figure
3. Centerpunch this location and drill through the casting
wall with a letter “R” drill ( .399 dia.), then tap the hole with a 1 /
8
NPT tap. Clean all chips from inside the casting.
Reinstall air inlet casting on intake manifold. Use new
gasket provided in kit. Tighten loose clamps, reinstall
brace. Install boost gauge hose fitting into hole tapped in air inlet
casting. Boost gauge hose fitting is supplied in boost gauge kit.
Use a pipe thread sealer (such as Teflon tape) on fitting pipe
thread.
Loosen the clamp attaching the exhaust pipe to the tur-
bocharger outlet elbow. Remove the complete exhaust
system from the vehicle. Leave the exhaust clamp on the turbo out-
let elbow.
Install the Banks Stinger exhaust system as shown in
Figure
4. Adjust the turbo outlet pipe and exhaust system
to provide maximum clearance to frame and other components.
Check alignment of muffler and tailpipe to hangers and vehicle.
When alignment and clearances look good, tighten all clamps,
including clamp at turbocharger outlet elbow.
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