Gale Banks Engineering - Diesel Performance Specialists 6.5L User's Manual
Contents
1. 64001 1 MOUNTING PANEL Two Gauge Black 63002 01 1 MUFFLER x 3 Stainless eek es er 52419 4 NUT 042 20 Crimp Lock eO e 91619 2 Machine Screw 10 32 91833 1 OWNERS MANUAL 555 RERBA see 96312 1 PIPE Chrome Tailpipe pr ibo m ree 52285 1 PIPE Intermediate 3 52063 1 PIPE Tailpipe 3 Aluminized eer n 52074 1 PIPE Turbine Outlet 00 00 00 52014 2 PLAQUE BANKS POWERPACK u 96008 2 SCREW Machine 10 32 x Pan Head 91834 1 SERVICE KIT Air Fiter tos 90094 107 TIE Gable TI Black o eat 62002 WARRANTY STATEMENT cocos cnica coito td 96362 WASHER A ta 91602 2 WASHER 10 Ext Tooth Lock hee e eons 91832 11 963122. LVI NO 4 1311010 WO3l4 AVL 57 201 OWEJ Sivas E 1 2ILATVIV2 33133ANO2 2ULATVIV2 NO 3313AO3A4 NI aald doN 9 anis SAANA 39034 J3JAOMWZ3 333H 102 3313 0344 NOLLYOd SIHL 6 J3ySV9 alvId3W33lNI LATINI N2133ANO2 LATIN N2133ANO2 1311010 18nvHXxa 2ILATVIV2 AF9AYHIOAANL DT mi af x 4Wv 12 1envHxa ANYJA ASOLIV4 CLEANING AND OILING THE BANKS RAM AIR FILTER PRE CLEANING Tap the element to dislodge any large embedded dirt then gently brush with a soft bristle brush NOTE If complete cleaning is not practical at this time the element and reinstall in your vehicle SPRAY ON CLEANING Spray Banks air filter cleaner liberally onto the entire element and let soak for 10 minutes PAN CLEANING Large air filter elements can be rolled or soaked in a shallow pan of Banks air filter cleaner Remove immediately and let soak for approximately 10 minutes CLEANING HINTS Use only Banks air filter cleaner NO gasoline cleaning steam cleaning NO caustic cleaning solutions NO strong detergents NO high pressure car wash NO parts cleaning solvents Any of these NOs can cause harm to the cotton filter media plus SHRINK and HARDEN the rubber end caps 4 RINSE OFF Rinse off the element with low pressure water Tap water is okay Alway
3. gas temperature will be very low perhaps only 150 F As the throttle is opened for higher speeds and greater loads the EGT will rise The highest EGT will be seen under maximum load at full throttle such as climbing a steep grade with a heavily laden vehicle Use caution if your EGT approaches 1000 F with 1050 F being the SAFE MAXIMUM If the vehicle approaches these EGT levels under these conditions downshift the vehicle to reduce the load or back off the throttle Exhaust gas temperature in this system is measured after the turbocharger in the turbine outlet pipe as is commonly done on long haul diesel trucks Your boost gauge monitors the air pressure the turbo compressor is delivering to the intake manifold The Banks Stinger system is designed to provide a maximum boost pressure of approximately 10 11 PSI This is an average maximum figure which will vary from engine to engine This maximum figure will be reached only under hard acceleration heavy load conditions Light cruise conditions may show little or no boost 8 P N 96312 AVIA f NOISNVAXA 3dld 40 NOLLIINA N ANYVIIANV ANOAHD 201 ANIAD d 3 2 ji JIHSVM A P N 96312 ddld UVL v AJONVH T 2 JO AJVMOL AJOLIVA OL MOTIV N aINOHS AJONVH r N ave UL 4 UN 49144
4. to squeeze the locking tabs inward lift the factory PROM from the circuit board The Banks Ottomind PROM is keyed such that it will only install one way With the PCM positioned as mentioned in the previous step the Banks Ottomind will install with the label reading properly Install the Banks Ottomind in the socket left vacant by the factory prom DO NOT FORCE THE INSTALLATION If the Ottomind does not engage the pins with a slight downward pressure recheck the orientation of the Ottomind If difficulty persists check to that there are no bent or broken pins on the circuit board Once the Ottomind is installed in the PCM reconnect the vehicles batteries and start the vehicle Check to ensure that the Service Engine Soon and the Service Throttle Soon lights go out shortly after the vehicle is started If the vehicle starts and runs without any difficulty reinstall the access cover the PCM and the glove box panel Start engine allow engine to warm up Drive vehicle listen for exhaust leaks or rattles Reposition or tighten exhaust components as required P N 96312 OPERATING CHARACTERISTICS Your Banks Stinger will allow your GM 6 51 factory turbocharged engine to produce more power and respond quicker well within the safe operating range of the engine as long as the following guidelines are adhered to Use your pyrometer exhaust temperature gauge and boost gauge to monitor your engine s operation At idle EGT exhaust
5. E KIT where the extension pipe will stop to the end of the intermediate pipe Add 2 to the measurement to compensate for the slip joint on the extension pipe Cut the extension to this length Crew cab applications may not need trimming Install the trimmed pipe onto the intermediate pipe and into the muffler Install the 3 hanger clamp into the rubber hanger on the frame and lightly clamp it to the extension pipe Adjust the turbine outlet pipe and exhaust system to provide maximum clearance to frame and other components Check alignment of muffler and tailpipe to hangers and vehicle muffler should be straight and level and the rubber hangers should be swung or angled towards the front of the vehicle Y to 1 to allow for expansion of the pipes When alignment and clearances look good tighten all clamps including the factory v band on the turbine outlet pipe Remove pipe plug and install the pyrometer gauge probe supplied in pyrometer gauge kit in the bung on the turbo exhaust outlet pipe We suggest using an anti sieze compound on the probe threads to make removal easier for any future service Install instrument gauge panel in a location providing easy viewing for the driver NOTE An optional two gauge console is available from Banks for mounting gauges on top of the dash Wire and plumb gauges as shown in instructions included with gauges Route and tie wiring and nylon hose away from moving parts and hot exhaust compo
6. OWNERS MANUAL WITH INSTALLATION INSTRUCTIONS PIN Tyg STINGER CHEVROLET GM 6 5L DIESEL SUBURBANS WITH FACTORY TURBO OPTION 1994 96 2WD amp 1994 95 AWD WITH CATALYTIC CONVERTER THIS MANUAL IS FOR USE WITH SYSTEM 49044 banks GALE BANKS ENGINEERING 546 DUGGAN AVENUE AZUSA CA 91702 626 969 9600 FAX 626 334 1743 www bankspower com 1999 GALE BANKS ENGINEERING 03 10 98 96312 96312 GENERAL INSTALLATION PRACTICES For ease of installation of your Banks Stinger System please read this 8 page owner s manual before starting any work If any pages are missing from this package please call Gale Banks Engineering immediately for a replacement Become thoroughly familiar with all components and phases of the installation before starting any work Inspect all components supplied for any foreign material that may have entered during shipping amp handling WARNING NEVER work under any vehicle supported only by a jack of any kind DO NOT USE concrete blocks or other masonry items that may collapse under the vehicle weight p Pay particular attention to the routing of wires and hoses Keep them away from exhaust heat moving parts and sharp edges that may cause cuts or other damage Route or tie away from critical areas as required Keep all wires a minimum of 6 from hot exhaust parts 8 or more is recommended whenever possible Right hand and left ha
7. d sticker to the filter case included with every Banks replacement element Make sure you put the sticker in a highly visible place to alert your mechanic not to discard PERFORMANCE HINTS Service every 50 100 000 miles on street driven applications Service more often in offroad or heavy dust conditions If an airfilter restriction gauge is installed then change the element when the airfilter restriction reaches 18 H20 CAUTION Extremely fine dust from agriculture or offroad use will pull the oil from the element Frequent reoiling of the element s clean side might be required Completely service when practicable For extra protection use an air filter sealing grease on rubber ends of the element Service only with Banks air filter cleaner and Banks air filter oil P N 96312 Stinger GM 6 5 Factory Turbo Suburban 49044 QTY DESCRIPTION PART 4 BOIL 715 20 Bahia 91629 1 CARD Product 96392 4 CLAMP Exhaust 3 HD suoque pe aed 52465 1 DUCT SuperScoop Air Inlet oo rrt 42590 1 FASTENER Push In Inlet 92017 1 FILTER ELEMENT Banks ac xS 41022 1 GASKET Air Inlet Casting ne EE ER ee 93024 1 GASKET Cat Converter 93025 I GAUGE Boost D T5 PS ronde d nors ee 63021 1 KIT Installation Boost Gauge 63032 KIT Pyrometer
8. e manifold opening to prevent foreign objects from falling into engine WARNING Any foreign object that falls into the intake manifold can cause serious engine and or turbocharger damage upon engine start up Measure and mark the air inlet casting as shown in MI Figure 2 Centerpunch this location and drill through the casting wall with a letter drill 399 dia then tap the hole with a NPT tap Clean all chips from inside the casting Reinstall air inlet casting on intake manifold Use new gasket provided in kit Tighten loose clamps reinstall brace Install boost gauge hose fitting into hole tapped in air inlet casting Boost gauge hose fitting is supplied in boost gauge kit Use a pipe thread sealer such as Teflon tape on fitting pipe thread Reinstall decorative cover on engine Remove the factory exhaust system by first prying the pins from the rubber frame mounted hangers Spray some WD 40 or similar lubricant into the holes to make this easier Remove the factory clamps from the pipes and work the joints loose from the rear forward If the slip joints in the pipes will not come apart heat them with a torch until the pipes will separate Unbolt the catalytic converter assembly from the turbine outlet pipe Loosen the turbine outlet pipe clamp at the turbocharger and remove the pipe Loosely clamp the new turbine outlet pipe to the turbocharger Reinstall the catalytic converter assembly onto the turbine ou
9. nd designations refer to the driver s right or left as seated in the vehicle i e Right hand refers to the passenger side of the vehicle unless noted otherwise 3 P N 96312 INSTALLATION PROCEDURE Disconnect both batteries Pull crankcase vent hose out of turbocharger air inlet hose then loosen air intake hose clamp at turbo compressor Remove air cleaner assembly from vehicle to expose hole in inner fender panel If the vehicle has a plastic elbow inside the plastic adapter on the inner fender panel between the inner and outer fender panels remove this elbow by the following procedure This elbow may not be present 5 and newer vehicles however the Banks Ram Air inlet duct can be installed as described in the following step First remove the plastic tapered adapter that connects the air silencer to the inner fender panel Squeeze the sides of the adapter together to free it from the panel Use pliers to pull out the center button on the plastic retainer pin inside the elbow then remove the pin Next remove the two upper screws holding the underhood light assembly to the inner fender panel Also loosen the battery hold down clamps and remove one sheet metal screw in the inner fender panel near the front of the battery see Figure 1 Now remove the plastic elbow from within the fender by pulling and wiggling it rearward and toward the engine This elbow is part of a silencer about 16 long and will require qui
10. nents with cable ties provided Reinstall air cleaner assembly on right inner fender M panel Reinstall vent hose tighten hose clamps Install new air filter supplied See air filter cleaning and maintenance instructions elsewhere in this booklet P N 96312 OTTOMIND INSTALLATION In order to access the vehicle s Powertrain Control Module PCM the inner panel of the glove box must be removed Open the glove box and remove the contents Disconnect the nylon cables from the side of the compartment allowing the door to swing down out of the way 1994 models Use a small screwdriver to pry the white plastic cover from over the compartment light Carefully flex the top sides of the compartment toward the center allowing the inner glove box to be removed Look through the glove compartment opening IM toward the right to locate the PCM The PCM is held in place by two spring clips Grasp the PCM and pull towards the rear of the vehicle CAUTIONI DO NOT PULL ON THE CONNECTORS OR THE WIRES THAT ARE HOOKED TO THE PCM Pull the PCM out of the dash with the harness connectors intact just enough so that you can remove the access cover Remove the Torx screw and the access cover Position the PCM so the PROM access hole is viewed at the bottom left hand side of the PCM In this position the electrical connectors will be pointing away from you The factory PROM is secured to the circuit board by a blue plastic cover Using two fingers
11. s flush from the clean side to dirty side This removes the dirt and does not drive it into the filter DRYING HINTS Always dry naturally After rinsing shake off all excess water and let the element dry naturally DO NOT USE COMPRESSED AIR DO NOT USE OPEN FLAME DO NOT USE HEAT DRYERS EXCESS HEAT WILL SHRINK THE COTTON FILTER MEDIA COMPRESSED AIR WILL BLOW HOLES IN THE ELEMENT AEROSOL OILING After cleaning air filter always reoil before using Spray Banks Ram Air filter oil down into each pleat with one pass per pleat Wait 1O minutes and recoil any white spots still showing 7 OILING HINTS MEI Never use a Banks Ram Air filter without oil the filter will not stop the dirt without the oil Use only Banks Ram Air filter oil Banks air filter oil is a compound of mineral and animal oil blended with special polymers to form a very efficient tack barrier Red dye is added to show just where you have applied the oil Eventually the red color will fade but the oil will remain and filter the air NEVER USE Automatic Transmission Fluid NEVER USE Motor Oil NEVER USE Diesel Fuel NEVER USE WD4O LPS or other light weight oils REINSTALL Reinstall your Banks Ram Air filter element with proper care Make sure the element seats properly in the filter case Install the cover making sure it s in the right position Tighten all the nuts bolts screws or clips to factory specifications DO NOT DISCARD Affix the Do Not Discar
12. te a bit of effort to pull it free from the fender If it will not move at all check to make sure all sheet metal screws noted were removed The forwardmost screw near the battery attaches directly to this duct inside the fender and must be removed p Install the new Banks Ram Air duct into the inner MI fender opening to replace the factory silencer elbow Once the new duct has been squeezed into place inside the fender reinstall the factory plastic retainer pin or new pin provided through the hole in the duct and inner fender bracket Push in on the center button of the retainer pin to lock the pin in place Reinstall the underhood light assembly screws Reinstall battery Reinstall the plastic tapered adapter to the inner fender panel by squeezing the sides together and engaging it into the edge of the inner fender panel opening NOTE In extreme dust conditions such as frequent travel on dirt roads or in agricultural usage it is advisable to block off the lower air inlet opening that faces the ground using a piece of sheet metal or similar method This prevents premature contamination of the air filter element by excessive dust kicked up by the front tire See illustration for location Loosen compressor discharge hose clamp turbocharger Remove connecting strap between turbocharger and air inlet casting Remove decorative cover from top of engine Unbolt and remove air inlet casting from top of intake manifold Cover intak
13. tlet pipe with the provided gasket and hardware Slide the proper Banks intermediate pipe onto the catalytic converter assembly with the large notch aligned with the locating pin on the catalytic converter assembly and clamp lightly to hold in position Standard cab models install the muffler and then the tailpipe Extended cab and crew cab tighten the 3 clamp at the joint of the intermediate pipe and catalytic converter assembly Place the tailpipe into position and install 3 hanger clamp into the rubber hanger Place the muffler outlet over the end of the tailpipe and hold it in position level and straight with a jack or other suitable support Check that the hangers are angled properly and that the tailpipe outlet is level with the vehicle Measure the distance from the dimples in the muffler inlet P N 96312 SERVICE LAMP AIR DUCT REY 0 ASSEM REMOVAL 2208 ZA 4 lo N REMOVE N euu DUCT PLASTIC OUT OF BUTTON FENDER REMOVE Pi THIS SCREW BANKS SUPER SCOOP SUGGESTED MODIFICATION FOR HIGH DUST AREAS NOTE FORWARD OPERATION IN HIGH DUST AIR ENTRY AREAS WILL REQUIRE MORE FREQUENT AIR FILTER INSPECTION AND CLEANING i UA N In rn BLOCK OFF AIR ENTRY 7 M INTO BOTTOM OF VERTICAL DUCT AT THIS FOINT DUST KICKED UF BY TIRES 5 P N 96312 DRILL AIR INLET CASTING FOR 1 6 FITTING BOOST GAUGE HOSE COMPRESSION FITTING IN BOOST GAUG
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