Banks Power Ford Trucks: (Diesel ’94 - 97 7.3L Power Stroke) Power Systems- PowerPack, Stinger-Plus & Stinger '94-98 4

25.
loosen the clamps and remove
the flexible engine air intake hose
from between the plastic air filter
housing duct and the aluminum
elbow. unbolt and remove the
aluminum elbow and its mounting
bracket from the engine.
26.
Push the lower end of the
intercooler inlet tube into the silicone
hose on the driver’s side of the
intercooler. the tube will have to
be maneuvered under the a/C hose
on air-conditioned models. Push the
inlet tube into the hose until the tube
touches the intercooler connection,
then pull it out approximately 1 ⁄ 4
inch.
27.
Install a 3-inch diameter silicone
hump hose and two #313 T-bolt
clamps onto the upper end of the
intercooler inlet tube. insert the
turbocharger compressor outlet
elbow into the hump hose. Place
a new compressor outlet o-ring in
the groove on the compressor, then
attach the elbow to the compressor
with the original clamp. leave the
clamp loose enough to rotate the
elbow for adjustment.
28.
reinstall the aluminum air intake
elbow and flexible air inlet hose onto
the engine. tighten the clamps on
the air inlet and elbow, and any other
clamps loosened or removed from
the elbow.
29.
adjust the position of the
intercooler inlet tube to provide the
maximum clearance to adjacent
parts. make sure that nothing can
chafe or cut through the hump hose
from engine vibration. Position the
hump hose so that it is centered
on the junction of the inlet tube
and the compressor outlet elbow.
There should be approximately
1 ⁄ 4 -inch separation between the
tube and elbow inside the hump
hose, they should not rub together
within the joint. when all tubes are
positioned for best clearance, tighten
the clamps on the hump hose, the
intercooler inlet, and the compressor
outlet.
30.
Disconnect the hose between
the radiator and the coolant recovery
tank at the recovery tank end. insert
the lower end of the intercooler
outlet tube into the silicone hose on
the intercooler outlet. the bracket
supporting the battery cable will
need to be bent slightly to provide
enough clearance for the tube. Push
the tube all the way in and then pull
it out approximately 1 ⁄ 4 -inch. install a
3-inch diameter hump hose and two
#313 T-bolt clamps onto the upper
end of the intercooler outlet tube.
31.
remove the two center
bolts from the upper edge of the
passenger-side rocker cover. install
the two hoses removed from the
factory discharge plenum onto Banks
twinram ™ intake assembly. Push
them all the way on until the tube
just begins to come through the
hose. slide two original clamps onto
each hose.
32.
Slide the 3-inch end of the
twinram into the hump hose on the
intercooler outlet tube and position
the legs of the twinram over the
openings on the engine intake
manifolds. slide the hoses down the
legs of the twinram until they are
bottomed on the intake manifolds.
attach the bracket to the rocker
cover using the 8 mm x 30 mm
metric bolts and spacers provided.
see Figure 13.
Figure 11
Figure 12
96493 v.4.0
13