Banks Power Ford Motorhomes: (Gas ’97 - 05 6.8L V-10, Class-A (20-valve)) Power Systems- PowerPack, Stinger & Git-Kit Systems, (Class-A) '97-05 - Manual (Page 6)

For Git-Kit & Stinger installation, proceed
to step 24.
1.
The vehicle may have a bolted in
crossmember between the leveling
jacks at the front of the vehicle.
This will need to be removed prior
to removing the factory exhaust
system and reinstalled after the Banks
PowerPack system is place.
2.
Locate the oxygen sensors in each
exhaust headpipe, downstream of
the factory exhaust manifolds. Unplug
the connectors and remove both the
oxygen sensors. Mark the sensors for
correct reinstallation.
3.
Disconnect the three-bolt flange
at the front of the catalytic converter
from the factory Y-pipe assembly.
Disconnect the headpipes from the
exhaust manifolds and remove the
Y-pipe assembly from the vehicle.
4.
On the driver’s side of the engine,
unscrew the EGR tube from the
exhaust manifold with a 1 1 ⁄
4
” wrench
and remove the EGR tube from the
manifold.
5.
Pull out the dipstick and remove
the small bolt that attaches the oil
pan dipstick tube to the cylinder head.
At the front of the vehicle, behind
the front engine cover, remove the 2
screws that retain the dipstick tube to
the radiator support. Near the exhaust
manifold, pull the dipstick tube up out
of the engine block. Check to see if
there is an O-ring on the tube. If not,
the O-ring may be stuck inside the
hole in the engine block. This O-ring
should be retrieved if necessary and
placed back onto the tube before
reinstalling it.
6.
To remove the exhaust manifolds,
use a wrench or socket to back the
nuts away from the manifolds at least
one turn, then use a 5mm 6 point
socket to remove each stud from
the head. As an alternate method,
take the nuts off the studs, and then
remove the studs.
7.
After the manifolds have been
removed from the vehicle, remove
any remaining studs from the heads.
The studs must be removed from the
heads in order to install the Banks
TorqueTubes.
8.
On EGR models, remove the large
EGR adapter fitting from the left side
factory manifold and install it onto the
left Banks TorqueTube manifold. Reuse
the original copper washer between
the manifold and adapter. Use anti-
seize on the threads to prevent galling.
On non-EGR models, install the 3 ⁄
4
npt
pipe plug into the EGR fitting on the
manifold.
9.
On the passenger side of the
engine, loosen the three rearmost
outside valve cover with bolts. Slide
the valve cover heat shield provided
under the heads of the bolts and
tighten. See figure 2.
10.
On some vehicles a wire loom
bundle runs along the top of the
frame rail adjacent to the driver’s
side of the engine. In these instances
this loom and any other wiring must
be relocated away from the exhaust
manifold heat area. Pry the wire
loom clips from the frame rail to
provide enough slack in the wire loom
bundle so it may be routed and tied
up against the underside of the floor
of the coach. The wire loom bundle
may be routed up braces adjacent
to the upper engine area and along
supporting members under the floor
with the cable ties provided.
11.
Install the starter heat shield onto
the starter using the #52 hose clamp
provided. Caution: Make sure the heat shield
does not come in contact with the positive
terminal of the starter once the heat shield is
tightened down. See figure 3.
Section 1
TORqUeTUBe MANIFOLDS
6
96378 v.6.0