Banks Power Ford Trucks: (Diesel ’03 - 07 6.0L Power Stroke) Interface- PowerPDA Ford (03-09), Chevy (01-08), Dodge (03-07) - Manual (Page 20)

20
96801 v.9.0
8.
Route the thermocouple connector
along the factory harness to the
driver’s side and connect it to the Six-
Gun’s EGT connector. Use the supplied
cable ties to secure the harness.
Dodge Cummins 2003-2007
ThERMoCoUPLE INSTALLATIoN
1.
The thermocouple monitors the
temperature of the exhaust gases
entering the turbocharger at the
turbine housing. Installation requires
that the exhaust manifold be drilled
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 ISB engine uses a divided
exhaust manifold. The thermocouple
may be installed to sample exhaust
temperature in either exhaust
passage. We recommend the rear
passage (toward the firewall).
2.
Loosen the clamps that attach the
air inlet tube to the air filter housing
and to the turbocharger, and remove
the air inlet tube from the vehicle.
Remove the air filter housing from the
vehicle. This will allow easier access
to the turbocharger.
3.
Loosen the upper hose clamp on
the turbocharger oil drain-tube hose
that is located between the two
sections of the oil drain tube.
4.
Disconnect the oil supply hose
at the turbocharger. Disconnect the
compressor outlet hose that goes to
the intercooler.
5.
Remove the turbine outlet pipe by
loosening the V-band. Save V-band for
re-installation.
6.
Remove the turbocharger mounting
nuts/bolts and the turbocharger from
the exhaust manifold. Clean and
inspect the exhaust flange mounting
surfaces on the exhaust manifold.
Make sure the surface is clean and dry.
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 the 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. Cover the
open end of the intercooler pipe
with a clean rag, as this pipe is
very susceptible to foreign object
entry.
7.
Stuff clean shop towels into the
compressor outlet and inlet hoses
to prevent contamination from
entering the pipes. cover the turbo oil
drainpipe to avoid contamination.
8.
Stuff a small clean shop towel
or rag 4 to 5 inches into the rear
exhaust manifold passage through the
turbocharger mounting flange. This
is to prevent chips from entering the
manifold while drilling and tapping.
9.
Use a 7 ⁄
16
” drill, keeping the drill
perpendicular to the manifold surface
and drill through the exhaust manifold
into the rear passage as shown in
Figure 27.
10.
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
pipe coupling into the tapped hole.
The coupling should thread in 3 to
3 1 ⁄
2
turns handtight. Do not install the
probe in place at this time.
11.
Remove all loose chips from the
exhaust manifold. A shop vacuum or
small brush will help. Now remove the
rag using a welding rod or coat hanger
bent into a hook.