Banks Power Dodge Trucks: (Diesel ’03 - 07 5.9L Cummins) Tuner- Six-Gun Diesel Tuner (235, 250, 305 HP Dodge 5.9L Cummins (24-valve) Trucks) '03-04 For use with Six-Gun Switch - Manual (Page 23)

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If the thermocouple is not being installed,
skip to Section 4, tRANSMISSIoN
LeARNING PRoCeDURe on page 25 .
Note: the thermocouple is not required
to operate the Six-Gun.
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
outlet of the manifold adjacent to the
turbine housing. For this reason it is
essential that the turbocharger be
removed from the engine in order to
clean out any metal chips from drilling
that could cause turbine blade damage.
The cummins ISB engine uses a divided
exhaust manifold. The thermocouple
may be installed to sample exhaust
temperature in either exhaust passage.
We recommend the rear passage
(toward the firewall).
2.
Loosen the clamps that attach the
air inlet tube to the air filter housing
and to the turbocharger, and remove
the air inlet tube from the vehicle.
Remove the air filter housing from the
vehicle. This will allow easier access to
the turbocharger.
3.
Loosen the upper hose clamp on the
turbocharger oil drain-tube hose that
is located between the two sections of
the oil drain tube.
4.
Disconnect the oil supply hose
at the turbocharger. Disconnect the
compressor outlet hose that goes to
the intercooler.
5.
Remove the turbine outlet pipe by
loosening the V-band. Save V-band for
re-installation.
6.
Remove the turbocharger mounting
nuts/bolts and the turbocharger from
the exhaust manifold. Clean and
inspect the exhaust flange mounting
surfaces on the exhaust manifold. Make
sure the surface is clean and dry.
CAUTION: Anytime the turbocharger
is removed from the engine,
take care that no foreign objects
enter any of the turbocharger
connections on the engine or the
turbocharger. Foreign objects
entering air, exhaust, or oil
connections may cause major
damage to the engine and/or
turbocharger and is not covered
under any warranty. Cover the
open end of the intercooler pipe
with a clean rag, as this pipe is very
suscep-tible to foreign object entry.
7.
Stuff clean shop towels into the
compressor outlet and inlet hoses to
prevent contamination from entering
the pipes. cover the turbo oil drain pipe
to avoid contamination.
8.
Stuff a small clean shop towel
or rag 4 to 5 inches into the rear
exhaust manifold passage through the
turbocharger mounting flange. This
is to prevent chips from entering the
manifold while drilling and tapping.
9.
Use a 7 ⁄
16
” drill, keeping the drill
perpendicular to the manifold surface
and drill through the exhaust manifold
into the rear passage as shown in
Figure 19.
10.
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 pipe coupling into
the tapped hole. The coupling should
thread in 3 to 3 1 ⁄
2
turns hand tight. Do
not install the probe in place at this
time.
SECTION 3
OPTIONaL THERMOCOUPLE INSTaLLaTION