Banks Power Ford Trucks: (Diesel ’83 - 93 6.9 & 7.3L) Forced Induction- Sidewinder turbo system (Van) 6.9 & 7.3L - Manual (Page 15)

tighten compressor discharge hose clamps.
Install turbo compressor air inlet elbow and
3 x 1 3 ⁄
4
” long silicone hose on compressor.
See figure 1 . do not tighten clamps at this time.
mount compressor air inlet elbow brace
on rear of left cylinder head, using one
3 ⁄
8
”-16 x 3 ⁄
4
” hex head bolt and one 3 ⁄
8
” split lock
washer. Install anti-depression valve, with hose
connection facing upward, on the air inlet elbow,
using original bolts and two 9 ⁄
16
” Od x 5 ⁄
16
” Id flat
washers and 5 ⁄
16
”-18 nylock nuts. Be sure original
seal is in place on anti-depression valve mounting
surface. Remove existing o-ring and nylon sleeve
from the anti-depression valve hose connection
(through 1986 models). see figures 1 and 22 .
tighten air inlet elbow hose clamps, at
turbocharger and elbow.
connect oil feed hose to turbocharger oil
inlet elbow.
Install 3” diameter flexible fresh air inlet
hose between air cleaner assembly and air
inlet elbow, using two #52 hose clamps.
Remove and discard the hose clamp from
the heater hose connection on the water
pump. Hose clamp may be cut with snips to avoid
disconnecting hose.
thoroughly degrease the oil fill-pipe flange
face (injector pump drive cover flange face
on 1987 models) using acetone lacquer thinner or
other non-oil based solvent. Install the crankcase
vent hose adapter and oil fill-pipe (inspection
cover on 1987 models) using two 5 ⁄
16
”-18 x 2” hex
bolts and two 5 ⁄
16
split lock washers. use silicone
sealer on both flange surfaces. see figure 23 .
Replace the hose clamp previously removed
from the heater hose with a No. 10 hose
clamp, provided in the kit. Keep the tail of the
hose clamp clear of the alternator drive belt. See
figure 23 .
Install crankcase vent hose, from crankcase
vent adapter nipple to anti-depression
valve, using two #16 hose clamps, as shown in
figure 23. Be sure that hose is installed with no
low areas that could cause oil puddling in the
hose.
Install pyrometer and gauge panel. Refer to
manufacturer‘s instructions included with
pyrometer.
Install accessory instruments, if used. Refer
to manufacturer‘s instructions included with
instruments.
Install muffler and exhaust system (not
included with the turbo system) as shown
in figure 27. Because of various vehicle/chassis
combinations, the illustration provided is general,
but typical of the exhaust system routing.
nOte: the factory muffler and exhaust system
are nOt suitable for turbocharged engines. the
entire exhaust system, from the turbo down-pipe
through to the tail pipe, should be three inch
diameter, including the muffler. use of a smaller
muffler or exhaust piping will result in significantly
inferior performance. a separate 3” high-flow
exhaust system includes a special low restriction
3” core muffler, pre-formed tubing sections and
all components necessary to install the complete
exhaust system. the BanKs 3” exhaust system
is Required for emissions legal applications. use
of any other exhaust with the turbo system is not
emissions legal.
for those wishing to do their own exhaust system
fabrication, the following recommendations
should be followed (see figure 28 ):
A. Be sure to use a high quality, low restriction 3”
core muffler, designed for turbocharged diesel
applications. (Most 3” mufflers available from
muffler shops are low quality, high restriction
“economy” replacement mufflers, usually based
on a 2 1 ⁄
2
” or smaller core.)
B. Make all bends as gradual as possible. align all
weld joints as carefully as possible so the exhaust
flow will not experience “steps” in the tubing.
C. do not “cheat” bends or make miter-weld joints.
these types of bends are too abrupt for proper
exhaust flow.
D. Maintain adequate clearance to chassis,
floorboards, driveline, moving suspension parts,
etc. suspend exhaust tubing in rubber hangers to
allow for engine movement. the original hangers
may be reused if in good condition.
Install a 9 x 24” heat blanket on turbo down-
pipe. Make sure top of pipe is covered by
the heat blanket. secure using wire ties provided.
See figure 24 .
Install a 7 x 24” heat blanket on Y-pipe
extension, sliding it up from the bottom, all
the way up to the pyrometer fitting on the turbo
mounting bracket. secure, again using wire ties.
See figure 24 .
Install remaining 6 x 8” piece of heat
blanket on hoses for rear heater and/or
air conditioning if these hoses are routed near
exhaust.
Reroute the fuel injector return hose to the
left side of the transmission bellhousing. see
figure 22 . check to be sure the injector return
hose does not rub on any sharp edges.
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P.N. 96308 V.2.0