Banks Power Ford Trucks: (Diesel ’83 - 93 6.9 & 7.3L) Forced Induction- Sidewinder turbo system (early-body) 6.9L & 7.3L User Manual
Page 14
the turbocharger compressor to the wastegate actua-
tor diaphragm (on turbine housing) using a
3
⁄
16
x 10” sili-
cone hose and two spring band clamps.
install the 7” x 24” heat blanket on turbo down-
pipe. Form heat shield to the pipe to allow pro-
tection for the firewall. secure using wire ties provided.
Drop the turbocharger exhaust outlet pipe between the
rear of the engine and the firewall. start by lowering
the pipe with the flared end pointing toward the pas-
senger side of the vehicle (away from the turbo), then
rotate the pipe clockwise as it is lowered. install the
V-band clamp to couple the outlet pipe to the turbo.
Check that the outlet pipe is reasonably centered on
the outlet flange of the turbo as the clamp is tightened.
leave the clamp just loose enough to allow the outlet
pipe to move slightly for exhaust system adjustment.
a. remount the vacuum junction block (if removed) on
the firewall, relocating it upwards as required to provide
maximum clearance to the turbocharger and exhaust
outlet pipe. Drill new mounting holes to suit and reuse
original sheet metal screws.
NOTE: On C6 automatic transmission models, recon-
nect transmission modulator hose and tube. Route hose
away from hot turbo and exhaust piping.
install pyrometer (exhaust gas temperature) gauge and
any other optional instruments. instructions for pyrom-
eter installation are supplied with the pyrometer instru-
ment. route all wiring away from heat sources, moving
parts and sharp edges.
NOTE: If an optional turbo boost gauge (available from
Banks) is not to be installed, install a
1
⁄
8
” NPT pipe plug in
the port on the passenger side of the pressure chamber
casting (plug is supplied with turbo system hardware).
install the crankcase vent hose between the
antidepression valve and the crankcase vent
adapter on the front of the engine. Use two no. 16 hose
clamps.
From under the vehicle, install the exhaust
cross-over pipe assembly between the left
exhaust manifold and the turbocharger inlet casting.
reuse original nuts on left manifold studs. Use two
7
⁄
16
–
20 stainless collet locknuts and two
7
⁄
16
sae washers on
the turbo inlet casting studs.
install banks muffler and exhaust system work-
ing back from turbocharger outlet pipe. see
Figure
24
. because of various vehicle/chassis combi-
nations, some installations will require an extension
pipe.
NOTE: The factory muffler and exhaust system is NOT
suitable for turbocharged engines. The Banks “stan-
dard” and “monster” exhaust systems are specifi-
cally designed for use with this turbocharger system.
The use of any other exhaust components may result
in significantly inferior performance and may cause
excessive exhaust gas temperature. The use of a Banks
exhaust system is required for the turbo system to be
emissions legal.
now that the complete exhaust system is
installed, go back to the turbine outlet pipe and
tighten clamp to approximately 25 to 30 inch pounds.
FINAL CHECKS:
a. Check to be sure the injector return hose does not
rub on firewall lip or any other sharp edges. reconnect
battery cables.
b. Disconnect oil feed line connection at the turbo-
charger. Crank engine until oil flows from feed line and
crank another 5 to 10 seconds. Cranking time should
be limited to 20 to 30 seconds, followed by one minute
of cooling. This cycle should be repeated as required.
c. reconnect wires to injection pump. start engine.
it may not start immediately, due to fuel lost when
adjusting the injector pump. Observe the cranking rec-
ommendations noted previously. it also may be neces-
sary to depress the accelerator pedal somewhat.
CAUTION: Visually check the installation for any
improperly installed components, improperly routed
wires and hoses too close to hot exhaust, turbo com-
ponents, or sharp edges.
D. run engine at idle for a few minutes, to allow it to
warm. Check oil feed lines for leaks. engine may idle
erratically or surge until air is fully purged from fuel
system.
Drive vehicle. several short bursts of acceleration are
required to completely purge the fuel system of air.
The engine may run slightly rough until the purge is
complete, but will not in any way cause damage to the
engine.
Check injector pump adjustment. see “CHeCking
engine PerFOrManCe.”
14
25.
25.
24.
22.
23.
P.n. 96310 V.3.0