Banks Power Dodge Trucks: (Diesel ’94 - 98 5.9L Cummins) Forced Induction- BigHead Wastegate Actuator 1994-2004 Dodge ISB 5.9L Cummins - Manual (Page 5)

InsTAllATIon
InsTruCTIons
CAuTIon: When working
on the turbocharger
system, 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. such damage
is not covered under any
warranty.
1.
loosen the clamps that
attach the air inlet tube to
the air filter housing and
turbocharger. remove the air
inlet tube and air filter housing
from the vehicle. loosen the
clamp holding the compressor
outlet tube to the compressor
outlet and slide the tube off
of the turbocharger. This will
allow easier access to the
turbocharger and wastegate
actuator.
2.
Stuff clean shop towels
into the compressor outlet
and inlet hoses to prevent
foreign objects from entering
the pipes.
3.
Disconnect the boost line
attached to the nipple on the
wastegate actuator. Discard
the two (2) spring clamps and
factory boost line, as they will
not be reused.
for ease of installation,
Gale Banks engineering
recommends removing the
turbocharger from the vehicle
prior to installing the Banks
Big Head wastegate actuator.
if installing the Banks Big
Head actuator without
removing the turbocharger,
proceed to step 8 .
4.
remove the v-band clamp
that attaches the turbine
outlet elbow to the turbine
housing. retain the V-band
clamp for reassembly.
5.
loosen the upper hose
clamp on the turbocharger
oil drain-tube hose that is
located between the two
sections of the oil drain tube.
Disconnect the oil supply hose
at the turbocharger.
6.
remove the turbocharger
mounting nuts or bolts and
the turbocharger from the
exhaust manifold. Save the
nuts for reassembly. clean
and inspect the exhaust
flange mating surfaces on
the exhaust manifold and
turbocharger. make sure all
surfaces are clean and dry.
7.
cover the turbo oil drain
pipe with a clean shop
towel to avoid oil system
contamination.
8.
using a small standard
screwdriver or similar tool,
carefully remove the e-clip
securing the factory actuator
rod link to the pin on the
wastegate arm. Retain the
e-clip for reassembly. a spare
clip is provided with the kit
in case the factory clip is
damaged or lost - use of a
magnet during removal may
aid in retaining the factory
clip.
9.
remove and discard
the two (2) nuts holding
the factory actuator to the
turbocharger compressor
housing or mounting bracket.
remove the actuator.
10.
install the Bighead
actuator in place of the
factory actuator using the two
(2) supplied locknuts.
11.
Turn the rod end link on
the threads of the actuator
rod until the end link will
slip over the pin on the
wastegate arm. Turn the rod
end clockwise an additional
six (6) full turns, such that it
will shorten the rod and add
preload to the wastegate.
12.
apply a regulated
supply of air pressure to
the nipple of the actuator
(a standard schraeder valve
filler attachment can be used)
until the rod extends enough
to slip over the pin on the
wastegate arm. Reinstall the
e-clip on the pin. Tighten all
bolts and nuts that remain
loose.
if the Banks Bighead™
actuator was installed without
removing the turbocharger,
please proceed to
step 15 .
TurBoCHArGer
InsTAllATIon
CAuTIon: remove all
the rags that are inside
the compressor hoses
before re-installing the
turbocharger.
13.
re-install the
turbocharger on the exhaust
manifold. as the turbocharger
is reinstalled, slip the oil drain
tube into the drain hose.
Apply a small dab of anti-seize
compound on the threads
and tighten the turbocharger
mounting nuts or bolts to 32
ft-lbs. Tighten the oil drain
hose clamp. reconnect and
tighten the turbo oil supply
hose.
14.
re-install and tighten the
v-band clamp that attaches
the turbine outlet elbow to
the turbine housing.
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