Banks Power Dodge Trucks: (Diesel ’98 - 02 5.9L Cummins ISB) PowerPack & Stinger-Plus systems (connects to pump wire) - Manual (Page 8)

EXHAUST REMOVAL
1.
Under vehicle, remove the entire
factory exhaust system. Starting
at the rear of the vehicle, remove
each component by either cutting
through the pipe near the clamps or
by removing the clamps and heating
the joints to a red-orange color to
allow the crimped pipes to separate.
Remove the pin-type hangers from
the rubber frame mounts by prying
with a pry-bar or by pressing the pin
out of the rubber with large water
pump pliers. A soapy water solution
or a penetrating lubricant will ease
the removal of pin-type hangers from
the rubber frame mounts. Remove the
two bolts that attach the turbine outlet
pipe to the turbine outlet elbow and
remove the turbine outlet pipe from
the vehicle. Keep these bolts for later
use. To remove the turbine outlet pipe,
it may be necessary to cut the pipe
just to the rear of the pin hanger that
slides into the hanger bracket on the
transmission mount.
TURBOCHARGER REMOVAL
2.
Loosen the clamps that attach the
air inlet tube to the air filter housing
and to the turbocharger, and remove
the air inlet tube from the vehicle.
Remove the air filter housing from the
vehicle. This will allow easier access to
the turbocharger.
3.
Loosen the upper hose clamp on
the turbocharger oil drain-tube hose,
located between the two sections of
the oil drain tube.
4.
Disconnect the oil supply hose at
the turbocharger.
5.
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 turbocharger mounting
nuts or bolts 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.
6.
Clean and inspect the exhaust
flange mounting surfaces on the
exhaust manifold. Make sure the
surface is clean and dry.
THERMOCOUPLE INSTALLATION
7.
The thermocouple monitors the
temperature of the exhaust gases
entering the turbocharger at the
turbine housing. Installation requires
that the exhaust manifold be drilled
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 ISB engine uses
a divided exhaust manifold and
turbocharger. The thermocouple
may be installed to sample exhaust
temperature in either exhaust
passage. We recommend the rear
passage (toward the firewall).
8.
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.
System Installation Procedure
8
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