Banks Power Ford Trucks: (Diesel ’99 - 03 7.3L Power Stroke) Power Systems- PowerPack, Stinger-Plus, Stinger & Git-Kit '19991_2-2003 F-250 & F-350 Trucks and Excursions - Manual (Page 15)

96336 v.10.0
15
side of the clamp. Reinstall the bracket
using a #56 hose clamp provided to secure
the filter/dryer unit to the bracket.
NOTE: Before slipping any boost tubes
and the corresponding hoses, into
position, ensure that all connection ends
are clean and free of any oil residue and
contaminates. Clean compressor outlet
and all connection points with a non-oil
based solvent such as Acetone, Mineral
Spirits, Denatured Alcohol or Lacquer
Thinner. Read and follow the manufactures
operation instruction
15.
Slide three #52 hose clamps over the
left boost tube. These will be used later to
secure the heatshield in place. Set both
boost tubes into place in the vehicle. Place
two of the 3” silicone hump hoses onto
the intercooler inlet and outlet, and fasten
with the T-bolt clamps provided. Position
two more clamps on the open ends of the
silicone hoses, and place the intercooler
into the vehicle slipping the boost tubes
into the hoses on the intercooler and the
intercooler into the rubber saddles on the
lower mounting brackets. Do not tighten
these clamps yet.
16.
Place the air conditioning condenser
back into its original position. Reinstall
upper crossbar into truck, using the
original bolts. Reinstall the diagonal braces
to the radiator support and reattach the
power steering cooler to the right side
diagonal.
NOTE: Rotate the upper power-steering
fluid tube in the clip to allow the hose
portion to clear the bottom of the right
lower intercooler bracket.
17.
Remove the factory rubber isolators
from the factory intercooler and install
them into the upper brackets of the
Banks intercooler. Install the original
studs through the isolators into the upper
crossbar and tighten them. Tighten the
upper mounting-bracket bolts on the
intercooler.
For late 1999
1 ⁄
2
–2003 models,
proceed to Step 23 .
18.
Remove the sensors from the factory
compressor discharge plenum casting
and install them into the Banks TwinRam
intake assembly.
Early 1999
1 ⁄
2
models: Remove the
heating element from the factory
compressor discharge plenum casting
and install it in the Banks TwinRam intake
assembly.
19.
Slide the two 2” silicone hoses up the
legs of the TwinRam. Slip two #36 hose
clamps over each hose and install the
TwinRam to the engine, sliding the hoses
down the legs and onto the intake stubs,
making sure that the hoses are positioned
equally between the TwinRam legs and
the manifold stubs. Tighten the clamps.
Attach the bracket to the rocker cover
using the 8mm x 30mm metric bolts and
spacers provided.
20.
Attach the wastegate control
solenoid to the tab on the TwinRam with
the supplied 1 ⁄
4
-20 x 1 1 ⁄
4
” hex bolt and
washer. Reconnect the wiring harnesses
to the sensors.
21.
Attach the right side boost tube to
the TwinRam using a 3” silicone hump
hose, and two T-bolt clamps.
22.
Place the new O-ring into the recess
in the compressor housing and attach
the compressor discharge elbow to the
compressor housing with the new V-band
clamp provided. A small amount of bearing
grease may be used to hold the O-ring in
position while installing the elbow. Bolt
the compressor discharge elbow to the
TwinRam through the tab provided for this
purpose using the 5 ⁄
16
” bolt, washers, and
nylock nut provided. Install a 1 ⁄
8
” NPT x 1 ⁄
8
”
compression fitting (supplied in the boost
gauge kit) in the bung on the compressor
discharge elbow. Sparingly apply pipe
sealant tape or paste on the male pipe
threads, and tighten the hex on the fitting
body (NOT the compression nut). Proceed
to Step 24 .
23.
Late 19991⁄2–2003 models (All
models for Stinger-Plus installation):
Place the O-ring into the recess in the
turbo compressor outlet and reinstall the
factory compressor discharge plenum
casting on the turbocharger. A small
amount of bearing grease may be used to
hold the O-ring in position while installing
the casting. Slide the hump hoses on the
boost tubes onto the compressor plenum
discharge casting. Reconnect any wiring
or sensor tubes to components on the
compressor discharge casting. Reconnect
boost line to wastegate actuator.
If a Banks Brake is being installed,
proceed to Step 25 .
24.
To reconnect the exhaust
backpressure control valve, hold the cover
on the end of the rod back and have
someone start the engine. When the rod
extends after a few seconds, push it up
onto the valve linkage and allow the cover
to snap back into position.
wARNING! Stay clear of moving
parts such as engine cooling fan and
belts. Do not drive the vehicle until
the remainder of the installation is
complete.
25.
While engine is running, check for oil
leaks around the base of the turbocharger
center section or the pedestal mount.
Repair any leaks before continuing.
NOTE: The most likely cause of an oil leak
in this installation is a pinched O-ring at
the base of the turbocharger.
For Stinger-Plus installation proceed to
Step 32 .
26.
Make sure that the boost tubes clear
all moving parts, and that the hoses do not
chafe on any sharp edges. Tighten all of
the boost tube clamps.
27.
Reposition the left and right air
deflectors back into their original positions,
and use the pushpins to attach them to
the radiator support. Reattach the wiring
harness removed from the intercooler
mounting studs. Reinstall the original
radiator mount brackets onto the radiator
upper support. Tighten the bolts. Reattach
the radiator overflow tank to the upper
radiator bracket. Reinstall the jacking tools
to the core support. Reinstall the grille
support to the vehicle using the original
hardware. Reinstall the air conditioning
condenser upper brackets. Reattach
the right and left air deflectors to the
grille support with the original hardware.
Reinstall the hood latch in its original
position.
28.
Reinstall the light bulbs into the
turn signal/marker light combinations,
and reinstall the combinations into the
vehicle. Press them firmly, straight back
into the attaching clips and bolt them into
place. Reinstall the headlight bulbs into
the headlight assemblies. Be careful not
to touch the headlight bulbs themselves
with your fingers, as oil from your skin can
cause damage to the bulbs. If necessary,
clean the bulbs thoroughly with rubbing
alcohol before reinstalling them.
29.
Turn on the headlights and turn
signals briefly to check for proper
operation.
30.
Reattach the upper radiator air
deflector to the grille support and upper
radiator support with the plastic pushpins
previously removed. Reinstall the grille by
pushing it into the lower clips. Reinstall the
original screws.
31.
Recheck all clamps to ensure that
they are tight before driving the vehicle.
32.
Clean an area that is easily visible
on the upper radiator core support with
a non-oil based solvent, such as Acetone,
Mineral Spirits, Denatured Alcohol or
Lacquer Thinner. Allow to dry and then
attach the Banks E.O. sticker to the upper
radiator core support.
–END, SECTION 7–