Banks Power Chevy_GMC Trucks: Diesel ’82 - 93 6.2L Forced Induction- Sidewinder Turbo System (early-body) - Manual (Page 7)

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drain coolant from radiator. Remove the lower
radiator hose. Install the new radiator hose
provided. Relocate the ground wire on the frame rail
to an alternate bolt hole location that will not allow
the bolt head to rub against the radiator hose. Replace
coolant.
Locate the injector fuel return tube in front of
the right cylinder head (see Figure 3 ). Remove
lower mounting clamp and hoses, and caRefuLLY bend
tubing as shown in the illustration. use gentle pressure;
do NOT kink the tube. Route the injector return hose as
shown to keep it as far as possible from the exhaust
manifold. additional fuel return hose is provided in
the kit if existing hose is not long enough. discard the
lower tube mounting clamp. Retain mounting bolt for
reuse. Install spring band clamps (provided) on hoses.
Install the pyrometer probe adapter (in the
pyrometer gauge kit) into the BanKs exhaust
manifold. Install the pyrometer probe. use an anti-seize
lubricant on the threads. Install four 3 ⁄
8
” x 1 3 ⁄
4
” studs
in the turbo mounting flange of the exhaust manifold.
Install three 3 ⁄
8
” x 1 3 ⁄
4
” studs in the 3-bolt crossover pipe
flange on the manifold.
Insert the eight original exhaust manifold
mounting bolts into the BanKs exhaust
manifold; note the new location of the two short bolts
(see Figure 4 ). Use rubber bands over each pair of
bolt threads to hold the bolts in place. no gasket is
required. Install the exhaust manifold, removing the
rubber bands once all the bolts are started in place.
Tighten bolts to 25 ft.-lb. use anti-seize on threads.
Re-install glow plugs. carefully bend glow plug
spade terminals up and away from hot manifold
surfaces (see Figure 5 ). Re-install glow plug wiring.
shorten any fuel return lines between injectors
as required to prevent lines from hanging in
close proximity to exhaust manifold. Tie fuel return
lines to wire loom with plastic cable ties provided. do
nOT pinch lines! See Figures 3 and 6 .
caRefuLLY bend air conditioning line(s), if
equipped, as shown in Figures 7 and 8. exercise
utmost care when bending the air conditioning lines.
ImPORTANT: Remove the plastic shipping plugs
from the oil inlet and oil drain flange on the
turbocharger.
Mount the turbocharger oil drain tube to the
turbocharger center bearing housing using the
turbo drain gasket, two 3 ⁄
8
” – 16 x 1” hex head bolts,
and two 3 ⁄
8
” split lock washers. See Figure 9.
Loosen, but do NOT remove, the six bolts that
hold the turbine housing (hot side) to the center
bearing housing of the turbocharger.
Temporarily mount the turbocharger to the
exhaust manifold (no gasket is used).
Rotate the turbo center bearing housing as
required to install the mounting bolt (from the
injection fuel return tube, previously removed) through
the tab on the turbo oil drain tube into the engine
block. do nOT tighten the bolt. Lightly snug one of
the six bolts on the turbo to secure the position of the
turbine housing.
25.
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figure 3 figure 4
figure 5
19.
p.n. 96291 v.3.0
30.