Banks Power Dodge Trucks: (Diesel ’98 - 02 5.9L Cummins ISB) Power Systems- Stinger & Git-Kit Systems (does not connect to pump wire) - Manual (Page 5)

The cummins ISB engine uses
a divided exhaust manifold and
turbocharger. The thermocouple
may be installed to sample exhaust
temperature in either exhaust
passage. We recommend the rear
passage (toward the firewall).
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.
Drill through the exhaust manifold
into the rear passage at the location
shown in Figure
1 . Use a 7 ⁄
16
” drill,
keeping the drill perpendicular to the
manifold surface.
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
thermocouple into the tapped hole.
The thermocouple should thread in 3
to 3
1 ⁄
2
turns hand tight. 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.
caution! make sure rags
are removed from exhaust
manifold prior to reinstalling
turbocharger!
12.
Install the thermocouple in
the manifold using anti-seize on the
threads.
actuator inStallation/
modiFication
Note: At this point in the installation
process, it is necessary to determine
which model turbocharger your
vehicle is equipped with. A
turbocharger identification tag
is located on the front of the
compressor housing of the turbo or
on the actuator. If your turbocharger
is an HY35W, follow Steps
13-17 .
If your turbocharger is an HX35W,
follow Steps
18-21 .
13.
Remove the E-clip from the
wastegate arm, allowing the actuator
rod to be released. Save the E-clip for
reinstallation. Remove the two nuts
holding the actuator to the compressor
housing and remove the actuator.
14.
Tap the end of the boost
reference tube on the stock actuator
with the supplied
1 ⁄
4
-28 UNF tap.
Tap the tube just deep enough so
that the end of the jet is recessed
approximately
1 ⁄
32
” to 1 ⁄
16
” when
threaded into the end of the boost
reference tube and tightened until
snug.
15.
Install the jet into the end of
the boost reference tube then peen
the edge of the tube so that the
jet cannot back out. DO NOT use
a thread locking compound as a
substitute for peening the end of the
tube. Thread locking compounds
will become ineffective due to
temperature.
16.
Using the supplied #55 bit,
drill a hole in the side of the boost
reference tube close to the area
where the tube is attached to the
actuator can.
17.
Reinstall the actuator on the
compressor housing. Be careful not
to damage the O-ring that seals
the boost reference tube to the
compressor housing. Next, reinstall
the actuator rod end on to the
wastegate arm. This will be difficult
since considerable force is required
to extend the rod far enough.
Re-install the E-clip. Proceed to Step
22 .
18.
There are two possible
wastegate actuator configurations
for HX35W turbos. The early style
actuator, found on 1998 and
some 1999 model year vehicles, is
attached to a bracket that is bolted
to the turbine housing. Later style
actuators are mounted to a flange
on the compressor housing. Remove
the e-clip from the wastegate
arm, allowing the actuator rod to
be released. Save the e-clip for
reinstallation. If the actuator is an
early style, unbolt the 3 actuator
bracket bolts from the turbine
housing. Note the location of all 5
spacers and retain the spacers and
bolts for reinstallation. Remove the
2 nuts holding the actuator to the
bracket and remove the actuator. If
the actuator is a later style, remove
the two nuts holding the actuator to
the compressor housing and remove
the actuator.
19.
Install the Banks BigHead
actuator in place of the factory
actuator. If a mounting bracket is
used, loosely bolt the bracket into
place on the turbine housing with the
actuator bolted to the bracket using
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