Banks Power Dodge Trucks: (Diesel ’03 - 07 5.9L Cummins) Power Systems- Stinger system '03-04 - Manual (Page 3)

EXHAUST REMOVAL
Important: DO NOT DAMAGE
CATALYTIC CONVERTER TUBING
DURING THE REMOVAL PROCESS.
1.
From under the vehicle, remove
the entire factory exhaust system.
Starting at the rear of the vehicle,
remove each component by either
cutting through the pipe near the
clamps or by removing the clamps
and heating the joints with an
oxyacetylene torch to allow crimped
pipes to separate. DO NOT CUT OR
DAMAGE CATALYTIC CONVERTER
TUBING DURING THE REMOVAL
PROCESS. Remove the hanger pins
from the rubber hangers with a pry
bar. (Spray lubricant will ease hanger
removal.)
2.
Remove the clamp attaching
the turbine outlet pipe (T.O.P.) to
the catalytic converter headpipe
(or intermediate pipe if applicable)
and remove the catalytic converter
assembly or intermediate pipe.
Remove the band-clamp that attaches
the T.O.P. to the turbine outlet elbow
and remove the factory T.O.P. from
the vehicle.
3.
Remove the v-band clamp that
attaches the turbine outlet elbow
to the turbine housing and remove
the turbine outlet elbow from the
vehicle. Retain the V-band clamp for
reassembly.
TURBOCHARGER
REMOVAL
4.
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.
5.
Loosen the upper hose clamp
on the turbocharger oil drain-tube
hose that is located between the two
sections of the oil drain tube.
6.
Disconnect the oil supply hose
at the turbocharger. Disconnect
compressor outlet hose that goes to
the intercooler.
7.
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 susceptible to foreign object
entry.
8.
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.
THERMOCOUPLE
INSTALLATION
9.
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).
10.
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.
11.
Drill through the exhaust
manifold into the rear passage as
shown in Figure
1 . Use a 7 ⁄
16
” drill,
keeping the drill perpendicular to the
manifold surface. NOTE: A 90º drill
will work better.
12.
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.
9 6 7 6 7 v . 3 . 0
| 3