Banks Power Dodge Trucks: (Diesel ’03 - 07 5.9L Cummins) Power Systems- Stinger system '03-04 - Manual (Page 4)

13.
Remove all loose chips from
the exhaust manifold. A shop
vacuum or small brush will help.
Now remove the rag using a welding
rod or coat hanger bent into a hook.
caution! Make sure rags are
removed from exhaust manifold
prior to reinstalling turbocharger!
14.
Install the thermocouple in
the manifold using anti-seize on the
threads.
BIG HEAD
ACTUATOR
INSTALLATION
15.
Remove the actuator pressure
hose on the turbocharger by
removing the two (2) clamps.
Remove the two (2) nuts holding the
actuator to the bracket and remove
the actuator.
16.
Install the BigHead ® actuator in
place of the factory actuator. Install
the supplied actuator pressure hose
and secure it by using the two (2)
supplied spring clamps. See Figure
2 .
17.
Turn the rod end link on the
threads of the actuator rod until the
end link will slip over the pin on the
wastegate arm. Turn the rod end
clockwise an additional six (6) full
turns, such that it will add preload to
the wastegate.
18.
Apply a regulated supply of air
pressure to the nipple of the actuator
until the rod extends enough to slip
over the pin on the wastegate arm.
Reinstall the E-clip on the pin. Tighten
all bolts and nuts that remain loose.
TURBOCHARGER
INSTALLATION
CAUTION: Remove all the rags that
are inside the compressor hoses
and the exhaust manifold before
re-installing the turbocharger.
19.
Install the new turbine inlet
gasket provided and apply a dab
of anti-seize compound to the
four turbo mounting studs. Install
the turbocharger on the exhaust
manifold. As the turbocharger is
reinstalled, slip the oil drain tube
into the drain hose. Tighten the
turbocharger mounting nuts to 24
ft-lbs. Tighten the oil drain hose
clamp.
20.
Reconnect and tighten the
turbo oil supply hose.
Figure 1
Figure 2
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