Approval Details

Valid E.O.

Validity

This Executive Order approved the specified parts on on October 26, 1992.
As of Wednesday, July 17th, 2019 this Executive Order has not been overturned or superceeded.

Approved Parts

Models
1989-1992 Cummins 6BT 5.9L heavy-duty diesel engine Late 1992-1993 Cummins 6BTA 5.9L engine

This Executive Order may be listed as:
  • C.A.R.B.E.O. D-161-29
  • Executive Order 161-29 / D161-29
  • ARB # D-161-29
  • Executive Order No: D-161-29
  • C.A.R.B. No. D-161-29
  • Resolution D-161-29
For Free CARB Executive Order Status verification, email an image of the device Executive Order label as well as the Year/Make/Model and Test Group # of the vehicle to [email protected]

Download: Executive Order D-161-29 PDF

D-161-29 Document:



                                                              (Page 1 of 2)

                                 State of California
                                 AIR RESOURCES   BOARD


                               EXECUTIVE ORDER D—161—29
                  Relating to Exemptions Under Section 27156
                             of the Vehicle Code

                                GALE BANKS ENGINEERING
                               wWASTEGATE TURBO UPGRADE



Pursuant to the authority vested in the Air Resources Board by Section 27156
of the Vehicle Code; and

Pursuant to the authority vested in the undersigned by Section 39515 and
39516 of the Health and Safety Code and Executive Order G—45—5;

IT IS ORDERED AND RESOLVED:  That the installation of the Wastegate Turbo
Upgrade, manufactured by Gale Banks Engineering of 546 Duggan Avenue, Azusa,
CA 91702, has been found not to reduce the effectiveness of required motor
vehicle pollution control devices, and therefore is exempt from the
prohibitions of Section 27156 of the Vehicle Code for the following Cummins
heavy—duty dlesel applications:

     MODEL YEAR       ENGINE    FAMILY             MAXIMUM BOOST


     i989—1991           6BT 5.91                    20 p.s.i.g.        L
     1991—1992           6BTA 5.91                   17 p.s.i.g.
     late 1992—1993      6BTA 5.91                   20 p.s.i.g.
This exemption shall not apply to any device, apparatus, or mechanism
advertised, offered for sale or sold with, or installed on, a motor vehicle
prior to or concurrent with transfer to an ultimate purchaser.

This Executive Order is valid provided that installation instructions for
this device will not recommend tuning the vehicle to specifications
different from those submitted by the device manufacturer.

Changes made to the design or operating conditions of the device, as
exempted by the Air Resources Board, that adversely affect the performance
of a vehicle‘s pollution control system shall invalidate this Executive
Order.

Marketing of this device using an identification other than that shown in
this Executive Order or marketing of this device for an application other
than those listed in this Executive Order shall be prohibited unless prior
approval is obtained from the Air Resources Board.  Exemption of a kit shall
not be construed as an exemption to sell, offer for sale, or advertise any
component of the product as an individual device.


                  GALE BANKS ENGINEERING                                   EXECUTIVE ORDER D—161—29
wzntims..




                  WASTEGATE TURBO UPGRADE                                  (Page 2 of 2)



                  This Executive Order does not constitute any opinion as to the effect that
                  the use of this device may have on any warranty either expressed or implied
                  by the vehicle manufacturer.

                  THIS EXECUTIVE ORDER DOES NOT CONSTITUTE A CERTIFICATION, ACCREDITATION,
                  APPROVAL, OR ANY OTHER TYPE OF ENDORSEMENT BY THE AIR RESOURCES BOARD OF ANT
                  CLAIMS OF THE APPLICANT CONCERNING ANTI—POLLUTION BENEFITS OR ANY ALLECGED
                  BENEFITS OF THE WASTEGATE TURBO UPGRADE.

                  No claim of any kind, such as "Approved by the Air Resources Board" may be
                  made with respect to the action taken herein in any advertising or other
                  oral or written communications.

                  Section 17500 of the Business and Professions Code makes untrue or
                  misleading advertising unlawful, and Section 17534 makes violation
                  punishable as a misdemeanor.

                  Section 43644 of the Health and Safety Code provides as follows:

                       "43644,    (a)   No person shall install,     sell offer for sale,       or
                       advertise or except in an application to the stats board for
                       certification of a device, represent, any device as a motor vehicle
                       pollution control device for use on any used motor vehicle unless that
            270




                       device has been certified by the statse board.         No person shall sell,
                       offer for sale,    advertise, or represent any motor vehicle pollution
                       control devige as a certified device which, in fact, is not a certified
                       device.>   Any violation of this subdivision is a misdemeanor."

                  Any apparent violation of the conditions of this Executive Order will be
                  submitted to the Attorney General of California for such action as he deens
                  advisable.
                                                                     #4
                  Executed at El Monte,    California,   this Cgé.        of October,   1992.
                                                                                        /\




                                                                       07?%%/
                                                          R.B./Summerfield
                                                          Assistant Division Chief
                                                          Mobile Source Division


Leoris,




                                        State of California
                                       AIR RESOURCES BOARD




                                EVALUATION OF GALE BANKS ENGINEERING‘S
                   wWASTEGATE TURBO UPGRADE FOR EXEMPTION FROM THE PROHIBITIONS OF
            VEHICLE CODE SECTION 27156 IN ACCORDANCE WITH SECTION 2222, TITLE 13, OF THE
   Fommst




                                    CALIFORNIA CODE OF REGULATIONS




                                            October 1992


                            State of California
                           AIR RESOURCES BOARD




                   EVALUATION OF GALE BANKS ENGINEERING‘S
      WASTEGATE TURBO UPGRADE  FOR EXEMPTION FROM THE PROHIBITIONS OF
VEHICLE CODE SECTION 27156 IN ACCORDANCE WITH SECTION 2222, TITLE 13, OF THE
                       CALIFORNIA CODE OF REGULATIONS




                                     by

                           Mobile Source Division
                            State of California
                            Air Resources Board
                            9528 Telstar Avenue
                          El Monte, CA  91731—2990




(This report has been reviewed by the staff of the California Air Resources
Board and approved for publication.  Approval does not signify that the
contents necessarily reflect the views and policies of the Air Resources
Board, nor does mention of trade names or commercial products constitute
endorsement or recommendation for use.}


                                    SUMMARY



       Gale Banks Engineering (Banks) of 546 Duggan Avenue, Azusa, California

91702, has applied for an exemption from the prohibitions in Section 27156 of

the California Vehicle Code (VC) for the Wastegate Turbo Upgrade.        The

Wastegate Turbo Upgrade is designed for installation on 1989—1992 Dodge Cummins

6BT and 6BTA heavy—duty diesel engines.

       Banks submitted a completed apélication and other required information,

as well as results from snap—idle tests performed at the Gale Banks facility

in Azusa,   in accordance with Section 2182,   Title 13,   California Code of

Regulations.

       Based on the submitted information and an engineering evaluation, the

sfiaff concludes that the Banks turbo upgrade will not adversely affect exhaust

emissions from vehicles for which an exemption is requested.

       The staff recommends that Gale Banks Engineering, be granted an

exemption as requested and that Executive Order D—161—29 be issued.


                                              TABLE OF CONTENTS
Wae5th,




                                                                  Page Number




          SUMMARY
          conTENTs                                                     ii

          I.        INTRODUCTION
          II.       CONCLUSION
          III.      RECOMMENDATION
          Iv.       WASTECGATE TURBO UPGRADE DESCRIPTION
          v.        DISCUSSION
                    APPENDIX A:    INSTALLATION INSTRUCTIONS




                                                     ii


                       EVALUATION OF GALE BANKS ENGINEERING‘S
           WASTEGATE TURBO UPGRADE FOR EXEMPTION FROM THE PROHIBITIONS OF
     VEHICLE CODE SECTION 27156 IN ACCORDANCE WITH SECTION 2222, TITLE 13, OF THE
                            CALIFORNIA CODE OF REGULATIONS



I.        INFRODUCTION

          Gale Banks Engineering (Banks) of 546 Duggan Avenue, Azusa, California

91702, has applied for an exemption from the prohibitions in Section 27156 of

the California Vehicle Code (VC) for their Wastegate Turbo Upgrade.         The

turbo upgrade is designed for installation on 1989—92 Cummins 6BT and 6BTA

heavy—duty diesel engines.

          Banks submitted a completed application and other required information,

as well as results from snap—idle tests performed at the Gale Banks facility in

Azusa,    in accordance with Section 2182,   Title 13,   California Code

of Regulations.




II.       CcOoNCLUSIONS

          Based on the submitted information and an engineering evaluation, the

staff concludes that the Banks turbo upgrade will not adversely effect exhaust

emissions from vehicles for which an exemption is requested.




III.      RECOMMENDATION

          The staff recommends that Gale Banks Engineering, be granted an

exemption for their Wastegate Turbo Upgrade for installation on 1989—1992 Dodge

Cummins 6BT and 6BTA heavy—duty diesel engines.          The staff also recommends that

Executive Order D—161—29 be issued.


IV.      WASTEGATE TURBO_UPGRADE DESCRIPTION

         Banks‘s Wastegate Turbo Upgrade consists of a replacement turbine

housing and a wastegate valve.       The purpose of the turbo upgrade is to

decrease turbo lag by speeding up the air through the turfiocharger, increasing

the acceleration of the turbine blades.       The velocity of the air is increased

by reducing the area of the exhaust passage to the turbochaiger.       By increasing

the velocity of the air entering the turbocharger, the turbine is accelerated

more quickly, reducing the lag between engine acceleration and turbo boost.

The boost pressure is maintained at the factory level by adding a wastegate

valve, which bypasses some exhaust air when the pressure exceeds the limit.

         The Wastegate Turbo Upgrade is designed to maintain the factory boost

level.    For this reason, two different wastegate actuators will be produced.

The first actuator is for 1989—1991 Cummins 6BT and late 1992—1993 Cummins 6BTA

engines with a factory boost pressure of 20 p.s.i.g.       The second wastegate

actuator is for late 1991 to late 1992 Cummins 6BTA engines with 17 p.s.i.g.

boost pressure.




         v.   pISCUSSION

         Gale Banks Engineering has requested that the Wastegate Turbo Upgrade

be exempted for the 1989—1992 Cummins SBT and 6BTA heavy duty diesel engines.

The Wastegate Turbo Upgrade is designed to reduce the lag time between engine

acceleration and turbo boost.       During the lag time between engine acceleration

and turbo boost, the engine is running rich resulting in unburned fuel due to a

shortage of oxygen.        The reduction of turbo lag time could decrease Hydrocarbon

and particulate emissions by reducing the duration of the oxygen shortage.        The

difference in turbo lag time between the original equipment (OEM) turbocharger

                                            =3—


perein,,




              and the modified turbocharger is three seconds or less.      All other operating

              conditions of the turbocharger remain the same.      Because the modification

              occurs only during initial acceleration, and the reduction in turbo lag is

              minimal,   the combustion temperature is not affected.    For this reason,   the

              staff has determined that the Oxides of Nitrogen emissions will not be

              increased.




                     Banks provided snap—idle test results for a 1992 Cummins GBTA 5.9 liter

              engine with the Wastegate Turbo Upgrade installed.       The results of the snap—

              idle test performed at Banks are shown in Table 1.




                                                    Table 1
      lemm.




                                            SNAP—IDLE TEST RESULTS

                                           (Gale Banks Engineering)




                                                     MAX OPACITY




                             Standard                   40%

                             Modified                   34%

                             difference                 —6%




                         These results show that the modified vehicle emissions do not exceed

              the 40% opacity standard.


                   Banks submitted all of the required information and fulfilled the

            requirements for an exemption.   The test results and engineering analysis show

            that the Banks Wastegate Turbo Upgrade meets the requirements for exemption.
.‘K‘«.\‘“


                               .*                                             —   #ee* _      'f”_.'
                       J                                                            ho    *    n




              banifo
Lactcs.,




              Gale Banks Engmneering   546 Duggan Avenue       Azusa, Calforma S1702     {(B18] 962 9605




                                          GALE BANKS ENCINEERING
                                       DODGE/CUMMINS DIESEL PICKUP
                                         WASTEGATE TURBO UPGRADE




           The Banks Wastegate Turbo Upgrade package is designed to greatly
           improve the response of the Dodge/Cummins 5.9BT 6—cylinder diesel
           pickup. The addition of a wastegate controlled turbine housing on
           the existing factory turbocharger allows the engine to achieve its
           rated power level in a much shorter time interval.   The wastegate
           turbo upgrade is not intended to increase the maximum power level,
           only to     allow   the     engine     to    reach     it   in   a much       quicker manner.
           This equates to a far more drivable vehicle and maximized use of
           the engine‘s full potential while retaining existing engine
           durability.
n
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           The Banks Wastegate Turbo Upgrade will work well with either the
           factory or Banks intercooling, and the Banks PowerPack® exhaust
           systems .       Please refer to page            2    for    installation tips               if   other
           Banks    products        are   being        installed       with   the        Wastegate          Turbo
           Upgrade.


           If you have any questions or need assistance                           in     installing your
           Wastegate Turbo Upgrade, please call our Service Department between
           8:00am. — 5:00pm. PT at (818) 969—9605.   Thank you.




           P.N.    96382


                                                                                            . #e
                                                                                               #
 ustiee,




                                      GALE BANKS ENGINEERING
                                   DODGE/CUMMINS DIESEL PICKUP
                                     wWASTEGATE TURBO UPGRADE



                               GENERAL INSTALLATION PRACTICES



            1.   For ease of   installation and trouble—free operation of your
           BANKS   turbocharger    system,    PLEASE   READ   THIS   ENTIRE   INSTRUCTION
           PACKAGE BEFORE STARTING ANY WORK.           (This package contains 9 pages
           of instructions,    5   sheets of illustrations,      and 1 sheet of parts
           listing.  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.

            2. Inspect all components supplied for any forsign material that
           may have entered during shipping and handling.        Inspect all
~ ‘d.—\




           castings for damage resulting from shipping.   Check all machined
           surfaces for nicks or other damage.

            3. Any time the vehicle is raised off its whesls, it should be
           supported by jack stands, ramps, or a hoist of adequate capacity
           for the vehicle‘s weight.         NEVER PERFORM ANY WCORK UNDER A VEHICLE
           sUPPORTED ONLY BY ITS SERVICE JACK OR A HYDRAULIC JACK.

            4. Pay   particular attention to the routing of all hoses and
           wiring.   Keep them away from exhaust heat, moving parts and sharp
           edges that may cause cuts or other damage.          Routs or tie hoses away
           from critical arsas as required.

            5.   Right—hand and left—hand 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.

            6.   All BANKS components are designed,        tested and manufactured to
           standards far exceeding factory OEM specifications. However due to
           normal variations in production vehicles, it may be necessary to
           slightly modify some exhaust components for proper fit.




                                             Page 2 of 9


         »
             h * %*,*               *
F




             7.   The turbo boost       level calibration is pre—set at our         factory.
         Any increase of the               boost level calibration rmay cause engine
         damage, and evidence              of tampering will be grounds for warranty
         denial.

          8. Torque values for fasteners are given in instruction steps. If—
         torgue wrenches are available, use them where applicable, however
         some fasteners may be in places inaccessible for torquing.      In
         these          instances   and    when    no   torque   wrenches   are   available,
         reasonable tightening for the fastener size should be employed.

         NOTE:      Torque values are given             in metric values    (Newton—meters),
         foot—pounds,         and inch—pounds.




                                          INSTALLATION PRCCEDURE

                                        wWHEN COMBINED WITH OTHER

                                              BANKS PRODUCTS
    ~m




         when the Banks Wastegate Turbo Upgrade package is to be installed
         simultanecusly with other Banks power products, the following
         suggestions will assist in a savings of time and effort during the
         overall installation.



          1. If a Banks Intercooler is being installed on a non intercooled
         truck, complete the intercooler installation first.      This will
         provide a reference for lining up the turbo ducting when the turbo
         upgrade is installed.


             2.   If    the   factory     intercooler    is   being replaced with   a   Banks
         Intercooler,         complete the intercooler installation first.


          3. If a Banks PowerPack exhaust system is being installed,
         complete the wastegate turbo upgrade installation before installing
         the exhaust systen.




                                                  Page 3 of 9


                             DODGE/CUMMINS PICKUP
                           wWASTEGATE TURBO UPGRADE
                          INSTALLATION INSTRUCTIONS



                             TURBOCHARGER REMOVAL

                 (SEE FIG.   1 FOR COMPONENT IDENTIFICATION)


  1.    Position   vehicle   on   a    hoist.         If    no ~hoist   is   available,
_ position vehicle on a flat level surface.

   2.   Disconnect the battery cables from the battery.

  3. Disconnect the air inlet tube from air cleaner and exhaust pipe
 from the turbocharger.

  4. Remove the two cil drain tube bolts from the turbocharger.

  5.    Disconnect the oil supply hose at the turbocharger.

  6. Loosen the two hose clamps that connect the turbocharger to the
 air crossover pipe (or intercooler pipe on intercooled models).

  7.    Slide the connecting hose onto the turbocharger far enough to
 expose the gap between the turbocharger and the crossover pipe (or
 intercooler pipe.

  8. Remove the turbocharger mounting nuts and the turbocharger from
 the exhaust manifold.



 CAUTION: Anytime the turbocharger is removed from the engine, take
 care that no foreign objects enter any of the turbocharger
 connections on the engine or turbocharger.         Foreign objects
 entering air, exhaust, or oil connections may cause major damage to
 the    engine   and/or   turbocharger,         and    is    not   covered   under   any
 warranty. If the vehicle is intercooled, cover the open end of the
 intercooler pipe with a rag, as this pipe is very susceptible to
 foreign object entry.



                                      Page 4 of 9


 9. Clean and inspect the exhaust flange mounting surfaces on the
exhaust manifold.   Remove any remaining gasket material from the —
turbocharger oil drain flange surface. Make sure surface is clean
and dry.

10.   if an exhaust gas pyrometer gauge is to be installed, refer to
pyrometer installation instructions and install the pyrometer probe
in the exhaust manifold at this time. <(See separate section on
pyrometer installation) .

11. Raise front of vehicle and remove exhaust pipe support strap
attached to engine.

12. Remove the U~clamp and separate the turbo exhaust pipe from the
extension pipe. Heat from a torch may be required on the extension
pipe slip joint to allow turbo exhaust pipe to be pulled free.

13.   If the factory turbo exhaust pipe @oes not have a heat shield
(near firewall) attached, go to step 16 and continue installation.
If heat shield is present, continue with step 14.

14.   Locate the rivets that attach the heat shield to the exhaust
pipe.   Use a small power drill with a 3/16 inch drill bit to drill
out the rivets and remove the shield.

15. Reinstall the heat shield on the new Banks turbo exhaust pipe.
Four 3/16 inch "POP" rivets are provided.   See fig. 2.

16. Install the Banks turbo exhaust pipe in the existing extension
pipe. A light lubricant andj/or heat may be required to allow full
engagement of the exhaust pipe into the slip joint.   Do not clamp
at this time.  Reconnect the support strap.

NOTE: If the vehicle is a four wheel drive model and a Banks
PowerPack exhaust system is to be installed at this time, skip over
this step and install the Banks turbo exhaust pipe when the
PowerPack®    exhaust   components   are   installed.   The   4WD   Banks
PowerPack® systenm includes a new exhaust extension pipe.



               TURBOCHARGER DISASSEMBLY AND REASSEMBLY

17.   Clamp the exhaust inlet flange of the turbocharger in a bench
vise. Loosen the four bolts, attaching the turbine housing to the
center bearing section of the turbocharger. See fig. 3.




                              Page 5 of 9


18. Remove the bolts,      lockplates, and clamplates.   Carefully remove
the center bearing and compressor assembly from the cast iron
turbine housing. If the turbocharger has been in service for some
time, rust and carbon may prevent the center bearing and compressor
assembly from easily separating from the turbine housing. If light
hammer blows, penetrating oil, or heat will not free the compressor
assembly from the turbine, the clamp bolt adjacent to the turbo oil
inlet connection may be backed out so as to push against the
 bearing casting and separate the two components.  Remove any loose
_rust or carbon from the bearing housing that nmight prevent proper
 engagement into the new turbine housing.

19. Install the center bearing and compressor assembly into the new
turbine housing supplied in the Banks upgrade kit. Apply a dab of
anti—seize compound to the bolts, then install bolts, clamp plates,
and lock plates finger tight to allow for final positioning.

20. Clamp the exhaust inlet flange of the new turbine housing in a
bench vise.   —Install the turbo exhaust outlet adapter casting to
the turbine housing with five mm x 20mm metric hex bolits.    Apply
a dab of anti—seize compound to the bolts, then torque bolts to
11.3N—m (100 in.—lbs.).     Make sure turbine inlet flange does not
rotate in the vise while torquing.    See fig. 4.

21.   Make   a mark on    the   turbocharger compressor housing directly
adjacent to the     oil    inlet   connection.   This will   allow you to
rep051tlon the compressor housing in this location once the V—band
clamp is removed.  See fig. 5.

22.   Loosen   the nut   on the V—band clamp attaching the     compressor
housing to the turbo center section.         Remove the V—band clamp fronm
the turbo.

23.   Loosen the nut on the new V—band clamp provided and slip the
clamp onto the turbocharger.          Note the position of the clamp bolt
and nut in fig.    6.     Rotate the clamp so that the actuator brace,
provided in upgrade kit,        may be installed between the tabs on the
V—band clamp and the wastegate actuator bracket.      See fig. 6.
Attach the brace to the bracket with two 6mm x iO0mm metric bolts
and two 6mm washers.    Rotate the V—band clamp until the brace
aligns with the actuator bracket, then install a 6mm x 10nmm metric
bolt and 6mm washer to attach the brace to the actuator bracket.
Leave all bolts finger tight.

24. Rotate the compressor housing to align the mark you made on the
turbo compressor housing with the oil inlet fitting, then clamp the
V—band nut to 8N—m (72 in.—lbs.).    Tap against the clamp in four
places around it‘s circumference. Once again tighten the clamp to
the specified torque.



                                   Page 6 of 9


        25.   Spin the turbo compressor wheel to make'sure it turns freely.
        If not,   loosen the V—band clamp,        find and correct the problem,        and
        retighten as in the previous step.



                                  TURBOCHARGER INSTALLATION


        26. Remove the existing turbocharger oil darain tube from the
        engine.
        27. Use a new gasket provided to connect the new turbocharger oil
        grain tube to the turbocharger.     Make sure the turbocharger oil
        drain flange is clean and free of any old gasket material. Tighten
        the drain flange bolts to 24 n—m            (18 ft.—lbs.)   torqgue.   NOTE:    If
        bolts encounter excessive resistance prior to seating against the
        flange, check for paint build up in the threads of the turbo
        bearing housing.  The threads may have to be chased with an 8mn x
        1.25 metric tap.                     —

        28. Install a new turbo exhaust inlet gasket provided and apply a
        dab of anti—seize compound to the four turbo mounting studs.
        Make sure the turbo compressor hose is in place on the turbo, so it
        can be slid onto the crossover pipe or intercocler pipe.    Install
        the turbocharger on the exhaust manifold.      Slide the turbo oil
        drain tube into the hose on the engine.   Tighten the turbocharger
J‘—‘\




        mounting nuts to 32N—m       (24   ft.   lbs.)   torque.

        29. Now tighten the turbine housing clamp plate bolts to 1i1.3N—m
        {100 in.—lbs.) torque.

        30. Again spin the turbocharger shaft to make sure it turns freely.
        If not,   loosen the turbine clamp plate bolts and check for
        misaliqgnment between the turbine housing and turbocharger center
        section.   Retighten bolts and check again.

        31. Reconnect and tighten the turbo cil supply hose.               Tighten the
        oil drain tube hose clamps.

        32. Slide the turbo compressor hose onto the air crossover pipe or
        intercooler pipe.    Center the hose over    the gap between the
        turbocharger and    the pipe,      then position the clamps        so they are
        behind ({not over} the hose bead section of the turbo and pipe.
        Tighten the clamps to S5N—m (44 in.—lbs.) torque.

        33.   Install   the air    inlet tube     (from air cleaner)    and the turbo
        exhaust pipe onto the turbocharger.              Tighten each of these clamps
        to 8 N—m (72in.—lbs.)       torque.      Make sure exhaust pipe is centered
        over V—band flange on turbocharger.


                                           Page 7 of 9


            NOTE:    If the vehicle is a 4WD model and a Banks PowerPack® exhaust
            system is being installed at this time, do not install and clanmp
            the turbo exhaust pipe. It should be installed when installing the
            PowerPack.

            34.     The wastegate     in   the   turbine     housing   is    operated   by     boost
            pressure fed to the actuator through a hose from the intake systenm.
            This hose connection to the intake boost pressure will vary with
            vehicle model year and intercooled/non intercooled applications.
            Figure 7 shows three methods of connecting the wastegate actuator
            hose, choose the one that applies to your vehicle.

            NOTE:    When   tapping    the   air     crossover   pipe   on     an    ‘89—‘91    non—
            intercooled engine,       push a rag into the open end of the crossover
            pipe past the point to be drilled and tapped.    This will prevent
            chips from entering the engine. Drill through the back side of the
            crossover pipe using a letter "R" drill, just above the turbo
            compressor hose joint.   Tap this hole with an 1/8 N.P.T. pipe tap
            to accept the adapter fitting supplied.    Use grease on the drill
            and tap to allow a minimum of chips to fall into the crossover
            pipe.

            CAUTION! Make sure the rag is removed from the crossover pipe prior
            to reassembly and engine start up.   Use a hooked tool (hook—screib
            or welding rod) to pull the rag from the crossover pipe.    Inspect
            for and remove any remaining chips by placing a finger into the
        \
* ces




            pipe opening and manually removing loose material.
        «




            35. Install the 1/8 pipe x 1/4 inch hose adapter fitting in the
            intake manifold connection selected from step 34 {fig. 7).   Use
            Teflon tape or pipe sealant on fitting threads.

            NOTE: If a manifold boost gauge is to be installed, an additional
            manifolda pressure connection must be provided for the gauge.  An
            1/8 inch tee (not provided) must be installed at the intake
            manifold connection along with the 1/8 pipe x 1/4 hose adapter for
            a boost gauge connection.

            36.   Install a spring—band hose clamp onto one end of the i/4 inch
            I.D. silicone hose (squeeze clamp with pliers and slide onto hose).
            Push this end of hose onto the hose nipple adapter fitting
            installed in step 35.   Route the hose over the engine to the hose
            nipple on the wastegate actuator. Maintain 3—4 inches of clearance
            between the hose an exhaust manifolding.   Cable ties are provided
            to secure tubing to existing engine plumbing.    (See fig. 7.)

            CcAUTION!  bo not       pull     cable    ties   to tight       as the   hose may     be
            pinched shut!


                                                 Page 8 of 9


                               ®
                           Md




37. Trim hose as required to reach the wastegate actuator hose
nipple. Slide a spring—band clamp onto the hose and attach hose to
nipple.     Make sure both hose clamps are positioned over the hose
nipples.     See fig. 8.

38. If a boost gauge is to be installed, complete the installation
at this time.  Follow the instructions included with the gauge.

39.   If   an   exhaust    gas       pyrometer   ({temperature    gauge)   is    to   be
installed, complete the wiring from the probe and install the gauge
at this time.

40. Raise vehicle and tighten U4clamp‘ét slip joint between turbo
exhaust pipe and extension pipe.

NOTE: If the vehicle is a 4WD model and a Banks PowerPack® exhaust
system is being installed at this time, skip this step as the
PowerPack includes a new extension pipe.       This step will be
completed as part of the PowerPack assembly sequence.                        Reinstall
turbo exhaust pipe when installing PowerPack system, torque V—band
clamp to 8N—m (72 in.—lbs.).

41.   Installation        of       the   turbocharger   upgrade    package      is    now
complete.   If a Banks PowerPack exhaust system is to be installed
at this time, that assembly may be commenced.    Reconnect battery
cables.    Start vehicle and allow engine to warm up.   Test drive
vehicle and listen for any intake or exhaust leaks, correct as
necessary.                                          '




                                         Page 9 of 9


                                                   GALE BANKS ENGINEERING
                                                DODGE/CUMMINS DIESEL PICKUP
                                                  wWASTEGATE TURBO UPGRADE



                                                CUSTOMER BILL OF MATERIALS
                                                        Kit # 24050



                                       DESCRIPTION                            BANKS PART NO.
;




                                       CLAMP, V—BAND                          24301
     forop— he Lo pt tbA oR Uf f4og—




                                       NUT, V—BAND                            24302
                                       BOLT, 8MM X 20MM HEX HEAD          >   24303
                                       ADAPTER, EXHAUST OUTLET CONNECTOR      24304
                                       ASSEMBLY, TURBINE HOUSING              24305—00
                                       WASHER, 6MM I.D. FLAT                  24306
                                       BRACE, ACTUATOR                        24327
                                       BOLT, 6MM X 10 MM HEX                  24328
                                       GASKET, TURBO MOUNTING                 93027
                                       PIPE, TURBO EXHAUST                    52109—00
                                       HOSE, WASTEGATE ACTUATOR, 1/4" I.D.    94121
                                       X 36", SILICONE
                                       ELBOW, 1/8 N.P.T. X 1/4 HOSE, 90°      92245
    po paopsabe DJ p4ops d NJ fo4




                                       CLAMP, SPRING BAND HOSE, RED           92877
                                       RIVET, POP, 3/16 DIA. X 1/8 GRIP       91998
                                       TUBE, OIL DRAIN                        24077—00
                                       GASKET, OIL DRAIN                      93040
                                       PLAQUE, BANKS TURBOCHARGED             96003
                                       TIE, CABLE 8"                          62010
                                       INSTRUCTION BOOKLET                    96382
                                       wWARRANTY CARD   C                     96380
                                       wWARRANTY STATEMENT                    96381




                                                         Page 1 of i1


(          banifo                                                             rax menasacore.
           Gale Sanks Engineering       546 Nuggan Avenue   Azusa, Caiforns 91702       {[B18) 969—95605




           F/G. )




        eAC70ORYy
      W/EAT SHHIELD
    frare movbeL ONiy)
                             7LAAZRBO EXLIALIST RLLILLE                             ~

              (g\               / LEXHHALET Y—BAND CLAMZLEL                 %             Nz/y/g%ii%gaf




C                                   }                                  \\_/0/4 FEED HOSE
                         &                                                               Aife INLET MHOSE CLAM
                                                                                               AIR IALET HOGSE

                               7ZURBOCHARGER




                      O/L DRMA/N TUBE



                                                                          JNTZERCOOLE/L
                                                                           A/l PIPING


_    F/IG. 2            EXHALUUIST PIPE HEATSHIELD (esug=)
                                                         ONLTYT

      LFACTORY HEATSHIELD
      (Removen FrRom Orremnai
      EXHALUST PIPE)                BANKS TURBCO EXHHAUST PIPE




      oeremat wastien
      (&se in BOzom \({
      2 £0cArIONS
      OMer)

      "poP" RVIT,
LC    4 10CATIONS


     F/G. 3

      LR C’OMPA’C—SSOR/B&'AE/A/G
      ASSEABLEy*


      LOCKPLLATES


      CLAMIIMLLATES



      VZALRLS/AE IEIXLS/ANCG


(   F1IG. 4
      AXHMAUST OITEZADAPTER

       8 mm x 20 mm riexRar


    F£/16.5                 Nt
                /          makre compRessom Housine (mor crampP)
                      /’    ADJACENT 70 O INLET CONNECTION.
                       [ 7\




          comPRESSOR cover

          O—R/NG
           V— BAND C{AMPL AUUT                            — ABANO
                                                          CiamP
          L6mmx 10m»m ~———aq
                           \fi                            (suprieD)


                                —&
          BEX RBOLT
           mASIER, EmM /.D./'@\¢

           acrisarok BRace             ho
                                 G


           masHER, €EMM 1. D.
           6MAAX 1O MM


F!/IG. 7              maSTE6aIF Ac1rtiaToR HOSE HOOK—tip
jool/Ze ano 1ATER, INTERCOOLED
                      MKQUTE HASE
                      UNDER COVER




          70 waSsyECGaATE
           ACTEIATOR




                                                             [X  SPIR/ING —~BAND CLAMLP

                                     ’/@”Mez PoRT in INTFAKE MANWFOLD
                                         (Remove Pipe PLUEG]

1989 —l!9, wNow— INTERCOOLED
          Jq"siurcone mose
            (Teim aAsRepxuRED)
          SPRINMGE —BAND CZAMP\                          €

      S‘mar xYq"mosenmpprs
      DRLLAND TAP BACK                           |
      sroe or cRossove® . . [
      PiPE FoOR JENPT
      LITIING.

      70 WASTEGATE
      AcCrerA 70M                    .       \
                       Z                     7                              7/E HOSE 70
                            Lz>          —               m                 PriP/IMG
                             /\                      /       _

F/IG. 7                          ‘                   6
CONTINUED NEXT PAGE


APPENDIX A


FIG.7      conriveED
1O80—‘d/ wiTr! BANKS INTERCOOCLER
                    7E HOSE 70
                     PIP/ING

                           \                    Ha suiconNe
                (~        AXGZ                   9 Hose
      TD WASTEGATE @/
        ACTLATOfe


                           d —[as

                                          SPR/ING — BAND CLAMP
                                  lZmoarx/2"mosemippie€
                                 (THREAD INTO REAR OF BANKS
                                    mMANMIFOLD 1mMiE3 E180w)

F/IG. 8
WASTEGATE ACTUATOR HOOK—LP




                                       RoUTrE HOsSE ovek
                                       comprREssoR IMLET




                                                ZFRONT >

                                            SPRING —BAND CLAMPLP

                                           WasTEedCATE ACTOATOR


                                             DODGE/CUMMINS

                               PYROMETER INSTALLATION INSTRUCTIONS



       The optional exhaust gas pyrometer monitors the temperature of the
      ~— exhaust entering the turbocharger turbine housing. Installation
         requires that the exhaust manifold be drilled and tapped for a
       temperature probe near the outlet of the manifold adjacent to the
       turbine   housing.             For   this    reason      it   is       essential      that   the
       turbocharger be removed from the engine in order to clean out any
       metal chips from drilling that could cause turbine blade damage.

       The   Cummins       6BT     engine    uses    a    Givided           exhaust    manifold      and
       turbocharger.   The pyrometer probe must be installed                                 to sample
       exhaust temperature in one of the two exhaust passages.                               Typically
       the exhaust temperature will not differ appreciably between the two
       passages.  We recommend installing the probe in the rear manifold
       passage to simplify routing the probe wiring.
_=m




        1.   Stuff    a    small    shop    towel    or   rag    4~—5       inches    into    the   rear
       exhaust manifolda passage through the turbocharger mounting flange.
       This is to prevent chips from entering the manifold while drilling
       and tapping.

          2. Drill through the exhaust manifold into the rear passage at
       the location shown in fig. x.     Use a 7/16 inch d@rill, keep the
       garill perpendicular to the manifold surface.

        3. Tap the drilled hole with a 1/4 NPT pipe tap. Check the thread
       depth as you tap by periodically removing the tap and screwing the
       probe fitting (supplied in pyrometer kit) into the tapped hole.
       The probe should thread in 3 — 3 1/2 turns hand tight.      Do not
       install the probe in place at thistime..                         —

        4.   Remove       as   many    loose   chips      as    possible        from    the    exhaust
       manifold.  A shop vacuum, small brush, or fingers will help.    Now
       remove the rag using a welding rod or coat hanger bent into a hook.

       wARNING! Make sure rags are removed from exhaust manifold prior to
       reinstalling turbine housing!

        5. Install the probe in the manifold ({anti—seize on threads is
       recommended) and continue the pyrometer assembly as cutlined in the
       instructions supplied with the pyrometer.


— PYROMETER ProseE /A/szzzmr/a/v '
  DODGE]/CMMINS TRGO D/IESEL

       DALL ANOD FaAP !/4 mA PORT IMN MEA
       PASSAGE OF EXHALISyY MANIFOLD OLTLET




       40CATE POR] F INCH BEHIND
       FLANGE, CENTERED OvEeRr REAR
       EXHAUST MAMNIFOLD RASSACEE



Document Created: 2005-09-01 12:43:16
Document Modified: 2005-09-01 12:43:16

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