Gale Banks Engineering - Diesel Performance Specialists 49140 Automobile Accessories User Manual
Contents
1. 208 may need to use extension kit PN 49097 25 Slide a 3 exhaust clamp over the forward end of the Banks Dynaflow muffler assembly and install the assembly onto the end of the catalytic converter outlet pipe Position the pin hangers on the muffler assembly into the rubber hangers on the frame and adjust the rotation of the muffler as necessary to position the hanger pins level in the vehicle Make sure that the hangers are hanging forward This will allow the hangers to swing as the exhaust system expands while the engine is running With the muffler level and square to the frame of the vehicle tighten the clamp on the muffler assembly inlet Figure 5 FACTORY HANGERS TAILPIPE FLANGE NUT e a TAILPIPE TIP HEAT SHIELD TAILPIPE TIP 3 1 2 U CLAMPS 3 1 2 HANGER CLAMP TIP AND HEAT SHIELD ASSEMBLY TYPICAL FOR BOTH LEFT AND RIGHT EXIT LEFT EXIT SHOWN 96378 v 5 0 9 26 Two tailpipe options are available to provide either a right side or left side tailpipe exit Refer to the installation steps that are appropriate to your installation Left exit tailpipe position a 3 2 clamp over the muffler outlet and place the Banks Monster tailpipe up over the driveshaft and slide it into the outlet of the muffler Place the pin hanger on the pipe into the rubber hanger attached to the left side of the frame Support the pipe level with the vehicle and tighten the2. TorqueTube Wrap the hose with the supplied heat shield blanket Secure the blanket to the hose with the supplied wire ties 13 Inspect the exhaust mounting surfaces of the cylinder heads and clean away any deposits to assure proper sealing of the Banks TorqueTubes Be careful when doing this as the cylinder heads are made from aluminum and can be easily damaged We recommend the use of a Scotchbrite pad 14 Place a small amount of anti seize on the threads of each of the supplied manifold bolts Use the new gaskets provided when installing TorqueTubes Lift the Banks TorqueTube manifolds into place and install one or two bolts to hold them in position Install the remaining bolts into the heads and tighten See figure 1 15 On EGR models attach the EGR tube to the adapter fitting in the Banks Figure 3 y c ge 96378 v 5 0 7 TorqueTube manifold If necessary loosen the fitting at the top of the EGR tube to allow the tube to be positioned properly 16 Make sure the O ring is on the dipstick tube and reinstall it into the hole in the engine block Reattach the dipstick tube bracket to the cylinder head with the new longer bolt and spacer supplied Reattach the bracket at the radiator core support with the original hardware and put the dipstick back in 17 if additional clearance at the front of the right side TorqueTube manifold for the air conditioning hose is needed very gently
3. at the bottom of the filter housing This method is the preferred method but can only be used if there is room below the air filter housing to accommodate the Super Scoop The other method mounts the scoop to the grille or directly behind it and connects the scoop to the air filter housing via a flexible hose To mount the scoop directly to the air filter housing follow the directions in step 33 To mount the scoop to the filter via the hose skip step 33 and follow the directions in steps 34 thru 38 33 Cut off the curved portion of the Super Scoop outlet 1 2 inch above the edge of the inlet lip as shown in figure 6 Next make four saw cuts 1 2 inch deep equally spaced around the cut end of the Super Scoop outlet Deburr the cut edges to remove plastic chips Slide the modified Super Scoop outlet over the inlet of the air filter housing aim the scoop inlet toward the vehicle grille and secure with a No 64 hose clamp positioned over the four saw cuts Proceed to step 39 34 install the Banks Ram Air hose connector onto the bottom of the air filter housing with a 64 hose clamp This part adapts the 31 2 outlet of the filter housing to the 4 Ram Air duct 35 Determine a location for the Ram Air Super Scoop It should be placed as low as possible directly behind the grille with the air inlet opening pointing directly forward in the vehicle 36 The height difference between the Super Scoop and the air filter i
4. rags Section 3 11 e Pry bar or channel lock pliers Ram Air Intake e 1 4 and 38 drive ratchets with Section 4 14 metric sockets and a 1 4 drive Ottomind Installation extension Bill of Materials 15 e Metric combination or open end wrenches e Standard and Phillips head screwdrivers e Penetrating oil or light lubricant spray e Standard and phillips head screwdrivers 96378V50 3 General Assembly Figure 1 See Bill of Materials on page 15 O2 SENSOR FACTORY AIR FILTER BRACKET 4 96378 v 5 0 22 e D TT O2 SENSOR a E et A AS CONVERTER ASSY y o NT Ei Zur Ae A 96378 v 5 0 5 Section 1 TORQUETUBE MANIFOLDS For Git Kit amp Stinger installation proceed to step 24 1 The vehicle may have a bolted in crossmember between the leveling jacks at the front of the vehicle This will need to be removed prior to removing the factory exhaust system and reinstalled after the Banks PowerPack system is place 2 Locate the oxygen sensors in each exhaust headpipe downstream of the factory exhaust manifolds Unplug the connectors and remove both the oxygen sensors Mark the sensors for correct reinstallation 3 Disconnect the three bolt flange at the front of the catalytic converter from the factory Y pipe assembly Disconnect the headpipes from the exhaust manifolds and remove the Y pipe assembly from the vehicle 4 On the d
5. bend the line away from the manifold until there is a minimum of 3 4 of clearance Do not use a pry bar or other tool to bend it as this may damage the line Wrap the air conditioning line with the aluminum heat shielding blanket provided and tie it with the supplied wire ties 18 If it was removed reinstall the crossmember at the front of the vehicle 19 Place the new catalytic converter flange gasket onto the studs on the catalytic converter flange Install the Y pipe onto the catalytic converter using the original hardware and the pin hanger into the rubber hanger on the frame of the vehicle Place a conical seal into the flare at the forward end of the Y pipe and attach the Y pipe to the right side TorqueTube manifold using the 38 x 13 4 bolts and washers provided Do not tighten the bolts yet 20 Slip a 2 2 muffler clamp over the free end of the Y pipe and then slide the Y pipe extension into the slip joint With the slip joint fully seated mark the extension pipe with a pen so that as the clamp is tightened any slippage of the joint can be observed Place the second conical seal onto the flare on the extension and attach the extension pipe to the left side TorqueTube with the 3 8 x 13 4 bolts and washers provided Tighten the 212 clamp at the slip joint observing the mark to be sure the joint stays fully seated as the clamp is tightened Up to 1 4 slip is acceptable Tighten the bolts at the manifo
6. clamp Right exit tailpipe place a 31 2 clamp over the muffler outlet and insert the Banks Monster tailpipe into the end of the muffler Attach the universal hanger to the tailpipe with a 372 clamp then find a suitable hole in the frame rail directly over the tailpipe With the tailpipe supported level with the vehicle bolt the hanger into the 10 96378 v 5 0 hole with the 5 16 x 174 bolt washers and nuts also provided 27 Mount the floor heat shield and polished tip onto the pipe using the 37 2 clamps provided as shown in figure 5 28 Lower the vehicle and reconnect the battery cables Start the engine and listen for any exhaust leaks Tighten bolts or clamps to correct any leaks or make adjustment as required It is recommended that tack welds be placed on all slip connections to prevent slippage Note The vehicle exhaust may smoke upon initial start up This is normal as grease used in the tube bending process burns out of the pipes For Git Kit installation procedure is complete END SECTION 2 Section 3 RAM AIR INTAKE Figure 6 CUT OFF TOF FORTION OF SCODF AT THIS FOINT Marks BUPER SCOLI nm i MARE FOUR Y2 INCH DEEF SAW CUTS AROUND END OF SUPERSCOOF OUTLET Alf FILTER HOUSING MODIFIED SUPERSCOOP 29 Inside the vehicle with the engine cover removed find the rubber bellows at the inlet of the throttle body Loosen the clamp attaching the plastic a
7. es and straps may also be used 38 Connect the Super Scoop to the hose connector using the 4 flexible hose provided The hose may be shortened as needed Secure the hose with two 64 hose clamps END SECTION 3 96378 v5 0 13 Section 4 OTTOMIND INSTALLATION 39 Be certain battery ground cables have been disconnected 40 Locate the engine control unit ECU under the dash mounted to the left hand side of the steering column It will be housed in a black plastic case bolted to the column Loosen the bolt attaching the electrical connector to the ECU This will be pointing toward the floor of the coach 41 Remove the bolts attaching the ECU to the bracket using a 14 inch drive 5 5mm socket and ratchet A swivel and or a 14 inch universal joint may be required to remove one or more bolts Pull off the electrical connector and remove the plastic case and ECU from the vehicle 42 Note the code printed on the plastic cap on the back of the ECU This code should compare to the code printed on the Banks OttoMind label Pry the plastic cap from the rear of the ECU using a small screwdriver exposing the printed circuit board edge connector inside Retain the plastic cap The connector will be coated with grease and a clear silicone type coating which must be completely removed before installing the Banks OttoMind engine calibration module 43 Using a 5 5mm nut driver loosen and remove the six bolts that hold
8. gine primary battery is disconnected This is necessary for safety and to ease the installation of the passenger side TorqueTube exhaust manifold 5 Route and tie wires and hoses a minimum of 6 inches away from exhaust heat moving parts and sharp edges Clearance of 8 inches or more is recommended where possible 6 When raising the vehicle support it on properly weight rated safety stands ramps or a commercial hoist Follow the manufacturer s safety precautions Take care to balance the vehicle to prevent it from slipping or falling When using ramps be sure the front wheels are centered squarely on the topsides put the transmission in park set the hand brake and place blocks behind the rear wheels If the vehicle is supported by a hoist the front wheels may be removed for further accessibility CAUTION Do not use floor jacks to support the vehicle while working under it Do not raise the vehicle onto concrete blocks masonry or any other item not intended specifically for this use 7 During installation Keep the work area clean If foreign debris is transferred to any Banks component Clean it thoroughly before installing 2 96378 v 5 0 Tools Required Table of Contents e 1 MAT wrench General Assembly 4 e 5mm 6 point socket Section 1 6 e Chisel or hacksaw Torquetube Manifolds Section 2 9 e Saw or torch Monster Exhaust e Clean shop towels or
9. he EGR fitting on the manifold 9 On the passenger side of the engine loosen the three rearmost outside valve cover with bolts Slide the valve cover heat shield provided under the heads of the bolts and tighten See figure 2 10 On some vehicles a wire loom bundle runs along the top of the frame rail adjacent to the driver s side of the engine In these instances this loom and any other wiring must be relocated away from the exhaust manifold heat area Pry the wire loom clips from the frame rail to provide enough slack in the wire loom bundle so it may be routed and tied up against the underside of the floor of the coach The wire loom bundle may be routed up braces adjacent to the upper engine area and along supporting members under the floor with the cable ties provided 11 Install the starter heat shield onto the starter using the 52 hose clamp provided Caution Make sure the heat shield does not come in contact with the positive terminal 6 96378 v 5 0 Figure 2 of the starter once the heat shield is tightened down See figure 3 12 On some motorhomes there is a vertical hose fitting on top of the air conditioner compressor Skip this step if your motorhome does not have the vertical fitting Before installing the right side TorqueTube bend the hose fitting Va 12 inch towards the frame rail using a pry bar Be careful not to crease or puncture the fitting This will give clearance for the
10. igure 8 as a guide cut away the portion of the case between the first rib on the right side and second rib on the left side 4 inch in from the corner as shown A band saw or hack saw works well for this job Deburr the edges and reinstall the ECU in the plastic case then reinstall ECU and case in the vehicle The one corner screw shown may be omitted as it is very difficult to reinstall Reattach the electrical connector to the ECU and tighten the retaining bolt END SECTION 4 GIT KIT STINGER POWERPACK TORQUETUBE Right Y PIPE Y PIPE EXTENSION DYNAFLOW MUFFLER MONSTER TAILPIPE TAIL PIPE TIP OTTOMIND optional SUPER SCOOP 8e 00 Ns nana HOSE Air duct 4 x 5 11 CONNECTOR Ram Air Hose 12 HOUSING Air Filter 13 AIR FILTER ELEMENT 14 AIR INLET TUBE 15 HEAT SHIELD Starter SIS SIS S S SN SS IN 1 16 HEAT SHIELD Valve Cover 17 HEAT SHIELD Tail Pipe Extension 18 HEAT SHIELD Blanket 19 HANGER Exhaust Right Exit Only 20 4 MOUNTING STRAP SISISISISISISISISISISISISISISISISISISIS NINIS I 96378 v 5 0 15 FIG 1 COMPONENT GIT KIT STINGER POWERPACK 21 3 CLAMP Exhaust 3 2 HD Y Y 22 CLAMP Exhaust 3 HD Y Y 23 CLAMP Exhaust 2 2 HD 24 3 HOSE CLAMP 64 25 HOSE CLAMP 52 26 2 CONICAL SEAL Exhaust Outlet 27 GASKET TorqueTube E 28 GASKET Cata
11. ir inlet tube to the bellows loosen it and pull the plastic air inlet tube out of the rubber bellows At the front of the vehicle loosen the clamp that holds the forward end of the air inlet tube to the air filter housing elbow Remove the tube from the air filter housing elbow and pull the tube forward out of the vehicle 30 To install the Banks Ram Air air inlet tube into the vehicle place the forward end into the air filter housing elbow and the rear end into the rubber bellows on the throttle body Tighten both clamps HO 64 HOSE CLAMP 96378 v5 0 11 31 Unlatch the clamp that holds the two halves of the air filter housing together and remove the original filter Remove and discard the plastic cover from around the air inlet of the lower housing Remove the lower housing from the vehicle by unhooking the rubber strap from the mounting brackets and pulling the housing forward so that the feet disengage from the rubber mounting grommets 32 Install the Banks Ram Air filter housing in place of the factory housing Make sure that the mounting feet fully engage the rubber grommets and the strap is reattached Install the Banks Ram Air filter into the filter housing Reattach the upper half making sure the two halves are properly seated together and latch the clamp Note The Banks Ram Air Super Scoop may be installed in one of two configurations One method mounts the scoop directly to the air filter inlet
12. ld collectors 21 Install and tighten the oxygen sensors into the threaded bungs provided on the Y pipe and extension Use a small amount of anti seize on the threads of the oxygen sensors Be careful to not get any anti seize on the sensor elements themselves 22 On the connector on the oxygen sensor and on the male connector on the sensor extension lead remove the two index pins on the connector shell by cutting or filing Be careful to not damage the locking mechanism of the connectors See figure 4 23 Plug the oxygen sensor extension leads included in the kit into the wiring harness where each sensor was previously connected then plug the sensor lead into the extension Secure the leads away from any pipes or moving linkages with the cable ties provided END SECTION 1 Figure 4 REMOVE INDEX PINS FROM PLUGS 8 96378 v 5 0 Section 2 MONSTER EXHAUST 24 Disconnect and remove the factory tailpipe and muffler from the rear of the factory intermediate pipe Start from the rear and work forward prying the pins from the rubber hangers removing the tailpipe then the muffler If the slip joints will not come apart use a torch to heat the connections until they separate or cut the pipes apart with a saw or torch being careful to not cut the outlet portion of the intermediate pipe Save all hardware and hangers as some items will be reused in the PowerPack installation NOTE Wheelbases over
13. lytic Converter 29 4 BOLT 3 8 16 x 134 Hex 30 2 BOLT 9 16 18 x 17 4 Hex Right Exit Only J 32 2 NUT 16 18 Nylock right Exit only J SISISISISISISISISISISISIS Y 31 4 BOLT 1 4 20 x 11 4 Hex Y Y Y DISS Je 33 4 NUT Va 20 Nylock 34 35 20 BOLT 8mm x 1 25 x 30mm 36 BOLT 6mm x 1 00 x 25mm 37 4 WASHER 8 SAE Right Exit Only except PowerPack J Y 37 8 WASHER 8 SAE Right Exit Only 38 4 WASHER Va USS 39 WASHER Metric 6mm 40 SPACER Manifold Bolt 41 4 SCREW 10 x Ya 42 _ 2 WIRE EXTENSION O2 Sensor 43 5 WIRE TIES E 4 CABLE TIES 15 44 10 CABLE TIES 8 KIT Service Ram Air ANTI SEIZE 102 POLISH Metal 3 Grams OWNERS MANUAL 3 UROCAL Banks Power l SS SS SS SS SS SS Isis 2 DECAL Banks Power Large 2 DECAL Banks Power Small WARRANTY STATEMENT NINES SNES TT SINININ I UININIUINININI SS CARD Product Registration Gale Banks Engineering 546 Duggan Avenue e Azusa CA 91702 626 969 9600 e Fax 626 334 1743 Product Information amp Sales 800 438 7693 Customer Support 888 839 5600 Installation Support 888 839 2700 bankspower com
14. nlet should be as great as possible to prevent any rain water not eliminated by the water drain hole from climbing into the air box The curved outlet section of the Super Scoop may be trimmed back if less bend is required to make a more streamlined hose routing 37 Once a location has been determined for the Super Scoop mount it using one of the methods outlined below The Super Scoop may be mounted by several means If the grille consists of horizontal bars or a perforated screen heavy enough to support it the Super Scoop may be secured using four 14 nylon cable ties slipped through the ears on the Super Scoop and through the grille See figure 7 An alternate method is to mount the Super Scoop using the four perforated metal straps provided These can be bent as required and attached to the ears with the 1 4 20 x 1 1 4 bolts nylock nuts and 3 4 OD x 5 16 ID flat washers provided The other end of the brackets may be attached to any 12 96378 v 5 0 Figure 7 RAM AIR SUPER SCOOP MOUNTING METHODS CABLE TIE MOUNTING LOOP CABLE TIE THROUGH TAB AND AROUND GRILLE PULL TAUT 1 4 20 NYLOCK NUT STRAP MOUNTING 3 4 O D x 5 16 I D 1AE POETI FLAT WASHER Do BOLT BEND TABS lt 7 NO 10 x 3 4 SHEET AS REQUIRED METAL SCREW convenient mounting surface such as the gravel pan grille brackets etc as required with 10 x 3 4 sheet metal screws provided A combination of cable ti
15. river s side of the engine unscrew the EGR tube from the exhaust manifold with a 1 4 wrench and remove the EGR tube from the manifold 5 Pull out the dipstick and remove the small bolt that attaches the oil pan dipstick tube to the cylinder head At the front of the vehicle behind the front engine cover remove the 2 screws that retain the dipstick tube to the radiator support Near the exhaust manifold pull the dipstick tube up out of the engine block Check to see if there is an O ring on the tube If not the O ring may be stuck inside the hole in the engine block This O ring should be retrieved if necessary and placed back onto the tube before reinstalling it 6 To remove the exhaust manifolds use a wrench or socket to back the nuts away from the manifolds at least One turn then use a 5mm 6 point socket to remove each stud from the head As an alternate method take the nuts off the studs and then remove the studs 7 After the manifolds have been removed from the vehicle remove any remaining studs from the heads The studs must be removed from the heads in order to install the Banks TorqueTubes 8 On EGR models remove the large EGR adapter fitting from the left side factory manifold and install it onto the left Banks TorqueTube manifold Reuse the original copper washer between the manifold and adapter Use anti seize on the threads to prevent galling On non EGR models install the Ya npt pipe plug into t
16. the case of the ECU together Open the case of the ECU being careful not to lose the plastic spacer or damage any circuitry inside the ECU 44 Clean BOTH sides of the connector First clean the white grease off with a tissue Next scrape the clear silicone type coating from the connector fingers with the REN LEAVE TWO RIBS INTACT TO CLEAR OTTOMIND CUT OUT AND DIS R CARD THIS FORTION THIS SCREW MAT Ai E OMITTED UPON REASSEMBLY LEAVE THIS RIB INTACT 14 96378 v 5 0 abrasive square provided It is very important to clean both sides of the board in order to have a good connection between the ECU and the Banks OttoMind module It is only necessary to clean the connector fingers Be careful not to damage any circuit traces on the board further inside the ECU Reassmeble the ECU case and tighten the screw 45 Orient the module so that its edges line up with the edges of the ECU case If the edges do not line up the module is rotated 180 degrees off Place the OttoMind module over the connector and press firmly to set the connection DO NOT FORCE the OttoMind onto the connector as damage may result to either the ECU or the module If the module does not Bill of Materials FIG 1 COMPONENT TORQUETUBE Left install with firm pressure check the orientation and try again 46 A portion of the black plastic case must be cut away to provide clearance for the Ottomind module Using f
17. with Installation Instructions Banks PowerPack System Including Banks Stinger System Banks Git Kit Ford 6 8L V 10 Class A Motorhome THIS MANUAL IS FOR USE WITH SYSTEMS 49140 49141 49142 49143 49146 49147 49160 amp 49161 Gale Banks Engineering 546 Duggan Avenue e Azusa CA 91702 626 969 9600 e Fax 626 334 1743 Product Information amp Sales 800 438 7693 Customer Support 888 839 5600 Installation Support 888 839 2700 bankspower com 2005 Gale Banks Engineering 05 10 05 PN 96378 v 5 0 General Installation Practices Dear Customer If you have any questions concerning the installation of your Banks Stinger system please call our Technical Service Hotline at 888 839 2700 between 7 00 am and 5 00 pm PT If you have any questions relating to shipping or billing please contact our Customer Service Department at 888 839 5600 Thank you 1 For ease of installation of you Banks system familiarize yourself with the procedure by reading the entire manual before starting work 2 The exploded views provide only general guidance Refer to each step and section diagram in this manual for proper instruction 3 Throughout this manual the left side of the vehicle refers to the driver s side and the right side to the passenger s side 4 Disconnect the ground cables from the battery before beginning work If the vehicle has more than one battery be sure that the en
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