Banks Power Chevy_GMC Trucks: Diesel ’82 - 93 6.2L Forced Induction- Sidewinder Turbo System (late-body) - Manual (Page 16)

the bolt holes in the air filter mounting bracket, pro-
vided. This pair of bolt holes has a center-to-center
spacing of 1 1 ⁄
8
” . see figure 2.
With these bolts in place, use a pair of 3 ⁄
8
–16 x 3 ⁄
4
” long
bolts and four 3 ⁄
8
” ramp-lock washers to secure the air
filter mounting bracket to the air filter housing. see
figure 2 for proper positioning of the mounting bracket.
nOTe: Ramp-lock washers are used in pairs, with the
ramps against each other. see figure 14.
B. Install the air filter support bracket on the air filter
housing using a 3 ⁄
8
–16 x 1 ⁄
2
” bolt and two 3 ⁄
8
” ramp-lock
washers. Leave the bolt just loose enough so the
bracket can be adjusted.
C. Position the air filter housing in place above the right
inner fender panel. Make sure the plastic hose con-
nector (original gM) is properly engaged in the fender.
With the mounting bracket bolts through the outer two
holes in the fender panel (see figure 2 ), temporarily
tighten the filter housing in place using a 3 ⁄
8
–16 nylock
nut on the mounting bolt closest to the engine.
Position the support bracket so it hangs straight
down and contacts the inner fender panel next
to the battery tray. check that you have approximately
1 ⁄
2
” between the fron corner of the filter housing and
the inner fender panel. Mark through the hole in the
support bracket and drill a 3 ⁄
8
” diameter hole through
the inner fender panel.
D. The air filter housing may now be permanently
mounted using the two 3 ⁄
8
–16 x 1” hex bolts, two 3 ⁄
8
–16 nylock nuts and two 1” Od x 3 ⁄
8
” iD washers with
a back-up plate. use an open end wrench to hold the
mounting bolts while tightening. Bolt the filter support
bracket in place with a 3 ⁄
8
–16 x 1” hex bolt, 3 ⁄
8
–16 nylock
nut, and a 1” Od x 3 ⁄
8
” Id washer. Tighten the bolt that
holds the support bracket to the filter housing. clamp
the plastic hose connector in the fender to the nipple
on the air filter housing with a no. 64 hose clamp. see
figure 2.
Position the air filter element in the cover (other half) of
the air filter. Make sure the lip of the air filter element
is seated in the groove around the edge of the cover
casting. While holding the cover and filter together,
engage the tabs on the cover with the hinge clips on
the fixed housing half, and swing the cover/filter up
against the fixed housing. Make sure the filter is still in
the cover groove, then snap the latches onto the cover
to secure it.
Install the 3” dia. rubber elbow between the turbo-
charger and the air filter cover. The short leg of the
elbow goes on the turbo. secure the hose with two no.
52 hose clamps. carefully bend any air conditioning
lines as required for clearance.
Install the 1” molded rubber hose from the cdR (anti-
depression valve) to the nipple on the air filter cover.
secure with no. 16 hose clamps.
Hook up the remaining heater hose to the radiator.
secure with a no. 10 hose clamp. Replace any coolant
drained.
Install the pyrometer (exhaust temperature
gauge) following the instructions in the pyrom-
eter kit. a gauge panel is included for under-dash
mounting. check that any electrical connections are
not exposed where they could come in contact with
ground and render the gauges inoperative. Keep all
wiring away from exhaust heat and any mechanical
components that could damage the wire.
If optional instruments were ordered, they may be
installed at this time. follow the instructions provided
with the individual instruments. Route all instrument
wiring and tubing away from the exhaust heat and
mechanical components that could cause damage.
nOTe: remove the
1 ⁄
8
” nPT pipe plug from the left rear
corner of the pressure chamber for the boost gauge
connection, if this gauge is to be installed. If gauge is
not used, make sure connection is plugged.
NON EGR MODELS:
go to step 22.
EGR EQUIPPED MODELS ONLY: Install the fittings in
the solenoid valve provided in the Light duty emissions
Kit. aim the elbows as indicated in figure 11. Make
sure the fittings are installed in the correct ports on
the valve. The ports are stamped with the identification
“n.c.” and “cOM.” The third port is the “n.O.” port. do
not over-tighten the plastic fittings, finger-tight is suf-
ficient. no sealant is required on the threads.
Bolt the solenoid valve to the bracket supplied with
two 8 ⁄
32
x 3 ⁄
8
screws and lock washers. Make sure the
ports on the valve are oriented as shown in figure 10.
Bolt the solenoid valve and bracket to the intake mani-
fold as shown in figure 10. This will be at the location
of the fifth intake manifold bolt (or stud), counting from
front to back. If the vehicle is equipped with factory air
conditioning, this is at the rear bolt location on the air
conditioning bracket.
Route and connect the hoses as shown in figure
10.
use the black spring band clamp to secure the blue
silicone hose. use the green clamps on the neoprene
hose. Make sure your hoses connect to the proper
ports on the solenoid valve.
Hook up the wiring for the new solenoid valve as
shown in figure 11. use pliers to squeeze the terminals
onto the solenoid wiring as shown.
Raise vehicle, and install muffler and exhaust
system (not included with the turbo system) as
shown in figure 18. Because of various vehicle/chassis
combinations, the illustration provided is general, but
typical of the exhaust system routing.
a separate 3” high-flow exhaust system is available
from gaLe BanKs engIneeRIng. This exhaust system
includes a special low restriction 3” core muffler, pre-
formed tubing sections and all components necessary
to install the complete exhaust system. The BanKs 3”
exhaust system is ReQuIRed for emissions legal appli-
cations.
Re-install right battery, move battery as far forward in
battery tray as possible. Re-connect positive battery
cables. dO nOT connect negative cables.
16
19.
21.
20.
22.
P.n. 96292 V.2.0