Banks Power Jeep Trucks: (Gas ’91 - 06 Wrangler 4.0L) Sidewinder Jeep Turbo Jeep 4.0L I-6 models '05-06 User Manual
Page 15
96312 v.2.0
15
misaligned inside the housing,
as in Figure 16. Using damaged
catalytic converters may cause
catastrophic damage to engine
and/or turbo system.
6.
With “Y” pipe removed, measure
3 ¹/₄” from where welds join together.
Place a hose clamp around exhaust at
mark and use permanent marker to
create a line that will ensure a square
cut. Remove clamp. See Figure 17
7.
Cut exhaust on mark with pneu-
matic reciprocating saw. Take care
while cutting and beware of surround-
ing components.
!
CAUTION: Use eye and ear
protection while cutting.
8.
Remove oil pan by removing
all bolts. Note stud location for rein-
stallation.
⁷/₁₆" deep socket and extension
9.
Inspect oil pan gasket. Replace if
damaged or clean if reusable.
Turbocharger Oil Return
1.
Thoroughly clean oil pan in prep-
aration for welding. Scrape flange to
remove any silicone or gasket mate-
rial.
2.
Mark location for oil return bung.
Measure
2 ¹/₄
” from front edge and
³/₄” from top edge. Use a center punch
to mark oil pan once location is deter-
mined. See Figure 18
3.
Use a stepped drill bit to drill a
⁵/₈” hole in oil pan at marked location.
4.
Deburr edge of hole and prepare
oil pan for welding by using a wire
brush to remove paint around hole.
5.
Center oil return bung on drilled
hole and weld around outer edge.
!
NOTE: If you are not an expe-
rienced welder, take the oil pan
to your local welding shop to
have it welded by a qualified
welder.
6.
Clean weld with a wire brush and
inspect for imperfections that may
cause it to leak. Prime and paint raw
metal to prevent rust and corrosion.
Plug bung to protect threads during
painting.
7.
Using thread sealant, install 45º
brass fitting (P/N 92177) into oil return
bung on oil pan. Position as shown in
Figure 19.
8.
Clean gasket surfaces of oil pan
and engine block. Apply silicone seal-
ant to rear main bearing cap corners
and engine block to front cover joints.
See Figure 20
9.
Hold gasket and oil pan in posi-
tion, install all ¼” bolts and torque to 7
lb-ft. Install four
⁵/₁₆"
bolts and torque
to 11 lb-ft.
10.
Install oil pan drain plug. Torque
to 25 lb-ft.
11.
Install oil drain hose (P/N 94203)
from turbocharger to 45º brass barb
with two spring clamps (P/N 92878).
Figure 17
Figure 19
Figure 20
Figure 18