Banks Power Dodge Trucks: (Diesel ’98 - 02 5.9L Cummins ISB) PowerPack & Stinger-Plus systems (connects to pump wire) - Manual (Page 10)

to 3 1 ⁄
2
turns hand tight. Do not install
the probe in place at this time.
11.
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.
Caution! Make sure rags are
removed from exhaust manifold
prior to reinstalling turbocharger!
12.
Install the thermocouple in the
manifold using anti-seize on the
threads.
Note: At this point in the installation
process, it is necessary to determine
which model turbocharger your vehicle
is equipped with. A turbocharger
identification tag is located on the front
of the compressor housing of the turbo
or on the actuator. If your turbocharger
is an HY35W, follow steps 13-17.
If your turbocharger is an HX35W,
proceed to step 18.
ACTUATOR INSTALLATION/
MODIFICATION
13.
Remove the E-clip from the
wastegate arm, allowing the actuator
rod to be released. Save the E-clip
for reinstallation. Remove the two
nuts holding the actuator to the
compressor housing and remove the
actuator.
14.
Tap the end of the boost
reference tube on the stock actuator
with the supplied 1 ⁄
4
-28 UNF tap.
Tap the tube just deep enough so
that the end of the jet is recessed
approximately 1 ⁄
32
” to 1 ⁄
16
” when
threaded into the end of the boost
reference tube and tightened until
snug.
15.
Install the jet into the end of the
boost reference tube then peen the
edge of the tube so that the jet cannot
back out. DO NOT use a thread locking
compound as a substitute for peening
the end of the tube. Thread locking
compounds will become ineffective
due to temperature.
16.
Using the supplied #55 bit, drill a
hole in the side of the boost reference
tube close to the area where the tube
is attached to the actuator can.
17.
Reinstall the actuator on the
compressor housing. Be careful not to
damage the O-ring that seals the boost
reference tube to the compressor
housing. Next, reinstall the actuator
rod end on to the wastegate arm. This
will be difficult since considerable
force is required to extend the rod far
enough. Reinstall the E-clip. Proceed
to step 23.
TURBOCHARGER DISASSEMBLY and
RE-ASSEMBLY
18.
Remove the turbine discharge
elbow by removing the five bolts
around the backside of the turbo.
19.
Clamp the turbine inlet flange
of the turbocharger in a smooth-
jaw bench vise. Loosen the four
bolts attaching the turbine housing
to the center bearing section of the
turbocharger. See Figure 5.
20.
Remove the bolts, lock plates,
and clamp plates. carefully remove
the center bearing and compressor
assembly from the cast iron turbine
housing. If the turbocharger has been
in service for some time, rust and
carbon may prevent the center bearing
and compressor assembly from easily
separating from the turbine housing.
If light hammer blows, penetrating oil
or heat will not free the compressor
assembly from the turbine housing,
the clamp bolt adjacent to the turbo oil
inlet connection may be backed out so
as to push against the bearing casting
and separate the two components.
10
96397 v.8.0