Banks Power Dodge Trucks: (Diesel ’94 - 98 5.9L Cummins) Power Systems- PowerPack, Stinger-Plus & Stinger systems - Manual (Page 4)

Disconnect the oil supply hose at the
turbocharger.
Note the orientation of the compressor
housing in the vehicle. when the new
assembly is installed the orientation of the
compressor outlet should remain the same.
Remove the boost pressure hose from the nipple of
the wastegate actuator. Remove the turbocharger
mounting nuts and the turbocharger from the
exhaust manifold.
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 rag, as this pipe is
very susceptible to foreign object entry.
Clean and inspect the exhaust flange
mounting surfaces on the exhaust manifold.
Remove any remaining gasket material from
the turbocharger oil drain flange surface. make
sure the surface is clean and dry.
for quick-Turbo installation only, proceed to step 21.
Pyrometer (Exhaust Temp.) Gauge
11.
The exhaust gas pyrometer monitors the
temperature of the exhaust entering the
turbocharger turbine housing. Installation requires
that the exhaust manifold be drilled adjacent to
the temperature probe 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 6bT engine uses a divided exhaust
manifold and turbocharger. The pyrometer probe
must be installed to sample exhaust temperature
in one of the two exhaust passages. Typically the
exhaust temperature will not differ appreciably
between the two passages. we recommend
installing the probe in the rear manifold passage
to simplify routing the probe wiring.
12.
Stuff a small 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.
13.
Drill through the exhaust manifold into the
rear passage at the location shown in figure
2. Use a 7 ⁄
16
inch drill, keeping the drill perpendicular
to the manifold surface.
14.
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
probe fitting (supplied in pyrometer kit) into the
tapped hole. The probe should thread in 3 to 3 1 ⁄
2
turns hand tight. Do not install the probe in place
at this time.
15.
Remove as many loose chips as possible
from the exhaust manifold. a shop vacuum,
small brush, or fingers will help. Now remove the
rag using a welding rod or coat hanger bent into a
hook.
8.
9.
10.
figure 2
4 p.N. 96384 V.3.0