Banks Power Dodge Trucks: (Diesel ’98 - 02 5.9L Cummins ISB) Tuner- Big Hoss Diesel Tuner (connects to pump wire) - Manual (Page 10)

10
96759 v.4.0
THERMOCOUPLE
INSTALLATION
1.
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).
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. Remove the two
bolts retaining the turbine outlet pipe
onto the turbine housing.
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.
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.
7.
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.
8.
Drill through the exhaust manifold
into the rear passage at the location
shown in Figure 3. Use a 7 ⁄
16
” drill,
keeping the drill perpen-dicular to the
manifold surface.
9.
Tap the drilled hole with a 1 ⁄
4
”
NPT pipe tap. Check the thread
depth as you tap by periodically
removing the tap and screwing the
thermocouple into the tapped hole.
The thermocouple should thread in 3
to 3 1 ⁄
2
turns hand tight. Do not install
the probe in place at this time.
10.
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!
11.
Install the thermocouple in the
manifold using anti-seize on the
threads.
Section 2
MODULE INSTALLATION PROCEDURE