Banks Power Dodge Trucks: (Diesel ’94 - 98 5.9L Cummins) Power Systems- PowerPack, Stinger-Plus & Stinger systems - Manual (Page 16)

Install the silicone and fiber insulating
sleeves removed with the factory heater
power supply studs into the thru-holes in the
banks heater housing castings. See figure 13.
Install the heating elements and ceramic insulator
assemblies into the top of the heater housings.
Install the power supply studs, mica insulating
washers, flat and lock washers, and nuts into
the heater housings and through the heating
element coils. The heating element coils will have
to bent slightly to line up the holes in the coils
with those in the housings. Check that there is a
mica washer on both top and bottom side of each
stud against the housing where the stud passes
through. Re-stake the stud threads with a chisel
to prevent loss of the nuts after assembly.
Install a 10 - 32 x 3 ⁄
4
inch hex bolt, No. 10
washer, ground strap and jet-locknut
through the side of each heater housing. See
figure 11. bend the heating element coil slightly to
install the bolt through the slot in the ground end
of the coil. Tighten the bolt and nut to ground the
coil and ground strap against the heater housing.
Check that no part of the heating element coil
other than the ground end comes in contact
with the inside of the heater housing. bend the
other (power input) end of the coil as required to
provide clearance. See figure 14.
16ì
Set a heater housing gasket
and the rear heater housing casting in place upon
the manifold baseplate. Note that the gasket goes
on one way to match the outline of the baseplate
flange. also note that the rear heater housing has
a machined flat area and two threaded holes in
the front surface of the housing. See figure 11.
Set the other heater housing gasket
and front heater housing in place on the
baseplate. It may be necessary to slightly bend
one injector tube to clear the front corner of the
forward heater housing. The injector tube must
not contact the housing after assembly. bend the
tube as little as possible to obtain about 1 ⁄
16
-inch
clearance to the housing. Use a smooth, rounded-
edge pry tool to avoid nicking or gouging the tube.
Slip a 3 ⁄
8
washer on one of the 3 ⁄
8
x 5-inch
hex bolts, then apply a drop of Loctite to
the first few threads and slide the bolt into the
rearmost long bolt hole on the banks TwinRam
manifold. Set an air inlet manifold gasket on top
of each heater housing, then set the TwinRam
manifold in place while guiding the bolt through
the heater housing and gaskets. Use extreme care
not to tear or damage the gaskets while installing
the bolts as boost leaks can occur. Thread the
bolt into the baseplate finger-tight, then install
washers and apply Loctite to the remaining three
5-inch hex bolts and thread them into the baseplate
through the manifold, heater housings and gaskets.
Use pliers to bend the upper end of each heater
housing ground strap to line up over the adjacent
corner bolt hole. Install a 3 ⁄
8
washer on two 3-inch
3 ⁄
8
hex bolts and thread the bolts into the baseplate
through the ground straps, manifold, heater
housings and gaskets. Install a 3 ⁄
8
washer on the
remaining two 3-inch 3 ⁄
8
hex bolts, apply Loctite
and thread the bolts into the baseplate through the
manifold, heater housings and gaskets. Torque all
bolts in the pattern shown in figure 15. Tighten all
eight bolts to 20 lb-ft, then in 5 lb-ft increments to
35 lb-ft, each time using the pattern shown.
once the bolts are torqued, slide one of the
factory injector tube spacers between the
rear heater housing and the three injector tubes, so
that the spacer is positioned over the two threaded
holes in the housing. See figure 11. Install the other
factory spacer half, and the factory clamp plate
to the heater housing using two 10 - 24 x 1–inch
bolts. when tightening the bolts, adjust the position
of the clamp assembly to center the heater coil
ground nut between the tubes. The tubes must not
be allowed to vibrate against this nut. once this
position has been established, remove each bolt
one at a time, apply Loctite and tighten.
Tighten all 12 injector tube nuts to 22 lb-ft.
using a 19mm or 3 ⁄
4
-inch crow’s–foot wrench
on a torque wrench. Install factory injector tube
clamp hardware onto the new bracket at the front
of the baseplate and tighten.
60.
65.
64.
63.
62.
61.
figure 14
16 p.N. 96384 V.3.0