Gale Banks Engineering - Diesel Performance Specialists 6.5L User Manual download pdf (Page 4)

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 in ’95

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 quite 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.

Install the new Banks Ram-Air duct into the inner

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 at

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 intake 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

Figure 2. Centerpunch this location and drill

through the casting wall with a letter “R” 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 outlet 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

10.

P.N. 96312

1 2 3 4 5 6 7 8 9 10 11 12

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Gale Banks Engineering - Diesel Performance Specialists 6.5L User Manual Page 4

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