Banks Power Chevy_GMC Trucks: Diesel ’82 - 93 6.2L Forced Induction- Sidewinder Turbo System (late-body) User Manual
Page 8
8
Install the exhaust manifold heat shield on the
Banks exhaust manifold. Hammer three
1
⁄
8
” dia.
x
1
⁄
4
” long drive screws through the heat shield into the
manifold.
Install the pyrometer probe (in the pyrometer gauge
box) into the Banks exhaust manifold. Install four
3
⁄
8
” x
1
3
⁄
4
” studs in the turbo mounting flange of the exhaust
manifold. Install two
3
⁄
8
” x 2
1
⁄
4
” studs in the 2-bolt cross-
over pipe flange on the manifold.
Insert the eight original exhaust manifold mounting
bolts into the Banks exhaust manifold; note the loca-
tion of the four short bolts. use rubber bands over each
pair of bolt threads to hold the bolts in place. (no gas-
ket 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.)
check that heater hoses are tucked close to the fire-
wall, as far away from exhaust heat as is possible, and
that they will not rub on sharp edges of heat shielding.
Re-install glow plugs. carefully bend glow plug
spade terminals up and away from hot manifold
surfaces. see figure
8.
CAUTION: To avoid breaking terminals off the glow
plugs, grip the terminal tab where it is spot welded to
the terminal stud with a pair of long nose pliers, then
bend tab with another pair of pliers. see figure
8.
nOTe: some glow plugs may tighten into a position
where it is not possible to bend the tab to provide
clearance to the exhaust manifold. at these locations,
cut the existing connectors off of the glow plug wires,
as close to the connector as possible. crimp a 90’
female spade terminal onto the wire, and adjust termi-
nal and wire to clear exhaust manifold when installed.
The glow plugs may also be installed in other cylinders
to obtain other final tightening positions before bend-
ing their terminal tabs. see figure
9.
Re-connect all glow plug wires to glow plugs. Make
sure wires and connectors are routed as far away from
exhaust manifold surfaces as is practical. glow plug
wires should route down and behind the rear of the
exhaust manifold, and up to each glow plug.
A. Mount the turbocharger oil drain tube to the
turbocharger center bearing housing using the
turbo drain gasket, two
3
⁄
8
” – 16 x
3
⁄
4
” hex head bolts,
and two
3
⁄
8
” split lock washers. see figure
12.
IMPORTanT: Remove the plastic shipping plugs from
the oil inlet and oil drain flange on the turbocharger.
B. 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 a
1
⁄
4
–20 x
1
⁄
2
” mounting bolt through the tab on
the turbo oil drain tube into the exhaust manifold. do
nOT tighten the bolt. Lightly snug one of the six bolts
on the turbo to secure the position of the turbine hous-
ing.
C. Loosen, but do not remove the six bolts that hold
the compressor housing (cold side) of the turbocharger
to the turbocharger center bearing housing.
Temporarily install the large end of the intake “boost”
tube into the silicone hose on the pressure chamber.
Rotate the turbo compressor housing so it lines up
with the other end of the boost tube. Lightly snug one
of the six bolts on the compressor housing to secure
this position.
remove the boost tube.
D. Install a
1
⁄
4
” nPT x – 4 tube, 90° elbow fitting in the oil
inlet of the turbocharger center bearing housing. use
Teflon tape on the threads. aim the elbow so it points
up, toward the engine.
E. Remove the turbocharger from the engine, tighten
all 12 compressor and turbine housing bolts, and bend
the lock tabs against the bolt heads.
A. drop the exhaust head pipe into place
between the engine and the right frame rail.
B. slip a piece of
5
⁄
8
” Id x 1
1
⁄
2
” long blue silicone hose
onto the tube on the oil drain adapter/drain plate. slip
a pair of no. 10 hose clamps over the hose.
drop the turbocharger in place over the exhaust manifold
studs. (no gasket is used, or needed, between the turbo-
charger and exhaust manifold.) guide the turbocharger
oil drain tube into the oil drain hose on the adapter.
secure the turbocharger with four
3
⁄
8
” Id x
5
⁄
8
” OD wash-
ers and four
3
⁄
8
–24 stainless collet lock nuts. see figure
11.
12.
figure 8
figure 9
10.
P.n. 96292 V.2.0
13.