Banks Power Chevy_GMC Trucks: Diesel ’82 - 93 6.2L Light-duty emissions kit - Manual (Page 2)

IMpOrTaNT: please read all instructions
both these and sidewinder turbo system
instructions) before starting any work. this package
contains 3 pages of copy, 7sheets of illustrations, and
1 page of parts listing. if any pages are missing from
this package, please call gale banks engineering
immediately for a replacement.)
OpEraTION: the egr valve functions as it
normally would under all operating conditions.
the solenoid valve in this kit protects the egr valve
diaphragm from turbo boost conditions when the
egr valve is closed. this also prevents exhaust
pressure from lifting the egr valve off its seat during
boost conditions.
IMpOrTaNT: all emissions components on
the vehicle must be hooked up and functioning
in order for the engine to run properly with this kit.
egr valves that are disconnected from the emissions
plumbing and inoperative electrical systems may
allow exhaust gas to recirculate during boost
conditions which is detrimental to performance
and could cause engine damage. if this system is
properly installed, the emissions system will function
just as it did in the original factory installation.
NOTE: the gm 6.2L Light duty diesel engines
use an epr (exhaust pressure regulator) valve
in the exhaust system. this valve looks like a typical
heat riser valve, and is mounted on the outlet of the
left exhaust manifold. this valve closes while the
egr valve is open, to create a higher exhaust pres-
sure and help the egr to function. the epr valve is
open under boost to allow for unrestricted exhaust
flow. the epr valve must be in place and functioning
for the emissions and turbo system to operate prop-
erly. exhaust cross-over piping is included with this
kit to allow the epr valve to remain in place on the
exhaust manifold.
rETrOfIT TO hEavy DuTy TurbO KIT:
this Light duty emissions kit may be used to
adapt the banks sidewinder turbo system intended
for heavy duty (non egr equipped) diesels to the light
duty diesel engine. Note: the early heavy duty Banks
pressure chamber must be modified inside to clear
the eGR valve. See step 4 for identification of those
pressure chambers and necessary modification
.
GeNeRal INStallatIoN PRactIceS
5.
4.
3.
2.
1.
2 p.n. 96293
INStallatIoN INStRuctIoNS
install the fittings in the solenoid valve
provided and aim the elbows as indicated
in figure 1 . make sure the fittings are installed
in the correct ports on the valve. the ports are
stamped with the identification “in” and “out”. the
third port is the “n.o.” port. do not over-tighten the
plastic fittings, finger-tight is sufficient. 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 1 .
bolt the solenoid valve and bracket to the
intake manifold as shown in figure 2 . this
will be at the location of the fifth intake manifold
bolt (or stud), counting front to back on the driver’s
side. if the vehicle is equipped with factory air
conditioning, this is the rear bolt location where the
air conditioning compressor bracket attaches to the
intake manifold.
inspect the inside of the pressure chamber
casting between the two bolt bosses.
if the pressure chamber is an early style casting,
it will have a rib joining the bosses together (see
figure 3 ). this rib must be ground away to provide
clearance for the egr valve, see figure 3 for details
on modification. if no rib is present, proceed to step
5 .
With the pressure chamber off the engine, drill
a 21 /
64
” hole through the side of the pressure
chamber 3 /
4
” above the existing threaded hole
(see figure 4 ) with drill bit provided. remove all
burrs from the hole and all chips from inside of the
pressure chamber.
1.
3.
2.
5.
4.