Banks Power Ford Trucks: (Diesel ’83 - 93 6.9 & 7.3L) Forced Induction- Sidewinder turbo system (early-body) 6.9L & 7.3L - Manual (Page 7)

a. on 1987 and later models, unbolt the glow plug
relay from the rear of the intake manifold (leave wire
loom attached to relay). remove cable clamps holding
wire loom to rear of engine. Disconnect relay ground
wire from engine.
b. remove the two intake manifold bolts located
between the third and fourth fuel injector (counting
from the front to the rear) on the right (passenger) side
of the engine. see Figure
4 .
c. on 1987 and later models, Mount the glow plug
relay to the glow plug relay bracket (provided) using
two
1 ⁄
4
” – 28 x 1” hex bolts, two 1 ⁄
2
” O.D. x 1 ⁄
4
” i.D. wash-
ers, and two 1 ⁄
4
” – 28 nylock nuts. Clamp the relay
ground wire under one of the nuts. see Figure 4.
D. install the turbine inlet casting support bracket and
glow plug relay bracket to intake manifold using two
3 ⁄
8
– 16 x 3” hex bolts and two 3 ⁄
8
split lock washers. leave
bolts loose. see Figure 4. route the relay wiring, if
equipped, as shown in Figure
5.
Important! The glow plug relay bracket must be
installed on all models to provide proper spacing
between the turbine inlet casting support bracket and
the intake manifold, regardless of the presence of a
glow plug relay.
locate oil pressure gauge sender wire (discon-
nected in step 3). Carefully pull approximately
one foot of this free from the wire loom jacket.
Carefully clean around the hole where the origi-
nal grommet was installed at the rear of the
valley cover and where the anti-depression valve was
mounted on intake manifold. Use acetone, lacquer thin-
ner or other non-oil based solvent. install grommet in
valley cover as follows. Fill new grommet groove with
rTV silicone sealer provided. Press grommet through
opening in valley cover and smooth rTV around grom-
met. remove excess rTV. see Figure
6 . install rub-
ber o-ring in groove in manifold block-off plate. see
Figure 6. install manifold block-off plate (and o-ring)
on intake manifold where anti-depression valve was
removed, using two
5 ⁄
16
” – 18 x 1” hex head bolts and
split lock washers. see Figure 6. Do not tighten bolts
at this time.
remove and discard the hose clamp from the
heater hose connection on the water pump.
Hose clamp may be loosened and cut with snips to
avoid disconnecting hose.
a. Thoroughly degrease the injector pump drive cover
flange (oil fill-pipe flange on pre-1987 models) using
acetone, lacquer thinner, or other non-oil based sol-
vent. install the crankcase vent hose adapter and
original cover (or oil fill pipe) using two
5 ⁄
16
– 18 x 2” hex
bolts and two 5 ⁄
16
split lock washers. Use silicone sealer
at both joints.
b. replace the hose clamp previously removed from
the heater hose with a no. 10 hose clamp. keep the
tail of the hose clamp clear of the drive belt. see
Figure 7.
remove exhaust head pipes and exhaust sys-
tem, including muffler and tailpipe.
on automatic transmission models, remove
the transmission dipstick and then remove
the dipstick tube from the transmission. retain all
these components for later installation. Cover the
9.
12.
13.
10.
11.
7
Figure 5
Figure 6
Figure 7
P.n. 96310 V.3.0