Banks Power Ford Trucks: (Diesel ’03 - 07 6.0L Power Stroke) Power Systems- PowerPack & Stinger '03-07 Compatible w_ Optional Banks iQ - Manual (Page 23)

96824 v.3.0
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Section 3
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. The manifold
must be removed from the engine to
thoroughly clean out all metal chips
from drilling. All metal shavings must
be cleaned from the manifold to avoid
turbine wheel damage and possible
interference with the turbochargers
variable geometry turbine stage.
2.
Disconnect the Exhaust Back
Pressure Sensor tap located at the
front of the driver side manifold. The
pressure tap must be removed by
using a 9 ⁄ 16 ” open-end wrench to hold
the fitting stationary, and loosen the
tube using a 5 ⁄ 8 ” open-end wrench.
The fitting is shown in Figure 22.
Note: Failure to hold the fitting
stationary will damage the tube upon
removal.
3.
Remove the driver side exhaust
manifold.
4.
Drill a 7 ⁄ 16 ” hole in the driver side
exhaust manifold at the location
shown in Figure 23.
5.
Tap the hole for a 1 ⁄ 4 ” NPT thread.
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. Caution: Running the tap
too deeply can prevent the pipe
fitting from properly sealing.
6.
Remove the NPT fitting from
the pyrometer and install it on the
exhaust manifold. Use anti-seize
lubricant on the threads and torque to
14–16 lb-ft.
7.
Remove all metal chips from the
exhaust manifold.
Note: Failure to remove all metal
chips could result in catastrophic
damage to the turbocharger’s turbine
wheel or interfere with the operation
of the variable geometry vane
mechanism.
8.
Re-install the exhaust manifold.
Apply anti-seize lubricant to the
manifold bolt threads and torque to
28 lb-ft. Use the tightening sequence
shown in Figure 24.
9.
Tighten the turbocharger adapter
pipe fasteners to 20 lb-ft as shown in
Figure 25.
10.
Reconnect the exhaust
backpressure static line tube.
11.
Install the DynaFact pyrometer
probe in the fitting.
Note: The thermocouple will be
connected to the EconoMind in
Section 4, Step 11.
-END, SEcTION 3-
Figure 22
Figure 23
Figure 24: Exhaust manifold
tightening sequence
Figure 25: Turbocharger adapter
pipe torque specification