Banks Power Dodge Trucks: (Diesel ’03 - 07 5.9L Cummins) Tuner- Bullet Diesel Tuner '03-07 235, 250, 305, 325 HP Dodge 5.9L Cummins (24-valve) Trucks User Manual

Page 10

96581 v.7.0

Note: If not installing or connecting an

eGt thermocouple to the Banks Bullet

Diesel tuner then install the supplied

eGt thermocouple bypass plug. the

bypass plug is installed on the two-pin

connector attached to the backside of

the tuner.
If your vehicle already has a Banks

DynaFact EGT probe installed, please

skip to step 19.
If your kit does not have EGT sensing

and limiting functions, please skip to

Section 2.

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.
Note: 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).

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.

Loosen the upper hose clamp on

the turbocharger oil drain-tube hose

that is located between the two

sections of the oil drain tube.

Disconnect the oil supply hose

at the turbocharger. Disconnect the

compressor outlet hose that goes to

the intercooler.

Disconnect the turbine outlet pipe

by loosening the V-band. Save V-band

for re-installation.

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.

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.

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.

Use a

⁄

” drill, keeping the drill

perpendicular to the manifold surface

and drill through the exhaust manifold

into the rear passage as shown in

Figure 2.

10.

Tap the drilled hole with a

⁄

”

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

Section 1

ExHAUST GAS THERMOCOUPLE INSTALLATION INSTRUCTIONS