owners manual with installation instructions SIDEWINDER T U RB O BANKS SIDEWINDER® TURBO SYSTEM FOR CHEVROLET/GM 6.2L DIESEL TRUCKS NEW BODY STYLE THIS MANUAL IS FOR USE WITH SYSTEM PART NUMBER 21007 gale banks engineering 546 duggan avenue • azusa, ca 91702 (626) 969-9600 • fax (626) 334-1743 www.bankspower.com ©2009 gale banks engineering 02/12/09 P.N. 96292 V.2.
Sidewinder turbo system GM 6.2L DIESEL TRUCKS NEW BODY STYLE Dear Customer: You have just purchased the finest, most technologically advanced turbocharging system available for light truck diesel engines. GALE BANKS ENGINEERING has utilized the knowledge and experience gained through years of turbocharged engine design to combine performance, durability and good looks into a professional quality turbocharger system.
IMPORTANT To obtain optimum performance from your BANKS Sidewinder turbo system, it is necessary to make an adjustment to the fuel injection pump. This adjustment is easily made by following the enclosed instructions. However, it is extremely important that the instructions be followed very carefully.
figure 1 SEE PARTS LIST, PAGE 22 4 P.N. 96292 V.2.
figure 2 SEE PARTS LIST, PAGE 22 5 P.N. 96292 V.2.
Installation Instructions Disconnect ground cables from both batteries. Remove the air filter, housing, intake silencer and flexible duct, from the engine and inner fender panel. Cover the intake manifold opening with a clean rag to prevent foreign objects from entering the intake manifold. studs and intake manifold. Spacers are included in the Banks Heavy Duty Emissions Kit (ordered separately, part no. 21058). See Figure 3. 1. B. NON EGR MODELS ONLY: Go to Part C.
Figure 5 Figure 6 Install new adapter/drain plate to engine block using original bolts and new gasket supplied. Use silicone sealer on the gasket surfaces. Fuel line tubing may have to be bent slightly to clear the oil drain tube portion of the adapter/drain plate. Re-attach ground strap. See Figure 1. Lower the vehicle. 7. plugs. nipples. Open a No. 12 hose clamp and install it over the hose/ nipple assembly of the previous step.
Install the exhaust manifold heat shield on the 10. Banks exhaust manifold. Hammer three 1⁄ ” dia. Figure 9 8 x ⁄ ” long drive screws through the heat shield into the manifold. 14 Install the pyrometer probe (in the pyrometer gauge box) into the Banks exhaust manifold. Install four 3⁄ ” x 13⁄ ” studs in the turbo mounting flange of the exhaust manifold. Install two 3⁄ ” x 21⁄ ” studs in the 2-bolt crossover pipe flange on the manifold.
figure 10 9 P.N. 96292 V.2.
figure 11 10 P.N. 96292 V.2.
Figure 12 Figure 14 Figure 15 13 for proper installation of collet lock nuts. fittings. See Figure 15. Bolt the oil drain support to the exhaust manifold with a 1⁄ –20 x 1⁄ ” bolt and 1⁄ ” split lock washer. Tighten the oil drain hose clamps. Install the boost tube using the 2” ID x 11⁄ ” long blue silicone hose and two No. 36 liner hose clamps at the turbo connection. Secure upper hose with two No. 40 liner hose clamps. Make sure clamps are installed behind hose beads. Raise the vehicle.
Figure 17 Figure 16 bly to the oil inlet fitting on the turbocharger. Tie the hose to the cross-over casting at the front of the engine with plastic cable ties. See Figure 17. NOTE: If the hose is not long enough to reach the turbo when routed over the intake manifold, run the hose under the manifold and to the turbo. B. Remove plastic connector from inner fender panel (push in on plastic to disengage from fender). Save connector for reinstallation. See Figure 21. EGR EQUIPPED MODELS ONLY: 15.
FIGURE 18 13 P.N. 96292 V.2.
FIGURE 19 FIGURE 20 14 P.N. 96292 V.2.
FIGURE 21 15 P.N. 96292 V.2.
the bolt holes in the air filter mounting bracket, provided. This pair of bolt holes has a center-to-center spacing of 11⁄ ” . See Figure 2. Install the pyrometer (exhaust temperature 20. gauge) following the instructions in the pyrom- eter kit. A gauge panel is included for under-dash mounting. Check that any electrical connections are not exposed where they could come in contact with ground and render the gauges inoperative.
IMPORTANT: Install the red plastic cap, supplied, over the end of the positive battery cable bolt, to prevent accidental shorting of the cable connection to ground. Cap will snap into place when pushed on. Re-install this cap anytime cables have been removed for service. installed components, improperly routed wires and hoses, intake air leaks and any wires or hoses too close to hot exhaust or turbo components, or sharp edges. The turbocharger must be oil-primed 23.
Remove the fuel return line from the pump cover. Remove the top attaching bolt and loosen the lower attaching bolts on the fast idle solenoid and place the solenoid aside. Remove the pump cover bolts and remove the cover. IMPORTANT: Utmost care must be used to prevent damage. the bottom of the pump bowl. (See Fig. 21.) On some late model trucks it may be necessary to remove the front crankshaft pulley to gain access to the vibration damper bolt to turn the engine over.
ADJUSTMENT section. A high EGT can also be caused by a restrictive exhaust system. need for an additional oil cooler. If you do not have and oil temperature gauge, watch your oil pressure. Falling oil pressure under a heavy load is caused by rising oil temperature. Use caution. We recommend engine oil temperature be below 220°F, as measured in the oil pan (an optional oil temperature gauge is available from GALE BANKS ENGINEERING). Optimum oil temperature is 220°F.
Cleaning and Oiling the banks ram-air Filter Notification The Banks Ram-Air Filter comes pre-oiled and no oiling is necessary for initial installation. 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. AEROSOL OILING After cleaning air filter always reoil before using.
trouble shooting chart symptom High EGT. Excessive fuel smoke, (black) Poor Performance. cause Excessive fuel delivery. Faulty injector(s). Restricted exhaust system. Faulty injector(s). remedy Change injector pump setting. Repair injector(s). Check for obstructions. Repair injector(s). Dirty air cleaner. Restricted air intake. Excessive oil smoke (blue). Lack of boost, excessive oil smoke, & poor performance.
parts list – 21007 Sidewinder Turbo System, Chevy/GMC 6.2 Late-Body Style Pickups QTY DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . item # PART # QTY DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . item # 1 CHAMBER, Pressure. . . . . . . . . . . . . . . . . 3 41070 1 COVER, Air Filter Housing. . . . . . . . . . . . . 6 41052 1 DECAL, Carb. E.O. -D-161-31 . . . . . . . . . . . 96021 1 DECAL, Fed. Emis. Comp. Turbo . .
P.N. 96292 V.2.
Gale Banks Engineering 546 Duggan Avenue • Azusa, ca 91702 (626) 969-9600 • Fax (626) 334-1743 Product Information & Sales: (888) 635-4565 bankspower.
