Banks Power Chevy_GMC Trucks: Diesel ’82 - 93 6.2L Forced Induction- Sidewinder Turbo System (early-body) - Manual (Page 11)

slip the 3-hole floating exhaust pipe flange
(previously removed) onto the left-hand
crossover pipe. Make sure the tapered side of the
flange sits against the flare in the pipe. Insert the left-
hand crossover pipe into the expanded end of the
right-hand crossover pipe. nOTe: It may be necessary
to back off the nuts or disconnect the right crossover
pipe from the manifold to assemble the crossover
pipes in place.
Install the assembled crossover pipes to the
exhaust manifolds using the factory exhaust
“doughnut” seal, springs, and nuts on the left manifold.
Tighten the stainless locknuts on the right manifold,
and make sure the 3-bolt gasket is in place. Install a 2”
exhaust u-clamp over the slip joint on the crossover
pipe assembly. Install the crossover pipe heat shield
(item 11) on the crossover pipe assembly as shown in
Figure 12. Be sure the shield is positioned between
the crossover pipe and the fuel and radiator hoses.
check the clearances between the fuel lines and
the exhaust crossover pipe in the vicinity of the
fuel pump. shorten or reroute the rubber fuel hose(s)
so there is a minimum of one inch clearance (1 1 ⁄
2
” or
more is recommended) between them and the exhaust
system. additional 3 ⁄
8
” and 1 ⁄
4
” fuel hose is provided for
the rerouting of the fuel supply and the injector return
lines. do not kink the fuel hoses.
Lower vehicle. Remove right-hand battery, jack
and jack handle.
Remove engine coolant recovery bottle bolts,
leaving those bolts that attach the bottle to the
battery tray. NOTE: Bolts may be accessible through
the grille, wheel well or depressions in the bottle.
Remove battery tray and coolant bottle as an
assembly.
On vehicles without cold inlet air duct, knock
out the 4” diameter slug in the right-side radiator
bulkhead, remove the grille and install the plastic air
inlet hood. Twist the hood into place. Reinstall the
grille.
Temporarily mount the air filter bracket to the
battery tray through the battery hold-down
threads using an M8-1.25 x 60mm metric full-thread
bolt and 5 ⁄
16
” I.d. x 3 ⁄
4
” O.D. washer. See Figure 1. Make
sure the narrow side of the bracket sits against the
vertical support section of the battery tray.
using the bracket as a template, drill two 11 ⁄
32
”
diameter holes through the battery tray.
Bolt the bracket and the back-up plate (located
opposite the bracket, see Figure 1 ) to the
battery tray with two 5 ⁄
16
” – 24 x 1” hex bolts, 5 ⁄
16
” I.D.
x 3 ⁄
4
” O.D. washers and 5 ⁄
16
” – 24 locknuts. Remove the
metric bolt and washer, apply Loctite to 1 ⁄
2
” of the
threads nearest head of the bolt, reinstall and tighten
(see Figure 1 for assembly sequence).
Install two 3 ⁄
8
” x 1 1 ⁄
2
” studs in the bottom of the air
cleaner casting. Install a 3 ⁄
4
” pipe x 1” hose, 90°
plastic elbow in the rear of the casting. use Teflon tape
on the threads. aim the elbow pointing slightly toward
the engine, as shown in Figure 13 .
Install air cleaner casting assembly to the
bracket on the battery tray using two 7 ⁄
16
” I.d. x
1” O.D. washers and two 3 ⁄
8
” – 24 locknuts. Reinstall
entire assembly into vehicle.
Install the rubber turbo air inlet elbow between the
air filter housing and the turbocharger with two
no. 52 hose clamps. See Figure 1. It may be necessary
to trim this elbow slightly to fit.
Install 4” diameter flex hose between the air
filter casting and plastic air inlet hood. Trim
hose to length as required. Relocate ground wires as
required to clear the hose. secure hose with two no.
64 hose clamps.
place air filter into air filter casting. Make sure
element is seated in depression in the bottom of
the casting.
Install the cover on the housing with four 7 ⁄
16
” –
20 x 3 ⁄
4
” hex bolts and 1 ⁄
4
” I.d. x 1 ⁄
2
” O.D. washers.
nOTe: cover goes on only one way; make sure the
cover registers properly on the filter element.
1982–1987 mOdELS
Install the 1” molded rubber hose between the
air filter housing and the anti-depression valve on
the engine. See Figure 13. Adjust the position of the
plastic elbow on the air filter housing as required for
installation. secure with two no. 16 hose clamps. Then
go to step 60.
1988 ANd NEWER mOdELS
Cut off and discard 2” of the hose that connected
the anti-depression valve to the intake manifold
1988 ANd NEWER mOdELS
cut off and discard the 90° bend from one end
of the 1” dia. molded rubber hose supplied in the turbo
kit. See Figure 14.
splice the remaining hose from step 58 to the molded
rubber hose using the 1” dia. steel tube and the two
original hose clamps. See Figure 14.
Reinstall the anti-depression valve in the valve cover.
connect the valve to the elbow in the air filter housing
using the lengthened 1” dia. molded hose with two no.
16 hose clamps supplied in the kit. See Figure 14.
figure 13
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p.n. 96291 v.3.0
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