Banks Power Ford Trucks: (Diesel ’99 - 03 7.3L Power Stroke) Power Systems- PowerPack, Stinger-Plus, Stinger & Git-Kit '19991_2-2003 F-250 & F-350 Trucks and Excursions - Manual (Page 8)

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96336 v.10.0
For Stinger installation, proceed to
Section 5, Step 4 .
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
turbcharger 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.
1.
Remove the decorative plastic cover
directly over the engine.
2.
Loosen the clamp holding the
air intake hose at the turbocharger
compressor inlet. Pull the hose free
of the turbo compressor. Disconnect
the boost line attached to the nipple
on the wastegate actuator. Disconnect
wiring and plastic tubing attached to
components on the turbo compressor
discharge plenum casting.
3.
Loosen the four clamps on the hoses
connecting the compressor discharge
plenum casting to the intake manifolds.
Loosen the clamp attaching the plenum
to the turbocharger compressor outlet
and the intercooler duct. Remove the
compressor discharge plenum from the
engine. Cover the two intake-manifold
hose nipples with clean rags to prevent
foreign objects from entering the engine.
4.
Disengage the exhaust-backpressure
control actuator rod by sliding the cover
on the end of the rod back toward
the turbocharger and pulling the rod
downward. This rod is below the turbine
housing; it is not the wastegate actuator
rod that runs across the top of the
turbocharger (see Figure 2).
5.
At the rear of the turbine housing,
loosen and remove the V-band clamp
attaching the turbine housing to the
exhaust inlet casting. Remove the two
bolts attaching the turbocharger bearing
housing to the pedestal base mounted
on the engine. Remove the turbocharger
from the engine by lifting while lightly
tapping the turbine housing with a
hammer.
6.
Remove the two O-rings from the
junction of the turbocharger bearing
housing and pedestal mount. Place a
clean rag over the oil passages in the
pedestal mount and the exhaust inlet
casting to prevent foreign object entry.
7.
At the back side of the turbocharger,
locate the small e-clip that retains the
actuator rod end on the wastegate arm.
Using a small screwdriver, carefully pry
the clip off of the wastegate arm and
retain for reuse.
CAuTIoN: This clip is very small
and is easy to lose. It may help
to use a magnet to retain the clip
as you remove it. Loosen the two
wastegate actuator nuts on the
turbocharger compressor housing
and remove the actuator.
8.
Clamp the turbocharger assembly in
a vise. Do not use the compressor inlet
or outlet to clamp the turbocharger. The
compressor housing is aluminum and
could be damaged. Observe and mark
the relationship of the turbine housing to
the center section of the turbo assembly.
If a Banks Brake is being installed,
proceed to Step 10 .
9.
Remove the exhaust backpressure
control valve from the factory turbine
housing, and install it onto the new
turbine housing with original hardware.
Duplicate the orientation of the original
assembly. Use anti-seize on the bolts.
10.
Remove the four bolts securing
the turbine housing to the turbocharger
center section. If the turbocharger is
more than a few months old, it may
be necessary to spray some Liquid
Wrench (or similar rust penetrating
lubricant) into the joint between the
turbine housing and the center section.
Work the housing loose from the center
section by tapping with a hammer and
brass drift or a soft face hammer. Work
from side to side and use plenty of
lubricant until the housing is loose from
the center section. Pull the housing
straight off of the center section to
avoid damaging the turbine blades.
–END, SECTION 4–
Section 4
TuRBoCHARGER REMoVAL
Figure 2- Disengage the Exhaust Back Pressure Control Actuator Rod