Banks Power Cummins Motorhomes: (Diesel ’98 - 03 ISC 8.3L) PowerPack TLC & Stinger TLC systems '98-03 8.3L, 315, 330 or 350-hp, 24-valve, Class-A MH, Except Common Rail - Manual (Page 4)

10.
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.
11.
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 coat hanger bent into a hook.
Caution! Make sure rags
are removed from exhaust
manifold prior to reinstalling
turbocharger!
12.
Install the thermocouple in
the manifold using anti-seize on the
threads.
For PowerPack installation, proceed
to Step 17.
Big-HeAD ACtUAtOr
inSTaLLaTion
13.
Before removing the stock
actuator, note the orientation of the
boost reference nipple. The Banks
BigHead actuator will need to be
installed in the same orientation.
Remove the e-clip holding the
actuator rod end to the wastegate
arm. Unbolt the three actuator
bracket bolts from the turbine
housing. Note the location of all
spacers and retain the spacers and
bolts for reinstallation. Remove the
two nuts holding the actuator to the
bracket and remove the actuator.
14.
Install the Banks BigHead
actuator in place of the factory
actuator using the two
7 ⁄
8
” long
hexagonal spacers provided. The
spacers are provided to clear the
turbocharger compressor housing on
some installations.
15.
Turn the rod end link on the
threads of the actuator rod until
the hole lines up with the pin on
the wastegate arm. Turn the rod
end clockwise an additional six full
turns such that it will preload the
wastegate.
16.
Apply a regulated supply of air
pressure to the nipple of the actuator
until the rod extends enough to slip
over the wastegate arm. Reinstall the
e-clip on the wastegate arm. An extra
e-clip is supplied in the kit. Tighten all
bolts and nuts that remain loose.
tUrBOCHArger DisAsseMBLY
and re-AsseMBLY
17.
clamp the turbine inlet flange
of the turbocharger in a bench vise.
Loosen the six bolts attaching the
turbine housing to the center bearing
section of the turbocharger. See
Figure 2.
18.
Remove the bolts, lock plates,
and/or clamp plates. carefully
remove the center bearing and
compressor assembly from the
cast iron turbine housing. If the
turbocharger has been in service
for some time, rust and carbon
may prevent the center bearing and
compressor assembly from easily
separating from the turbine housing.
If light hammer blows, penetrating oil
or heat will not free the compressor
assembly from the turbine housing,
the clamp bolt adjacent to the
turbo oil inlet connection may be
backed out so as to push against
the bearing casting and separate the
two components. Remove any loose
rust or carbon from the bearing
housing that might prevent proper
engagement into the new turbine
housing.
19.
Install the center bearing and
compressor assembly into the new
Banks Quick-Turbo turbine housing.
Apply a dab of anti-seize compound
to the bolts, and then install bolts,
clamp plates, and lock plates finger-
tight to allow for final positioning.
If the Banks BigHead actuator is
installed on the bracket in the wrong
orientation, remove the actuator and
rotate it 180 degrees. Do not change
the length of the actuator rod. Re-install
by applying regulated shop air to the
boost reference nipple until the rod
end drops over the wastegate arm.
Re-install e-clip.
tUrBOCHArger instALLAtiOn
20.
Install the new turbine inlet
gasket provided and apply a dab
of anti-seize compound to the
four turbo mounting studs. Install
the turbocharger on the exhaust
manifold. Tighten the turbocharger
mounting nuts to 24 ft-lbs.
21.
Align the compressor outlet
elbow with the boost tube and
tighten the clamp. Tighten the turbine
housing clamp plate bolts to 11.3N-m
(100 in-lb.) torque.
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