Banks Power Pack® System

Banks Power Pack®
System
Compatible with Banks iQ
Including Stinger® System
and EconoMind
2003-2005 Dodge Cummins
Turbo-Diesel Pickups
THIS MANUAL IS FOR USE WITH SYSTEMS 63807-63808
Gale Banks Engineering
546 Duggan Avenue • Azusa, ca 91702
(626) 969-9600 • Fax (626) 334-1743
Product Information & Sales: (888) 635-4565
Customer Support: (888) 839-5600
Installation Support: (888) 839-2700
bankspower.com
©2012 Gale Banks Engineering
09/20/12 PN 96820 v.4.0
Also Available from Banks Power
03-07 Dodge 5.9L
BigHead®
Wastegate
Monster
Exhaust
Banks iQ
Banks Bullet™
Banks Billet™
Torque Converter
DynaFact ®
Instrumentation
®
Monster-Ram
Advanced
Diesel Tuners
Banks Brake®
Banks Ram-Air ®
Intake
Techni-Cooler®
System
Super-Scoop®
Banks iQ System
(P/N 61148-61149)
- 5” touchscreen interface that can
control the Banks Diesel Tuner on
the fly.
- Interchangable gauge display, read
and clear codes, monitor engine
diagnostics, log data, time your
vehicles runs and much more.
Banks Monster® Exhaust System
Single (P/N 48640-48643, 48700,
48701, 48708)
Duals (P/N 48702-48707, 48709)
Sport (P/N 48777-48780)
- Increases exhaust flow, cuts
backpressure, lowers exhaust gas
temperatures (EGTs) and increases
power.
Banks Ram-Air Intake System
(P/N 42145)
- Increases your airflow over stock.
- Adds power, improves fuel
economy,
lowers EGTs and reduces smoke.
Banks Ram-Air Intake SuperScoop
(P/N 42190-42191)
- Adds cooler denser air to the
Ram-Air Intake housing, further
increasing fuel economy, reducing
smoke and lowers EGTs.
2
96820 v.3.0
Banks Monster-Ram
(P/N 42765-42766)
- Increased flow from intercooler
- Raises boost without increasing
backpressure at the turbine
Big Hoss Intake Manifold System
(P/N 42747)
- Increases flow and provides more
uniform air distribution to the
engine for more available power
at a given boost level.
Banks Exhaust Brake
(P/N 55222-55229)
- Increases the stopping power of
your truck and extends the
service life of your brakes
Banks SmartLock
(P/N 55270)
- Reduces wear on transmission
- Locks Torque Converter and
raises trans-line pressure
- Works with Banks Exhaust Brake
Boost and Pyro Gauges
(P/N 64507)
- Keep your engine safe by
monitoring vital engine
parameters.
Banks Billet Torque Converter
(P/N 72515)
- Higher torque capacity over stock
- Lockup clutch is slip-resistant so
transmission fluids stay cooler and
transmission life is prolonged.
Banks Bullet
(P/N 66522-66523)
- Adds power safely to your vehicle
- Displays critical engine functions
- Engine safeguards
- Change power levels on-the-fly
Banks Techni-Cooler® System
(P/N 25980-25981)
- Provides increased air flow to the
engine by increasing air density for
more increased power, lower EGTs
and improved fuel economy.
Thermocouple
- Add a temperature limiting function
to your Diesel Tuner .
Banks Speed-Loader
(P/N 62981)
- Furthers the power output of the
Banks Six-Gun and provides EGT
limiting safety.
Banks BigHead® Actuator
(P/N 24331)
- Achieves a higher peak boost over
stock and gives you precise
boost control that gives you crisp
acceleration and more mid-range
pulling power.
Banks Stinger Systems
(P/N 49692-49699, 49708-49711,
49716-49721)
Contains:
- Ram-Air Intake system
- Monster Exhaust (single or dual)
- EconoMind Tuner w/ Banks iQ
- Big Head Wastegate Actuator
Banks PowerPack Systems
(P/N 49700-49707, 49712-49715,
49722-49727)
Contains:
- Ram-Air Intake system
- Monster Exhaust (single or dual)
- EconoMind Tuner w/ Banks iQ
- Big Head Wastegate Actuator
- Monster-Ram
- Techni-Cooler System
Banks Six-Gun Bundle
(P/N 49728-49735, 49744-49747,
49752-49757)
Contains:
- Ram-Air Intake system
- Monster Exhaust (single or dual)
- Six-Gun Tuner w/ Banks iQ
- Big Head Wastegate Actuator
Banks Big Hoss Bundle
(P/N 49736-49743, 49748-49751,
49758-49763)
Contains:
- Ram-Air Intake system
- Monster Exhaust (single or dual)
- Six-Gun Tuner w/ Banks iQ
- Big Head Wastegate Actuator
- Monster-Ram
- Techni-Cooler System
For More Information please call (888) 635-4565
or Visit us online @ www.bankspower.com
96820 v.3.0
3
Tools Required:
•
1⁄ 4”
and
3⁄ 8”
drive ratchets
• Inch and metric deep sockets
• Ratchet extension
• Metric combination or open-end
wrenches
• Phillips and flat blade screwdrivers
• Standard and needle-nose pliers
• Pocket or X-Acto knife
• Clean shop towels or rags
• Drill bit set
• Drill motor
• Tap Handle
• 1⁄ 4” NPT tap
• 5⁄ 16 nut driver
• Pliers
• Torx bits
• Pry-bar
Highly recommended tools and
supplies:
Table of Contents
• Multimeter or 12-volt test light
General Installation Practices . . . 5
• Heat gun
Section 1 . . . . . . . . . . . . . . . . . . . . . . 6
Monster Exhaust System Installation
• Foot-pound torque wrench
• Penetrating oil or light lubricant
spray
• Reciprocating saw
• Inch-pound torque wrench
Section 2 . . . . . . . . . . . . . . . . . . . . . 13
Techni-Cooler Assembly Installation
Section 3 . . . . . . . . . . . . . . . . . . . . . 19
Thermocouple Installation
Section 4 . . . . . . . . . . . . . . . . . . . . . 20
Banks Ram-Air Filter Installation
Section 5 . . . . . . . . . . . . . . . . . . . . . 21
Banks EconoMind Diesel Tuner
Installation
Section 6 . . . . . . . . . . . . . . . . . . . . . 25
Mounting and Connecting the Banks iQ
Section 7 . . . . . . . . . . . . . . . . . . . . 27
Power Selector Switch Installation
Section 8 . . . . . . . . . . . . . . . . . . . . . 29
Optional Gauge Cluster Installation
Section 9 . . . . . . . . . . . . . . . . . . . . . 30
Transmission Learnng
Section 10 . . . . . . . . . . . . . . . . . . . . 30
Troubleshooting, EconoMind
Section 11 . . . . . . . . . . . . . . . . . . . . 33
Clearing Learned Information
Section 12 . . . . . . . . . . . . . . . . . . . . 33
Removal of the EconoMind Diesel Tuner
Section 13 . . . . . . . . . . . . . . . . . . . . 34
Filter Maintance
Section 14 . . . . . . . . . . . . . . . . . . . . 34
Placement of the Banks Power Decals
4
96820 v.4.0
General Installation Practices
5. Route and tie wires and hoses
Dear Customer, If you have
any questions concerning
the installation of your Banks
EconoMind Diesel Tuner, please
call our Technical Service
Hotline at (888) 839-2700
between 7:00 am and 5:00 pm
(PT). If you have any questions
relating to shipping or billing,
please contact our Customer
Service Department at (888)
839-5600.
Thank you.
1. For ease of installation of your
Banks system, familiarize yourself
with the procedure by reading the
entire manual before starting work.
This manual contains 40 pages of
copy, illustrations and parts listing.
If any pages are missing from this
manual please call Gale Banks
Engineering immediately for a
replacement.
2. The exploded illustrations provide
only general guidance, Refer to each
and section diagram in this manual
for proper instructions.
3. Throughout this manual, the
left side of the vehicle refers to the
driver’s side, and the right side refers
to the passenger’s side of the vehicle.
4. Disconnect the ground cable from
the battery before beginning work. If
there are two batteries, disconnect
both.
a minimum of 6 inches away from
exhaust heat, moving parts and sharp
edges. Clearance of 8 inches or more
is recommended where possible.
6. During installation, keep the
work area clean. If foreign debris
is transferred to any Banks system
component, clean it thoroughly
before installing.
7. When raising the vehicle, support
it on properly weight-rated safety
stands, ramps or a commercial hoist.
Follow the manufacturer’s safety
precautions. Take care to balance
the vehicle to prevent it from slipping
or falling. When using ramps, be
sure the front wheels are centered
squarely on the topsides; put the
transmission in park; set the parking
brake; and place blocks behind the
rear wheels.
Caution! Do not use floor jacks to
support the vehicle while working
under it. Do not raise the vehicle
onto concrete blocks, masonry
or any other item not intended
specifically for this use.
8. The Banks iQ displays a GREEN
indicator light when the battery is
fully charged. If an ORANGE light
is displayed the Banks iQ can be
charged with the supplied AC outlet
wall charger. Locate the supplied
AC-outlet wall charger, also located
in your kit and plug the charging cord
into the Banks iQ. Please refer to the
Banks iQ DashBoard PC, Owner’s
Manual for additional instructions.
Notification
The Banks Ram-Air Filter comes
pre-oiled and no oiling is
necessary for initial installation.
Service the filter as specified in
the Filter Maintenance Section of
this manual.
Warning: Below 32oF (0oC) or
above 140oF (60oC), the Banks iQ
may be susceptible to damage
as a result of extended direct
exposure to sunlight, heat
or extreme cold. It is highly
recommended that Banks iQ
be removed from its mounting
location if the vehicle will be
subjected to high concentrations
of sunlight, heat or cold for
an extended period of time.
Gale Banks Engineering is not
responsible for damage to Banks
iQ resulting from exposure
conditions.
9. Dual exhaust system only. The
Dual Exhaust System is designed to
accommodate the factory sized spare
tire. If the spare tire is oversized, it
may need to be removed.
10. Dual exhaust system only. The
tip is located for single rear wheel
applications. Installation on dually
systems is not recommended.
96820 v.4.0
5
Section 1
Monster Exhaust System Installation
Figure 1a
General Assembly
Banks Monster Exhaust (2003-05)
Item DescriptionYear
P/N
1
Monster Turbine Outlet Pipe
Front Intermediate Pipe
Qty
03-0453270 1
Item DescriptionYear
Qty
Tip, Tailpipe 5” Dual Wall
03-0552383 1
9
4”, V-Band Clamp
03-0492887 1
2Cat Conv Systems
03-04
53271
1
10
Gasket, Turbine Outlet
03-0493210 1
3
Non-Cat. Conv. Systems
03-04
53272
1
11
03-0493005 1
4
Rear Intermediate Pipe 03-0453273 1
12
Gasket, Exhaust Flange, (4-bolt)
3-1⁄2” Exhaust Clamp
5
Extension Pipe
13
4” Exhaust Clamp
03-04 524702**
Crew Cab Long Bed
03-04
53276
1
14
Front Muffler Hanger Clamp
03-0553284 1
Crew Cab Long Bed
04-05
53278
1
15
03-0553286 1
6
Banks Monster Muffler
16
Rear Muffler Hanger Clamp
7⁄16 SAE Washers
Muffler
03-04 53801 1
17
03-0491619 4
Muffler
04-05
18
7⁄16-20, Nut, Crimplock
7⁄16-20x1.50 Hex Bolt, Zinc
7
Tailpipe
53283
1
03-04524681*
03-0491601 8
03-0491629 4
03-0553275 1
* 03-04 Cat Models Only
**03-05 CCLB Models receive three 4”-clamps
13
5
13
13
3
16 17
9
10
1
18 16
11
6
P/N
8
96820 v.4.0
2
12
4
8
7
13
15
14
6
96820 v.4.0
7
Figure 1a
General Assembly
Banks Split Dual Monster Exhaust (2003-05)
Item DescriptionYear
P/N
1
Monster Turbine Outlet Pipe
03-04 53270
Front Intermediate Pipe
Qty
1
2Cat Conv Systems 03-04
53271
1
3
Non-Cat. Conv. Systems
03-04
53272
1
4
Rear Intermediate Pipe
Standard Cab Long Bed / Crew Cab Short Bed 03-04 53292
1
Crew Cab Long Bed
1
5
Extension Pipe 03-04
53293
1
Qty
T.O.P Gasket
03-0493210 1
12
Turbine Outlet Gasket (4-Bolt)
03-0493005 1
13
3-1⁄2” Exhaust Clamp
03-05 524682**
14
4” Exhaust Clamp
03-05524702*
15
Front Hanger Clamp
03-0553284 1
16
Rear Hanger Clamp
03-0553286 1
17
Frame Hanger Bracket
03-0553290 1
18
2”x 2” Hanger Plate
03-0553291 1
Rubber Insulator
03-0553732 1
7⁄16-20 x 4” Hex Bolt
03-0591635 1
Crew Cab Long Bed
04-05
6
Monster Muffler
03-0553285 1
19
03-0553287 1
20
21
Tail Pipe
7⁄16” SAE Washers
03-04 9160110***
8
Left Driver Side 03-05
53288
1
22
7⁄16-20 Crimp lock Nuts
03-04 916195****
9
Right Passanger Side
03-05
53289
1
23
7⁄16-20 x 1.25” Hex Bolt
03-0491629 4
24
Black 5” Cable Ties
03-0562001 3
10
V-Band Clamp
03-0492887 1
*04-05 SCLB use one 4”-Clamp
**03-04 Cat Conv. Models use three 3.5”-Clamp
***04-05 use two (2) washers
****04-05 use one (1) Crimp lock nut
14
5
14
14
3
21 22
10
11
1
21 22
23 21
12
8
P/N
11
7Y-Pipe
53278
Item DescriptionYear
96820 v.4.0
2
13
4
20
9
21
17
18
22
19
8
16
13
7
13
15
6
24
96820 v.4.0
9
1. Disconnect the battery ground
cables from each of the batteries.
Secure the cables so that they do
not come in contact with the battery
posts during the installation.
2. Raise the vehicle and support it
with properly weight rated safety
stands, ramps or a commercial hoist.
Follow the manufacturer’s safety
precautions. Take care to balance
the vehicle to prevent it from slipping
or falling. When using ramps, be
sure the front wheels are centered
squarely on the topsides; place the
transmission in park; set the parking
brake and place blocks behind the
rear wheels.
CAUTION: DO NOT WORK UNDER
ANY VEHICLE SUPPORTED ONLY
BY A JACK. SEVERE INJURY MAY
RESULT.
WARNING! The following step
requires the use of a torch and/or
saw. Proper safety equipment
should be used. Failure to use
proper safety equipment may
result in severe injury.
3. From under the vehicle remove
the factory exhaust system. Starting
at the rear of the vehicle, remove tail
pipe, muffler and any extension pipes
attached to the outlet of the catalytic
converter, by either cutting through
the pipe near the clamps or by
removing the clamps and heating the
joints with an oxy-acetylene torch to
allow crimped pipes to separate.DO
NOT CUT OR DAMAGE CATALYTIC
CONVERTER TUBING DURING THE
REMOVAL PROCESS. Remove the
hanger pins from the rubber hangers
with a pry bar. (Spray lubricant will
ease hanger removal.)
Steps 4 thru 10 for 2003-2004
Step 11 for 2005
4. Remove the clamp attaching
the turbine outlet pipe (T.O.P) to
the catalytic converter headpipe
(or intermediate pipe if applicable)
and remove the catalytic converter
assembly or intermediate pipe.
5. Remove the V-band clamp that
attaches the turbine outlet elbow to
the turbine housing and remove the
turbine outlet pipe and elbow from
the vehicle.
6. Attach the supplied T.O.P. gasket
to the Banks T.O.P. Loosely place
the supplied V-band clamp on the
Banks T.O.P. Install the Banks T.O.P.
to the turbine housing (NOTE: the
10
96820 v.4.0
factory turbine outlet elbow will not
be used). Loosely snug the V-band
clamp assuring the gasket and T.O.P
are aligned properly.
7. For vehicles that are NOT
equipped with a catalytic
converter, install the supplied Banks
front intermediate pipe and supplied
gasket onto the previously installed
Banks T.O.P. Place a small amount
of anti-seize onto the four (4) 7⁄ 16”
bolts. Loosely install the supplied
7⁄ 16” hardware onto the T.O.P. and
intermediate pipe flange (see Figure
1). Proceed to Step 10.
8. For vehicles equipped with
catalytic converters: With the
catalytic converter removed from the
vehicle and the headpipe removed
from the converter, measure 13”
inward from the outlet tubing rim
(3-1⁄ 2” of tubing from the outlet weld
should remain). Using a reciprocating
saw or equivalent, vertically cut and
remove 13” from the converter outlet
tubing (see Figure 2).
9. Install the supplied 3-1⁄ 2” clamp
onto the catalytic converter inlet.
Place the catalytic converter onto
the previously installed intermediate
pipe. Loosely snug the clamp on the
catalytic converter inlet.
IMPORTANT: If the vehicle
is equipped with a catalytic
converter, it should be inspected.
Diesel catalysts may become
plugged with soot and can
cause a restriction to exhaust
flow, impeding performance.
Shine a powerful flashlight into
the inlet end of the converter.
Observe the light through the
other end of the converter. The
full circle of the flashlight should
be visible without any blockage
in the gridwork of the catalyst.
If excessive soot is observed,
Figure 2
the catalyst may need to be
cleaned. TAKE PRECAUTIONS
to avoid blowing soot toward
the work area or where it
could be inhaled. ALWAYS
use breathing protection. Also
inspect the catalyst for damage
(i.e. chips, bent corners, etc.) to
the gridwork. If your catalytic
converter is damaged, it may
be covered under your vehicle’s
emissions warranty.
10. Place a supplied 4” clamp
onto the front of the supplied
rear intermediate pipe. Install the
intermediate pipe onto the catalytic
converter outlet or the front
intermediate pipe. Lightly snug the
exhaust clamp near the rim of the
intermediate pipe.
11. For 2005 NOTE: The catalytic
converter will not be removed
from the vehicle. Remove attached
intermediate pipe and corresponding
clamp(s). Take care not to damage
the catalytic converter outlet end.
Step 12 thru 20 for Single Tip
Step 21 thru 33 for Split Dual
12. 2003-2004 For quad cab long
bed (160.5” wheelbase) models only:
Place a supplied 4” clamp onto the
front of the supplied extension pipe.
Install the extension pipe hanger
pin into the corresponding rubber
hanger. Connect the extension pipe
onto the intermediate pipe and
loosely snug the 4” clamp.
13. For Crew Cab Long Bed (160.5”
wheelbase) ONLY, install a 4”
exhaust clamp onto the front of
the Banks intermediate pipe. Install
the intermediate pipe onto the
catalytic converter outlet. Install the
intermediate pipe hanger onto the
corresponding rubber hanger. Loosely
snug the 4” clamp.
14. Install the front hanger clamp
onto the Monster Muffler inlet.
Install the muffler inlet onto the
intermediate pipe or catalytic
converter if equipped. With the
hanger facing the rear of the vehicle,
insert the front hanger into the
vehicle’s rubber grommet.
15. Install the rear hanger clamp
onto the Monster Muffler outlet with
the hanger pins facing forward. Install
the two (2) rear hanger pins into the
vehicle’s rubber grommets. Orient
the Banks Monster logo to be level
with the frame rail. Install a 4” clamp
onto the muffler outlet.
16. Route the tailpipe over the rear
axle housing and into the muffler
outlet. Install the tailpipe hanger
pin into the corresponding rubber
hanger.
17. Install the 5” Monster tailpipe tip
on the exhaust. Keep the wrapping
on until installation is complete. The
tip should be rotated so the clamp
nut is pointing down. For a fleet-side
truck the 5” tip should be hung 1”
past the end of the tailpipe. For a
dually, the tip should be 3-1⁄ 2” past
the end of the tailpipe or where
aesthetically pleasing.
18. With everything positioned
properly, begin to tighten the clamps
starting with the ones closest to the
turbo and working your way back.
Torque the V-band clamp to 80 in-lbs
(not ft-lbs). Evenly torque the exhaust
clamps to 35 ft-lbs. Torque the 7⁄ 16”
hardware to 48 ft-lbs. Make sure that
each slip is fully inserted (+/- 1⁄ 4 inch)
and that all mount hangers are in the
forward position (see Figure 3).
NOTE: Whenever possible, tack
weld slip connections to prevent
disengagement is recommended.
19. Remove the protective covering
from the tailpipe tip.
Caution: the protective covering
may ignite and burn if not
removed prior to running the
engine.
Figure 3
20. Monster Exhaust Single tip
installation complete, proceed to
Section 2.
Step 21 thru 33 for Split Dual
21. Install the front hanger clamp
onto the Monster Muffler inlet. Install
a 4” clamp onto the muffler inlet.
Install the muffler inlet onto the
intermediate pipe. Insert the front
hanger into the vehicle’s rubber
grommet.
22. Install the rear hanger clamp
onto the Monster Muffler outlet with
the hanger pins facing forward. Install
the two (2) rear hanger pins into the
vehicle’s rubber grommets. Orient
the Banks Monster logo to be level
with the frame rail.
23. Install the Banks Y-pipe into the
Figure 4
muffler outlet such that the outlets
are pointing up. Install a 3-1⁄ 2” saddle
clamps onto each y-pipe outlet (see
Figure 4).
Y-PIPE
PASSENGER
SIDE
TAILPIPE
24. Install the Banks hanger bracket
DRIVER SIDE
TAILPIPE
3.5”
CLAMP
REAR
ORIENTATION OF
HANGER CLAMP MONSTER MUFFLER
4“
FRONT CLAMP
HANGER
INTERM
CLAMP
PIPE
onto the rear of the driver-side frame
rail. Behind the rear shock cross
member, place the hanger bracket
over the frame rail on the inside.
Align the 1⁄ 2” hole in the center of
the frame with the hanger bracket.
Install the 7⁄ 16”x 4” bolt & washer
through the bracket and frame rail.
Secure the bolt on the outside frame
rail using the 2”x2” plate, washer
and 7⁄ 16” nut. Be sure the hanger
pin is parallel with the frame rail and
torque 7⁄ 16” hardware to 48 ft-lb (see
Figure 5).
FORWARD
96820 v.4.0
11
25. Install the supplied rubber
hanger onto the Banks hanger
bracket.
Figure 5
DRIVER SIDE
FRAME
26. Install the driver-side tailpipe
HANGER
BRACKET
into the top Y-pipe outlet. Install the
driver-side tailpipe hanger into the
vehicle rubber hanger.
27. Install the passenger-side
tailpipe into the lower Y-pipe outlet.
Install the passenger-side tailpipe
hanger into the vehicle rubber
hanger.
28. Move the spare-tire to the rear
7/16” BOLT
& WASHER
7/16”
NUT &
WASHER
of the vehicle and center between
the dual tailpipes. Tighten the spare
tire with the manufacture tire tool
so that it is retained or in place (See
Figure 6).
2“ X 2”
PLATE
29. Un-clip the axle vent hose outlet
attached to the bed near the spare
tire. Re-route the vent hose on top of
the fuel tank and attach to the bed
away from the driver side tailpipe.
Zip tie the vent hose and brake line
to the emergency brake cable, away
from the tailpipe.
30. Adjust each of the pipes to
ensure that all of the hanger pins
are parallel with the frame-mounted
pins and fully inserted in the vehicle’s
rubber grommets.
31. Be sure that the two (2)
tailpipes are completely engaged
into the Y-pipe. Rotate the tailpipe
until the hanger pins are parallel
with the frame-mounted pin. NOTE:
Recommended distance between
exhaust tip and body is a half (1⁄ 2”)
inch.
32. Beginning with clamps closest to
the catalytic converter, and working
your way back. Align the saddle
clamps at the beginning of the slots
(on the 1⁄ 2” circle punch) and evenly
torque the 2-studs on the clamp.
NOTE: Whenever possible, tack
weld slip connections to prevent
disengagement is recommended.
33. Remove the protective covering
from the tailpipe tip. Caution: the
protective covering may ignite
and burn if not removed prior to
running the engine.
-end, section 1-
12
96820 v.4.0
SPARE
TIRE
DRIVER SIDE
TAILPIPE
Figure 6
ADJUST SO THAT
SPARE TIRE TO
TAILPIPE CLEARANCE
IS THE SAME
MOVE SPARE
TIRE TOWARDS
REAR OF
VEHICLE
BANKS
DRIVER SIDE
TAILPIPE
ZIP TIE ON
VENT HOSE
& BRAKE LINE
BANKS
PASSENGER SIDE
TAILPIPE
Section 2
Techni-Cooler Assembly Installation
Figure 7
Banks Techni-Cooler
General Assembly
P/N
Qty
1
Item Description
Techni-Cooler Assembly
25538 1
12
Hose Clamp 3.5” Spring Loaded 92897 6
2
Boost Tube Left
41330 1
13
Ground Strap Intake Heater
62182 1
3
Boost Tube Right
41331 1
14
Bracket Mntig Techni-Clr
25540 2
4
Hose 3.5” X 3.25” Black
94215 1
15
91812 1
5
Hose Comp Out 2.75 X 3.25
94277 1
16
Hex Bolt, M8-1.25x16, Zinc
Hex Bolt, S/S 5⁄16”-18 X 1⁄2
91223 4
6
Hump Hose 3.5” X 3.25” Black
94293 2
17
1
High-Ram Intake Manifold
42743 1
18
Nut, Hex, M6 X 1.0, Zinc
Nut, Nyloc 5⁄16”-24
91770 7
91211 4
8
2
19
2
2
20
Washers, Flat, Zinc, 6MM
Washer, AN, S/S 5⁄16”
91700 9
Gasket Air Inlet Manifold
93023 Stud, High-Ram Air Intake 5⁄16”-24 X 8MM 1.25 X 7.3091532 91201 9
10
Stud, High-Ram Air Intake 5⁄16”-24 X 8MM 1.25 X 7.8691533 2
Washer, Thread Sealing 5⁄16”
91209 2
11
Hose Clamp 2.75” Spring Loaded
2
92893 Item Description
21
P/N
Qty
18
21
20
7
20
12
8
4
9
10
15
20
11
17
12
19
2
13
20
6
5
12
16
20
16
3
14
14
6
20
16
1
20
96820 v.4.0
13
NOTE: For installation of the Banks
Stinger System proceed to Section 3.
1. Disconnect the Inlet Air
Temperature/ Pressure Sensor
connector located on the air box
cover. The connector is shown in
Figure 8.
2. Remove the nut that fastens the
air filter housing to the radiator cross
brace.
3. Loosen the hose clamp that
secures the air inlet duct to the
turbocharger inlet. Disconnect the
inlet duct from the turbocharger.
4. Remove the air box and inlet
duct as an assembly. The air box is
held in place with re-usable pushin fasteners and can be pulled out
vertically.
14. Remove the 4 hex head bolts
that attach the A/C condenser
mounting brackets to the CAC.
15. Swing the A/C condenser
upward as shown in Figure 10, then
out away from the vehicle as shown
in Figure 11.
Caution: Minimize the amount of
stress to the A/C condenser fluid
lines to prevent damage.
An assistant could be helpful to hold
the A/C condenser while the stock
CAC is being removed and the Banks
Techni-Cooler is being installed.
16. Remove the stock CAC from the
vehicle.
boost tube. The boost tubes are the
charge air ducting that route air from
the turbocharger to the Charge Air
Cooler (CAC) and from the CAC to
the intake manifold.
6. Cover the turbocharger inlet and
outlet with a clean rag to prevent
foreign debris from entering these
locations.
7. Remove the bolt the holds the
engine oil dipstick to the intake. Save
the bolt for re-use.
8. Remove the electric heater wire
9. Unbolt and remove the 4 bolts
at the base of the stock intake.
Remove the stock intake from the
vehicle. Cover the intake manifold
opening with a clean rag to prevent
any foreign debris from entering the
engine through the heater block.
10. Remove the driver side boost
tube.
11. Remove the two upper radiator
attachment bolts.
12. Remove the two upper CAC
attachment bolts.
13. Remove the 4 bolts (2 per
side) that retain the upper radiator
cross brace, then remove the upper
radiator cross brace. The brace is
shown in Figure 9.
14
96820 v.4.0
rubber bushings from the stock CAC
and install them on the Banks TechniCooler.
18. Remove the upper rubber
isolators from the stock CAC and
install them on the Banks TechniCooler.
19. Install the Banks Techni-Cooler
in the vehicle.
20. Remove the torx head screws
that fasten the lower two mounting
brackets to the A/C condenser.
Discard the stock lower mounting
brackets, but retain the torx head
bolts for re-use.
Figure 8. Location of the Inlet Air Temp/ Pressure Sensor
5. Remove the passenger side
harness from the stock intake by
pulling the plastic pin out. Remove
the wire harness brackets that are
mounted on the intake by removing
the nut and washer.
17. Remove the lower saddle mount
Figure 9. Upper radiator cross brace
21. Relocate the upper driver
side condenser mounting bracket
as shown in Figure 12. Place the
A/C condenser back in front of the
Techni-Cooler. Install the 5⁄ 16” bolts
and washers supplied with the Banks
Techni-Cooler system to fasten the
top two A/C condenser mounts to
the Techni-Cooler. Keep the bolts
loose to aid in the alignment of the
lower two mounting brackets. Install
the lower two A/C mounting brackets
supplied with the Banks system.
Use the torx head screws that were
previously removed from the vehicle
to fasten the brackets to the A/C
condenser. Use the 5⁄ 16” bolts and
washers supplied with the Banks
system to fasten the A/C condenser
mounts to the Techni-Cooler.
22. Tighten the 5⁄ 16” bolts at each
of the A/C mounting brackets and
torque to 19 ft-lbs.
23. Tighten the torx head bolts on
brace. Leave the bolts loose to aid in
the alignment of the cross brace with
the radiator and Techni-Cooler.
25. Loosely install the upper CAC
mounting bolts.
26. Loosely install the upper radiator
mounting bolts.
27. Tighten the radiator cross brace
bolts and torque to 21 ft-lbs
both of the lower and the upper A/C
mounting brackets.
28. Tighten the upper CAC mounting
24. Install the upper radiator cross
29. Tighten the upper radiator
Figure 10. A/C condenser removal procedure
bolts and torque to 8 ft-lbs (96 in-lbs).
mounting bolts and torque to 8 ft-lbs
(96 in-lbs).
30. Install the passenger side boost
tube. The passenger side uses a 2.75
inch diameter straight hose at the
turbocharger connection, and a 3.5
inch diameter hump hose at the CAC
connection. The orientation of the
hose clamps should be as shown in
Figure 13 to avoid clearance issues.
Do not install the straight hose onto
the turbocharger, and keep the hose
clamps at the CAC connection loose
until the thermocouple is installed in
Section 3. Cover the opening of the
boost tube to prevent foreign objects
from entering the boost tube during
the installation.
Figure 11. A/C condenser removal procedure
NOTE: Before slipping any boost
tubes and the corresponding
hoses, into position, ensure that all
connection ends are clean and free
of any oil residue and contaminates.
Clean compressor outlet and all
connection points with a non-oil
based solvent such as Acetone,
Mineral Spirits, Denatured Alcohol or
Lacquer Thinner. Read and follow the
manufactures operation instruction
for non-oil based solvent cleaner.
96820 v.4.0
15
31. Install the driver side boost
Figure 12. Relocation of the upper driver side A/C condenser mounting bracket
tube. The driver side tube uses a
3.5 inch diameter straight hose at
the intake manifold and a 3.5 inch
diameter hump hose at the CAC.
The orientation of the hose clamps
should be as shown in Figure 14
to avoid clearance issues. Keep the
hose clamps loose until the High Ram
is installed. Cover the opening of the
boost tube to prevent foreign objects
from entering the boost tube during
the installation.
32. Remove the three wires on the
electric heater block at the intake
manifold, then remove the heater
block. Save the fasteners for re-use.
Caution: Cover the opening in the
intake manifold with a clean rag
to prevent foreign objects from
entering the engine.
33. Completely remove the stock
gaskets from both sides of the heater
block and intake manifold. Take care
not to scratch or gouge any of these
surfaces when removing the gasket
material.
34. Remove the rag that was used
to cover the intake. Reinstall the
electric heater block onto the intake
manifold with one of the supplied
gaskets. Reattach the three electrical
connections to the heater element.
35. Caution: The High Ram studs
have different threads on each
end. Make sure the M8 ends go
into the engine intake manifold.
The shorter studs are placed inboard
closest to the valve cover. Apply the
supplied thread locking compound
to the M8 threaded end of the studs.
Hand tighten the studs to the intake
manifold.
16
96820 v.4.0
Figure 13. Orientation of the passenger side hose clamps to avoid clearance issues.
Figure 14. Orientation of the hose clamps on the driver side.
36. Using the two 5⁄ 16”-24 nuts
supplied, tighten the studs into
the intake by threading both nuts
onto the stud, then tighten the nuts
against each other with two 1⁄ 2” open
end wrenches. Tighten and torque
the stud to 2 ft-lbs by turning the top
nut. Remove the nuts from the stud
by using two open-end wrenches to
loosen the nuts in relation to each
other. Repeat the process for each
stud. The process
is shown in Figure 15.
37. If your vehicle is NOT equipped
with a factory ground strap on the
intake heater, install the supplied
ground strap from the intake heater
to the engine. Put a 6-mm washer
onto the bottom intake heater
stud, leaving the factory heater nut
installed. Next, install the smaller
diameter ground strap terminal over
the stud and retain with a 6-mm
washer and nut. Route the other end
of the ground strap to the threaded
section on the engine and retain with
a SAE washer and M8- 1.25x 16 bolt.
See Figure 15
Figure 15. High-Ram stud installation.
38. Slide the supplied intake gasket
/
12
over the four studs, then slide the
High-Ram over the studs.
FACTORY NUTS
GROUND STRAP
LARGER
DIAMETER
TERMINAL
INTAKE HEATER
M6 NUT & M6
WASHERS (2)
M8 X 1.25 BOLT
SAE WASHER
96820 v.4.0
17
39. Install the supplied Stat-O-Seal
washers on the two driver side
(longer) studs. Driver side studs are
longer than passenger side studs.
The washers should be installed in
a twisting motion to prevent tearing
their sealing element. Install the
supplied 5⁄ 16” flat washer on all
studs, then fasten with the supplied
5⁄ 16-24 nylock nuts. The nuts should
be tightened to 12 ft-lbs (144 in-lbs).
An exploded view of the High-Ram
assembly is shown in Figure 16.
40. Gently bend the engine oil
dipstick tube to it’s mounting location
on the High Ram as shown in Figure
16. Secure the dipstick tube with
the factory bolt that was previously
removed.
41. Remove rag that was used to
cover the boost tube opening. Make
the connection between the driver
side boost tube and the High-Ram.
Tighten all the driver side hose
clamps to 5 ft-lbs (60 in-lbs).
-end, section 2-
18
96820 v.4.0
Figure 16. Exploded view of the High-Ram assembly
Section 3
Thermocouple Installation
1. 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).
2. If not already done, remove the
factory air intake system as described
in Section 2 Steps 1-4.
3. Loosen the upper hose clamp on
the turbocharger oil drain-tube hose
that is located between the two
sections of the oil drain tube.
4. Disconnect the oil supply hose
at the turbocharger. Disconnect the
compressor outlet hose that goes to
the intercooler.
5. Disconnect the turbine outlet pipe
by loosening the V-band. Save V-band
for re-installation.
6. Remove the turbocharger
mounting nuts/bolts and the
turbocharger from the exhaust
manifold. Clean and inspect the
Figure 17
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.
depth as you tap by periodically
removing the tap and screwing the
pipe coupling into the tapped hole.
The coupling 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 pipe coupling into
the manifold using anti-seize on the
threads.
7. 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.
CAUTION: Remove all the rags that
are inside the compressor outlet
and inlet hoses and the exhaust
manifold before re-installing the
turbocharger.
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.
13. Install the new turbine inlet
9. Use a 7⁄ 16” drill, keeping the drill
perpendicular to the manifold surface
and drill through the exhaust manifold
into the rear passage as shown in
Figure 17.
10. Tap the drilled hole with a
NPT pipe tap. Check the thread
1⁄ 4”
gasket provided and apply a dab
of anti-seize compound to the
four turbo mounting studs. Install
the turbocharger on the exhaust
manifold. As the turbocharger is
reinstalled, slip the oil drain tube
into the drain hose. Tighten the
turbocharger mounting nuts to 24
ft-lbs. Tighten the oil drain hose
clamp.
14. Reconnect and tighten the turbo
oil supply hose.
15. Reconnect the turbine outlet
pipe to the turbocharger and secure it
with the V-band.
16. Re-install the air box and inlet
tube assembly. Secure the air box
at the radiator cross brace with
the factory nut that was previously
removed. Re-connect the Air Inlet
Temperature/ Pressure sensor at the
air box cover. Re-connect the air inlet
duct to the turbocharger inlet. Tighten
the hose clamp at the turbocharger
inlet to 8 ft-lbs (96 in-lbs).
17. Re-connect the compressor
outlet hose that goes to the
intercooler and tighten all hose
clamps to 5 ft-lbs.
-END, SECTION 3-
96820 v.4.0
19
Section 4
Banks Ram-Air Filter Installation
Notification
The Banks Ram-Air Filter comes
pre-oiled and no oiling is
necessary for initial installation.
Service the filter as specified in
the Filter Maintenance Section of
this manual.
1. Locate the engine air filter box on
the passenger’s side of the vehicle.
Remove the cover by releasing
the four (4) clips on the side of the
housing and slide the cover toward
the engine.
2. Remove the old air filter element
from the filter housing and replace
it with the Banks Ram-Air filter
element. Place the Banks filter
element in the right orientation
and check the filter seal is seating
properly around the housing to
ensure no leakage.
Figure 18 EconoMind and supplied wiring harnesses
20
96820 v.4.0
3. Slide the tabs on the cover into
the slots on the air filter box. Press
the cover down gently and re-attach
the four (4) clips on the side to
securely clamp the cover.
-end, section 4-
Section 5
Banks EconoMind Diesel Tuner Installation
Figure 19
1. Place the EconoMind Diesel
Tuner box on top of the fuse box
located in the left front side in the
engine compartment. See Figure
19. The in-cab cable with the three
small connectors will be routed into
the cabin via the grommet on the
firewall. The other two harnesses
will be routed under the intake to
their respective locations listed in the
following steps.
2. Locate the rubber grommet on the
Figure 20
drivers side firewall. Using a utility
knife, make a 1.5-inch-long slit in the
grommet next to the wire harness.
Be careful not to cut or damage
the harness. See Figure 20 for the
proper location of the required cut.
Insert a screwdriver from the engine
compartment into the cut hole and
gently thrust it through the grommet.
3. Inside the vehicle, remove the
lower dash panel beneath the
steering column by removing the two
(2) screws at the bottom of the panel.
Retain the screws for re-installation.
NOTE: There are also two (2) clips
located at the top corners of the
panel, which hold the panel in place.
These clips can be released by gently
pulling on the corners of the panel.
Use caution to avoid damaging the
panel during removal.
4. Remove the electrical connector
bracket on the left hand side of the
support below the steering column in
front of the firewall by removing the
two (2) bolts. This will allow access
to the inner grommet. See Figure 21.
5. Cut the grommet on the firewall
Figure 21
inside the vehicle along the hole
created by the screwdriver in Step 2.
6. Locate the in-cab cable with the
three connectors. From the engine
compartment, push the in-cab cable
through the hole cut in the firewall
grommet. NOTE: Taping the end of
the cable to a piece of stiff wire (i.e.
coat hanger) may make routing the
cable through the firewall a simpler
task. The stiff wire should be pushed
through the slit in the grommet and
then the wires can be attached to
the stiff wire and pulled through the
hole in the grommet.
CAUTION: Pull gently to avoid
damage to the cable connectors.
Always pull on the cable sheath
rather than the wires themselves.
96820 v.4.0
21
7. From inside the vehicle, continue
Figure 22
to pull the in-cab cable through the
firewall until it is approximately 22”
inside the cab. Secure the cable
to the lower access panel area.
Take precaution to leave the three
connectors accessible for usage
further in the installation process.
8. Locate the Banks OBDII Interface
Cable and 11” cable tie in your kit.
Connect the OBDII Interface Cable to
the vehicle OBDII connector. Use the
11” cable tie as shown in Figure 22
to secure the Banks interface cable
to the vehicle OBDII connector. Now,
connect the 8-pin connector from the
Banks OBDII Interface Cable to the
8-pin connector on the EconoMind
Tuner in-cab cable. NOTE: If you are
not installing the optional Banks IQ
then coil up and secure the cable
with the RJ12 (telephone style)
connector end.
Figure 23
9. In the engine compartment find
the Fuel Rail Pressure (FRP) sensor
on the fuel rail. It is located on the
drivers side of the engine. Unplug
the factory connector and plug it
into the corresponding male FRP
sensor connector on the EconoMind
harness. Plug the EconoMind’s
female FRP sensor connector into the
sensor. See Figure 23.
10. Locate the Manifold Pressure
(MAP) sensor on top of the intake
manifold. Unplug the factory
connector and plug it into the
corresponding male MAP sensor
connector on the EconoMind
harness. Plug the EconoMind’s
female MAP sensor connector into
the sensor. See Figure 23.
CAUTION: The Camshaft Position
(CMP) sensor and the Crankshaft
Position (CKP) sensor have the
same type of connectors and
they are in close proximity to
one another. Make sure the
right connectors are used when
installing these connections.
Refer to Figure 24. for their
locations on the EconoMind
Diesel Tuner wire harness.
22
96820 v.4.0
Figure 24
Figure 25
11. Locate the Crankshaft Position
(CKP) sensor on the lower front left
side of the engine. It is behind the
engine crankshaft pulley (engine
harmonic balancer). Unplug the
factory connector and plug it into
the corresponding male CKP sensor
connector on the EconoMind
harness. Plug the EconoMind’s
female CKP sensor connector into
the sensor. Take care to route the
wire harness away from the power
steering pump pulley and secure
it with the supplied cable ties. See
Figure 25.
12. Locate the Camshaft Position
Figure 26
(CMP) sensor below the fuel
injection pump between the timing
gear cover and the ECM. Unplug
the factory connector and plug it
into the corresponding male CMP
sensor connector on the EconoMind
harness. Plug the EconoMind’s
female CMP sensor connector into
the sensor. See Figure 26.
13. Attach the supplied
thermocouple lead wire extension to
the previously installed thermocouple
with the supplied nuts and bolts. The
YELLOW extension wire attaches to
the YELLOW thermocouple wire, and
the RED extension wire attaches to
the RED thermocouple wire.
14. Route the thermocouple lead
wire extension along the factory
harness to the driver’s side and
connect it to the EconoMind harness.
Cover both joints with the supplied
heat shrink tubing and heat until the
tubing conforms to the joint. Make
sure the entire joint is insulated.
15. Remove the fuse box cover,
Figure 27
located in left front side of the engine
compartment. Locate the mini-fuse
#50 and remove it. Install the miniauto blade tap onto the removed
mini fuse as shown in Figure 27.
Re-install the mini fuse with the
attached blade tap into location
#50 as shown in Figure 28. NOTE:
Install the mini-auto blade tap on the
terminal leg closest to the firewall.
This is the “hot” side of the circuit.
Caution: It is very important that
you select the proper fuse. The
Banks EconoMind Diesel Tuner
will not function properly if
installed incorrectly.
96820 v.4.0
23
16. It is recommended to cut a small
Figure 28
notch in the fuse box cover as shown
in Figure 29, to avoid a crimped or
stressed wire. Locate the RED/WHT
wire with the Power Terminal on the
EconoMind tuner wire harness and
connect it to the mini-fuse blade
tap. Replace the fuse cover and
make sure not to pinch the RED/WHT
power wire.
NOTE: Go over the entire installation
as a precautionary check to ensure
that all clamps are tight, wiring
and hoses are properly routed, and
connections are correct and tight.
Make sure that the EconoMind wire
harness is not lying in the way of the
brake and gas pedals, or any moving
parts.
17. (Engine Compartment) After
confirming all of the system
connections are correct, make
sure the entire mounting surface is
clean and free of dirt and oil before
mounting the EconoMind Diesel
Tuner. Clean and dry as required
using a cloth dampened with rubbing
alcohol or a similar cleaning solution.
CAUTION: Do not spray fluid
directly onto any electrical
equipment, or equipment damage
may result. Mount the EconoMind
Diesel Tuner on the top of the
fuse box cover as shown in Figure
19, by peeling the protective
backing off the adhesive tape on
the back of the EconoMind Diesel
Tuner.
18 . Hold the EconoMind Tuner
against the fuse box cover for
approximately 1 minute while
applying pressure to allow the
adhesive to properly adhere to the
surface.
-end, section 5-
24
96820 v.4.0
Figure 29
Section 6
Mounting and Connecting the Banks iQ
If not installing the optional Banks
iQ, skip to Section 7.
WARNING: Below 32oF (0oC) or
above 140oF (60oC), the Banks iQ
may be susceptible to damage
as a result of extended exposure
to sunlight, heat or extreme
cold. It is highly recommended
that the Banks iQ be removed
from its mounting location if the
vehicle will be subjected to high
concentrations of sunlight, heat
or cold for an extended period
of time. Gale Banks Engineering
is not responsible for damage to
Banks iQ resulting from exposure
conditions.
Figure 31
CAUTION: Do not use force
when working on plastic parts.
Permanent damage to the part
might result.
1. Locate the Window Mount
Assembly in your kit.
2. Assemble the Banks iQ docking
station to the Universal mount by
inserting and sliding the Universal
mount tab into the docking station
groove. Hand tighten the nut behind
the docking station to hold the
docking station in place.
Attaching Banks iQ to window mount
3. Attach the window mount to your
Banks iQ. See Figure 31. Align and
place the two (2) lower tabs on the
window mount to the corresponding
slots on the bottom of Banks iQ first
then snap the top of Banks iQ into
place.
NOTE: There may be a snug fit when
installing the Banks iQ into the window
mount. Take care not to force this
process.
4. Find a suitable place on the
windshield for ease of access and
viewing of Banks iQ. Use location
shown in Figure 32 as a reference
for mounting Banks iQ in your
vehicle. Loosen the knob and move
the swivel suction plate to achieve
desired viewing angle of the Banks
iQ screen. Do a test fit and note
the angle necessary to achieve the
correct viewing angle.
5. Make sure the suction cup and
the mounting area on the windshield
are clean and dry. With the suction
lever in the up position, ensure
the suction cup is flat against the
windshield, and then push the
suction lever down to secure in
place.
6. Next, remove and set the side
dash access panel aside.
7. Locate the RJ12 Cable (similar
to telephone connector) previously
secured behind the knee panel.
Remove the knee panel to gain
access to the RJ12 cable. See Figure
33.
8. Locate Banks iQ Bridge Module and
connect the RJ12 connector into the
Bridge Module. See Figure 34.
Figure 32
Mounting location for Banks iQ
96820 v.4.0
25
Figure 33 Banks iQ System
9. Route the Banks iQ USB interface
cable from the Banks iQ bridge
module under the dash and out
through the side access panel
opening. The cable can be slid under
the door frame’s seal and run up
to the top of the dash. Pull enough
cable to reach the Banks iQ and
connect it to the USB receptacle on
the left side of Banks iQ. See Figure
32. Snap the side access panel back
in place making sure not to pinch the
wire.
Figure 34 Banks Bridge Module
WARNING: THE CHARGING CABLE
CONNECTED TO THE BANKS
iQ IS DESIGNED TO SUPPLY
A CONSTANT LOW-VOLTAGE
POWER SOURCE (+5VDC) TO
THE BANKS iQ AND IS “LIVE”
AS LONG AS THE SYSTEM’S
OBD II INTERFACE CABLE OR
BANKS WIRING HARNESS IS
COMPLETELY INSTALLED AND
THE USB CABLE CONNECTOR
IS PLUGGED INTO BANKS iQ.
ALTHOUGH THIS CHARGING CABLE
IS SHORT AND ITS CIRCUITRY IS
FUSE-PROTECTED, THE USER IS
EXPECTED TO TAKE APPROPRIATE
MEASURES TO PREVENT SMALL
CHILDREN AND/OR PETS FROM
CONTACT WITH ANY PART OF THIS
SYSTEM.
10. Secure Banks iQ bridge module
under the dash to any dash frame
support using the supplied cable ties.
Use the cable tie support loops on the
side of the bridge module to securely
fasten it under the dash.
11. Route all wiring away from any
pedals or other moving components.
Using the cable ties supplied, secure
the wiring under the dash.
12. Reinstall the lower knee panel
back in place with the factory
hardware. Tuck any excess cable
behind it for a clean appearance.
-END, SECTION 6-
26
96820 v.4.0
Section 7
Power Selector Switch Installation
Not needed if Banks IQ is installed.
CAUTION: Do not use force
when working on plastic parts.
Permanent damage to the part
might result.
1. The Power Level Selector switch
will be installed on the drivers side of
the instrument panel (IP) next to the
steering column. See Figure 35.
2. Remove the headlamp switch
bezel on the drivers side by gently
pulling on it. Disconnect the electrical
connector once the bezel is removed.
Figure 35
3. To remove the center bezel, open
5. Cut out the supplied template (see
4. Remove the cluster bezel by first
6. Using a 3⁄ 8” Uni-bit, center the
the ashtray and cup holder and
remove the retaining screw. Gently
pull on the center bezel to disengage
all the clips that attach the bezel
to the dash. Disconnect the four
(4) electrical connections after the
bezel is removed. Keep the screw for
reinstallation.
removing the two (2) screws at the
top. Gently pull on it and disengage
all the clips that attach the bezel
to the dash. Retain the screws for
reinstallation.
Figure 36) and align the template
onto the front of the cluster bezel
by placing its left edge against the
cluster rib, and its bottom edge
against the cluster bottom edge. Use
masking tape to securely hold down
the template. NOTE: Do not tape over
the markings on the template.
bit onto the 3⁄ 8” drill location on the
template and slowly drill through the
IP. Using a 1⁄ 8” drill bit, center and
drill through the 1⁄ 8” location on the
template. Remove and discard the
template and any plastic shavings.
NOTE: It is important that the hole is
drilled at the recommended location.
The switch may not clear the
instrument panel structure if the hole
is shifted to another location.
7. Align the label onto the previously
drilled hole. Make sure the entire
mounting surface is clean and free of
dirt and oil before mounting the label.
Clean and dry as required using a
cloth dampened with rubbing alcohol
or similar cleaning solution.
CAUTION: Do not spray fluid
directly onto any electrical
equipment, or equipment damage
may result. Mount the EconoMind
Diesel Tuner switch label onto
the cluster bezel by peeling the
protective backing off the adhesive
tape on the back of the switch
label. Hold the label against the
panel for approximately 20 seconds
while applying pressure to allow the
adhesive to properly adhere to the
surface.
Figure 36— Template
96820 v.4.0
27
8. Remove the nut and internal
tooth washer from the Power Level
Selector switch. Rotate the shaft
counter clockwise until the shaft
stops. Verify that the locating washer
tab is inserted into the #6 position on
the switch (see Figure 37).
connector to the headlamp switch
bezel. Reinstall this bezel by gently
pushing on it until all clips are
engaged.
13. Reconnect the four (4) electrical
NOTE: If the washer is in any position
other than the #6, your EconoMind
Diesel Tuner will not select power
levels correctly.
connections to the center bezel.
Reinstall this bezel by pushing on
it to engage all the clips. Open the
ashtray and cup holder and reinstall
the original screw.
9. After confirming the locating
14. Route the Power Level Selector
washer is in the #6 location, install
the switch through the 3⁄ 8” hole
on the backside of the bezel. The
alignment pin should rest in the 1⁄ 8”
hole and with the switch fully rotated
counter clockwise; the shaft’s flat
side should be facing the steering
column. Secure switch with internal
tooth washer and nut. Snug the nut.
Be careful not to over torque the nut
and damage the plastic threads.
10. Install the knob onto the shaft
facing the #1 Level on the EconoMind
label. On the knob, snug the two (2)
set screws with the supplied 0.050”
hex key wrench.
11. Reinstall the cluster bezel by
pressing on it to ensure all the clips
are engaged. Secure it with the
original a two (2) screws.
28
12. Reconnect the electrical
96820 v.4.0
switch wires down to the steering
column.
15. Route the Power Level Selector
switch’s cable to the wire harness
that was routed into the passenger
compartment from the EconoMind
module, and plug the 2-pin connector
into the corresponding connector on
the EconoMind harness.
16. Route all wiring away from any
pedals or other moving components.
Using the cable ties supplied, secure
the wiring under the dash.
-end, section 7-
Figure 37 EconoMind switch, orientation of the tab on the washer
Section 8
Optional Gauge Cluster Installation
If not installing optional gauges,
Skip to next section.
1. Choose a suitable location under
the lower edge of the dash for the
mounting of the instrument panel
provided where the driver can
conveniently view it.
Note: Molded pillar mount and
additional gauges are available
through Gale Banks Engineering.
Figure 38
2. Using the panel as a template,
drill two 3⁄ 16” diameter holes in the
dash and mount the panel with the
supplied machine screws, nuts and
star washers provided.
3. Locate the supplied EconoMind
wire loom with the 4-pin connector.
Connect the 4-pin connector on
the EconoMind wire loom to the
connection labeled DYNAFACT
Gauges on the EconoMind wiring
harness. See Figure 18.
4. Install the DynaFact boost and
pyrometer gauges in the mounting
panel using the clamps and
thumbnuts provided. Plug the BLACK
wire lead to the male spade terminal
on the BLACK wire of each gauge
wire harness. Plug the YELLOW wire
into the Yellow wire of the boost
gauge wire harness and the RED wire
into the RED wire of the pyrometer
gauge wire harness. The ORANGE
wire remains unused.
5. Connect the 4-pin connector
of each gauge into the back of its
corresponding gauge.
a.Crimp the remaining Black and
RED wires from each 4-pin
connector gauge harness to the
butt connectors as shown in
Figure 38.
b. Strip one end of the RED wire and
crimp it to the butt connector
containing the RED wires from
step ‘a’.
c. Strip one end of the BLACK wire
and crimp it to the butt connector
containing the BLACK wires from
step ‘a’.
d. Route the RED wire to the fuse
box. Locate the appropriate
fuse for instrument lighting in
the owner’s manual. Cut the
RED wire as required and strip
the end. Crimp the push on
connector to the RED wire and
connect to the fuse as shown in
Figure 38. Alternatively, locate
power wire to dimmer switch and
install T-tap. Cut the RED wire as
required and strip the end. Crimp
the push on T-tap connector to
the RED wire and connect to
T-tap on dimmer power wire.
e. Locate a metal surface that will
serve as an acceptable chassis
ground. Cut the BLACK wire to a
sufficient length that will allow
it to reach the chassis ground
and strip the end. Crimp the ring
terminal to the BLACK wire as
shown in Figure 38.
f. Drill a 1⁄ 8” hole, if required, to
attach the ring terminal to the
chassis ground. Caution: If
drilling, check the backside
to make sure there are no
components that may be
damaged by drilling.
g. Use the supplied self-tapping
screw to secure the ring terminal
to the chassis ground.
-end, section 896820 v.4.0
29
Section 9
Transmission Learnng
Your EconoMind Diesel Tuner displays
the “4,3” diagnostic code (refer to
TROUBLESHOOTING in Section
10 on how to read codes) when it
needs to learn your transmission
configuration. This always occurs
when the EconoMind Diesel Tuner
is first installed on the truck. The
EconoMind Diesel Tuner is equipped
with advanced safety features to
preserve your automatic transmission.
One of them is the capability to detect
the occurrence of transmission slip,
and it will automatically de-rate the
engine output power accordingly.
Before this safety feature can take
effect, the EconoMind Diesel Tuner
needs to learn that your truck
is equipped with an automatic
transmission.
1. The following driving test shall
be performed in an area where
speeds over 55mph are safe and
traffic is light. For a vehicle with a
manual transmission, follow Step
2. For a vehicle with an automatic
transmission, follow Step 3. While
driving, listen for any exhaust leaks or
rattles, or intake boost leaks. After the
engine cools, re-tighten clamps and
hoses if leaks are detected.
2. (Manual trans) To teach the
EconoMind Diesel Tuner that your
truck is equipped with a manual
transmission, drive the truck at a
speed over 55 mph for at least 2
minutes. The “4,3” diagnostic code
will be eliminated.
3. (Auto Trans) To teach the
EconoMind Diesel Tuner that your
truck is equipped with an automatic
transmission drive the truck at a
speed over 55mph until the torque
converter is locked (the toque
converter is usually locked at speeds
over 55mph). With the torque
converter locked and with turbo boost
below 10psig (ie, light load), maintain
the attained speed steadily for at least
30 seconds. Once the transmission is
learned, the “4,3” diagnostic code will
be eliminated. Repeat if necessary to
eliminate code.
-end, section 9-
Repeat if necessary to eliminate code.
Proceed to Section 10.
Section 10
Troubleshooting, EconoMind
EconoMind Troubleshooting Using
The Banks iQ
Figure 40
Check the Banks iQ’s Status indicator
for the “OK” icon on the upper left
corner of the iQ screen. Any Tuner
fault will be indicated by the “Banks
Engine” icon (see Figure 39) and
its cause can be investigated by
running a ‘Tuner Diagnostic’ from the
Diagnostic menu.
Figure 39
Banks Engine
Icon
1. In the Environment select menu
press on the ‘Diagnostics’ button.
See Figure 40.
2. In the Diagnostics menu press on
the ‘Tuner Diagnostics’ button to run
a tuner diagnostics. See Figure 41.
3. The ‘Self Diagnostic’ screen
displays a log of diagnostic events
related to the Power Tuner. The
‘Logged Events’ list takes a moment
to update each time this screen is
opened. Once the list is updated,
the most current event will appear
30
96820 v.4.0
at the bottom of the list. Each event
has an associated timestamp and
description, which will be displayed
below the list when that event is
highlighted. Each key cycle of the
vehicle produces a minimum of two
logged events. See Figure 42. Table
1 lists the common diagnostic codes
and the suggested course of action
for each.
4. Use the arrow buttons to scroll
through the recorded events.
5. Touch the Banks iQ icon on the
lower left of the screen to return to
the environment screen or the return
icon to return to the Diagnostics
menu.
6. A pop-up “Log-File” screen will
appear asking you if you want to
erase the contents of the log. Press
‘No’ to keep the contents on Log-file
or ‘Yes’, to erase the Log-files.
• No LEDs will illuminate if the fuse
on the EconoMind wiring harness is
blown or the wiring harness is not
properly connected. If the fuse and
all connections are okay, contact
Banks Technical Service.
Figure 41
• The RED LED will flash in a certain
sequence if a connection is incorrect
of if there is a problem with the
system – this sequence will identify
one or more diagnostic codes. A
Banks EconoMind Diesel Tuner’s
diagnostic code is comprised of 2
digits. Each code is expressed in a
sequence of 2 sets of the flashing
red LED separated by a brief flashing
of the green LED in between. Each
set of a number of red LED flashes
represents a digit. A longer flashing
of the green LED separates the
sequences. The LEDs will continue
to flash to display all the errors,
and then repeat. Table 1 lists the
common diagnostic codes. For
example, if a faulty thermocouple
is detected (code “2,3”) by the
Banks EconoMind Diesel Tuner, the
following red and green LED flashing
sequence is observed when the key
is on:
Figure 42
(1) Two times flashing RED LED
(2) One time quick flashing GREEN
LED
Diagnosing EconoMind error
codes without the Banks iQ.
If you feel that your Banks EconoMind
Diesel Tuner is not functioning
properly, some diagnostics can be
performed. Your EconoMind Diesel
Tuner is equipped with diagnostic
features that will detect and display
certain errors.
Remove the Banks EconoMind Diesel
Tuner from its mounting location
while keeping all connectors plugged
in, and position it in such a way
that you can view the top of the
EconoMind housing that contains the
LEDs . Turn the vehicle key to the
ON position. Observe the two LEDs
mounted on the end of the Banks
EconoMind Diesel Tuner:
(3) Three times flashing RED LED
(4) One time longer flashing GREEN
LED
• A steady GREEN LED will illuminate
if all wire connections are correct,
the engine is running, and the engine
coolant temperature is within its
normal operating range.
The above flashing sequence will
repeat continuously. When the
problem is corrected, the diagnostic
code will be eliminated and replaced
by a steady green light.
• The GREEN LED will flash if all wire
connections are correct, the engine
is running, but the engine coolant
temperature is not within its normal
operating range. The GREEN LED will
stop flashing once the engine coolant
temperature is within its normal
operating range.
NOTE: If multiple codes are set, they
will be displayed in a series separated
by the longer flashing green LED. When
reading codes, make sure to watch the
entire series until you see the first code
repeat.
-end, section 10-
96820 v.4.0
31
Table 1 Banks EconoMind Fault Codes
Code
Event
Course of Action
1,1
Fuel Rail Pressure (FRP)
Input Voltage Out of Range.
Turn ignition OFF and check 3-pin FRP sensor connections. Turn ignition back
ON and re-check for presence of code.
1,2
Manifold Absolute Pressure
(MAP) Input Voltage Out of
Range.
Turn ignition OFF and check 4-pin MAP sensor connections. Turn ignition back
ON and re-check for presence of code.
1,3
Power Level Selector Switch
Input Value Out of Range.
Turn ignition OFF and make sure either Banks IQ or Power Level Selector Switch
is connected to EconoMind tuner. If Power Level Selector Switch is connected
(no Banks IQ), check 2-pin connection on tuner’s in-cab cable. Turn ignition back
ON and re-check for presence of code.
1,4
SCI Communications Error
With Vehicle.
Turn ignition OFF and check in-cab OBD II and 8-pin cable connections. Turn
ignition back ON and re-check for presence of code.
2,1
Fuel Rail Pressure (FRP) Output Turn ignition OFF and check 3-pin FRP sensor connections. Turn ignition back
Voltage Out of Range.
ON and re-check for presence of code.
2,2
Manifold Absolute Pressure
(MAP) Output Voltage Out of
Range.
Turn ignition OFF and check 4-pin MAP sensor connections. Turn ignition back
ON and re-check for presence of code.
2,3
Exhaust Gas Temperature
(EGT) Sensor Open Circuit or
Out of Range.
Turn ignition OFF and check thermocouple ring-terminal connections (2). Turn
ignition back ON and re-check for presence of code.
2,4
J1850 Communications Error
With Vehicle.
Turn ignition OFF and check in-cab OBD II and 8-pin cable connections. Turn
ignition back ON and re-check for presence of code.
3,1
Crankshaft Position (CKP)
Signal Fault or Intermittent
Power.
Turn ignition OFF and check 3-pin CKP and CMP sensor connections and fusetap power connection to EconoMind tuner (in engine compartment fuse box).
Start engine and re-check for presence of code.
3,2
Internal Module Malfunction.
Turn ignition OFF and check all EconoMind tuner connections. Turn ignition back
ON and re-check for presence of code.
3,3
Turn ignition OFF and check fuse-tap power connection to EconoMind tuner (in
Low Battery Voltage or Internal
engine compartment fuse box). Turn ignition back ON and re-check for presence
Module Malfunction..
of code.
4,2
Transmission Slippage
Detected.
Transmission is slipping excessively. Code will automatically clear once
transmission stops slipping (repaired).
4,3
Unlearned Transmission Type
and Gear Ratios.
Perform Transmission Learning procedure in Section 6. Code will automatically
clear once transmission type and gear ratios (auto trans. only) have been
learned successfully.
4,4
Engine Rating Changed or Not
Learned.
Turn ignition ON and allow EconoMind to learn engine rating (approx. 10
seconds). If EconoMind has been moved to a different truck and engine
platform, perform “throttle pedal CLEAR” routine and allow EconoMind to
re-learn engine rating.
If problem persists, call Gale Banks Engineering Tech Support.
32
96820 v.4.0
Section 11
Clearing Learned Information
NOTE: If clearing the EconoMind’s
learned parameters then all Banks iQ
tunable settings will be reset to factory
defaults. (Refer to the Banks iQ Owners
Manual for more detail.) This procedure
should only be performed if:
- A ”4,2” code for transmission slip
detection is repeatedly set or will
not clear and the transmission is not
actually slipping; or
- The EconoMind Diesel Tuner is moved
to a new vehicle; or
- The vehicle’s speedometer has been
factory recalibrated for different gearing
or tire size; or
- Instructed to do so by Banks
Technical Staff. Your EconoMind Diesel
Tuner also has the capability to clear
the information related to the learned
transmission type and gear ratios. The
diagnostic code “4, 3” will reappear
after the procedures are carried out
correctly. Follow the steps below
to unlearn the transmission on your
EconoMind Diesel Tuner.
CAUTION: The following
procedures can only be carried
out with the engine not running.
1. Turn the vehicle key to the ON
position but DO NOT start the engine.
2. Fully depress the accelerator pedal
and then release it completely. Repeat
for 5 times. The GREEN LED will flash
when this is completed successfully.
3. Turn the key OFF. Wait 10 seconds,
or until the GREEN LED goes off and
stays off. Turn the key to the ON
position but DO NOT start the engine.
4. Fully depress the accelerator pedal
and then release it completely. Repeat
for 5 times. The “4,3” diagnostic code
will flash when this is completed
successfully. NOTE: When the
transmission type and gear ratios are
cleared (with code “4,3” displayed), the
engine power returns and remains in
stock level until the EconoMind Diesel
Tuner re-learns the transmission and
the “4,3” code is eliminated. Follow the
procedures in ”Transmission Learning”
(Section 9) to eliminate the “4,3”.
-end, section 11-
Section 12
Removal of the EconoMind Diesel Tuner
If the EconoMind Diesel Tuner should
ever need to be removed from the
vehicle, perform the following:
5. Disconnect the EconoMind’s
Crankshaft Position (CKP) connections
from the vehicle’s CKP sensor and
harness.
NOTE: The ignition must remain in the
OFF position throughout the removal
process.
6. Re-connect the vehicle’s CKP
1. Disconnect the EconoMind’s Fuel
7. Disconnect the EconoMind’s
Rail Pressure (FRP) connections from
the vehicle’s FRP sensor and harness.
2. Re-connect the vehicle’s FRP
connector back into the FRP sensor.
3. Disconnect the EconoMind’s
connector back into the CKP sensor.
Camshaft Position (CMP) connections
from the vehicle’s CMP sensor and
harness.
8. Re-connect the vehicle’s CMP
connector back into the CMP sensor.
Manifold Absolute Pressure (MAP)
connections from the vehicle’s MAP
sensor and harness.
9. Unbolt the EconoMind’s ground
4. Re-connect the vehicle’s MAP
10. Unplug the EconoMind’s RED/WHT
connector back into the MAP sensor.
ring terminal from the fender stud and
retighten the stud’s 10mm nut.
power wire from the mini-fuse tap and
remove the tap.
11. Disconnect the 2 ring terminals
nearest the EconoMind from the EGT
thermocouple lead wire.
12. Disconnect the 3 small connectors
on the EconoMind’s in-cab cable and
gently pull the cable back through the
firewall.
13. Remove the EconoMind Diesel
Tuner.
NOTE: Failure to follow the above
instructions when removing the
EconoMind Tuner will result in a
“Check Engine” light on the dash and a
Diagnostic Trouble Code being stored in
the factory computer, in addition to the
engine not running.
-end, section 12-
96820 v.4.0
33
Section 13
Filter Maintance
Notification
The Banks Ram-Air Filter comes
pre-oiled and no oiling is
necessary for initial installation.
Service the filter as specified in
this Section of the manual.
1. Service Banks Ram Air Filter every
50-100,000 miles on street-driven
applications. Service more often in
off-road or heavy-dust conditions.
If an air-filter restriction gauge is
installed, then clean the element
when the air-filter restriction gauge
enters the restrictive red zone. See
Figure 43.
Figure 43
AIR-FILTER
RESTRICTION
GAUGE
RESTRICTIVE
RED ZONE
LEFT SIDE
2. Use Banks Ram Air Filter cleaning
system (part # 90094), available from
Gale Banks Engineering to service
the Air Filter. Follow the instructions
included with the cleaning system
to clean and re-oil your Banks Ram
Air Filter. No gasoline cleaning, No
steam cleaning, No caustic cleaning
solutions, No strong detergents, No
high pressure car wash, No parts
cleaning solvents. Any of these No’s
can cause harm to the cotton filter
media plus SHRINK and HARDEN the
rubber end caps.
CAUTION! Extremely fine dust
from agriculture or off-road
use will pull the oil from the
element. Frequent re-oiling of
the element’s clean side might
be required. Completely service
when practicable. For extra
protection use an air-filter sealing
grease on rubber ends of the
element. Service only with Banks
Ram-Air-filter cleaner and Banks
Ram-Air-filter oil.
-end, section 13-
Section 14
Placement of the Banks Power Decals
Figure 44
RIGHT SIDE
LEFT SIDE
Gale Banks Engineering
546 Duggan Avenue • Azusa, ca 91702
(626) 969-9600 • Fax (626) 334-1743
Product Information & Sales: (888) 635-4565
Customer Support: (888) 839-5600
Installation Support: (888) 839-2700
bankspower.com
RIGHT SIDE