Banks Power GM Motorhomes: (Gas ’01 - 10 8.1L Workhorse) PowerPack & Stinger systems '05 & Later Class-A MH, W-24 chassis - Manual (Page 3)

1.
With the motorhome safely raised,
ground wire(s) disconnected, and
precautions in place, remove the
factory exhaust system.
2.
To provide better access to
the manifolds remove the front
wheels from the motorhome. If the
motorhome is equipped with inner
front fender shields, remove them for
improved access.
Note: Before removing the lug nuts,
make sure a capable torque wrench is
available to tighten the lug nuts to the
manufacturer’s torque specifications
3.
Locate the oxygen sensors in the
exhaust headpipes on each side of
the engine, forward of the catalytic
converters. Unplug the connectors and
unscrew the oxygen sensors, keeping
track of the left and right sensors. Be
careful not to touch or contaminate
the sensor.
4.
Remove the factory hardware on
the front 2-bolt headpipe flanges.
Remove the hardware on 3-bolt
flanges on the exhaust manifolds /
headpipe assemblies. Remove the
headpipes from the exhaust manifolds.
NOTE: Whenever possible, it is
recommended that the catalytic
converters be inspected. Restricted
or damaged catalytic converters can
impede performance of your Banks
PowerPack.
5.
Remove the engine oil dipstick
by unbolting the bracket from the
alternator support and the engine
block (see Figure 2). Remove the
dipstick and dipstick tube by pulling
and twisting upward. If the dipstick
tube o-ring is stuck inside the hole in
the engine block, remove it and place
it back onto the dipstick tube. Retain
all hardware for reassembly.
6.
Remove the spark-plug wires and
the spark plugs from both sides of the
engine. Note their original locations so
they can be properly reinstalled.
7.
Remove the nuts holding the
spark-plug wire heatshields to the
exhaust manifold studs. Remove the
heatshields.
8.
With a wrench or socket, back the
exhaust manifold nuts at least one
turn away from the manifolds. Use a
#7 female torx socket to unscrew each
stud from the head. If this tool is not
available use a 7 ⁄
32
socket. Take out
the studs so the exhaust manifolds
can be removed.
9.
Caution: Make sure all ground cables
are removed from vehicle’s battery(s).
Remove the starter wire battery cable
from the starter motor. Remove the
factory starter cable from the starter
and install the 90-degree terminal
end of the supplied starter extension
cable (red) onto the starter motor
and tighten the retaining nut. Remove
the factory ground cable from the
starter and install the supplied ground
extension cable (black) to the starter.
10.
Route the starter extension
cables (red & black) forward under the
motor mount. Attach a supplied heat
wrap to the extension cables. Zip-tie
the extension cables and heat wrap to
the factory motorhome wire harness.
Route the extension cables inside the
frame rail (see Figure 3).
11.
Slide the 4-inch length of heat
shrink over the extension cables,
such that the red heat shrink is on
the red cable and black heat shrink
on black cable. Attach the extension
to the correct factory starter cable
using (1) 5 ⁄
16
-18 x 1 ⁄
2
” bolt, (1) 5 ⁄
16
-18
crimplock nut, and (1) 5 ⁄
16
washer per
cable. Slide the heat shrink over the
connection and heat with a heat gun
until the heat shrink tightly conforms
to the connection. Make sure the
connection is completely covered.
Installation Instructions
96438 v.2.0
3