OWNERS MANUAL WITH INSTALLATION INSTRUCTIONS STINGER TM S Y S T E M CHEVROLET/GM 6.5L DIESEL SUBURBANS WITH FACTORY TURBO OPTION 1994-96 2WD & 1994-95 4WD WITH CATALYTIC CONVERTER THIS MANUAL IS FOR USE WITH SYSTEM 49044 GALE BANKS ENGINEERING 546 DUGGAN AVENUE • AZUSA, CA 91702 (626) 969-9600 • FAX (626) 334-1743 www.bankspower.com ©1999 GALE BANKS ENGINEERING 03/10/98 P.N.
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GENERAL INSTALLATION PRACTICES ™ 1. For ease of installation of your Banks Stinger System, please read this 8-page owner’s manual before starting any work. (If any pages are missing from this package, please call Gale Banks Engineering immediately for a replacement.) Become thoroughly familiar with all components and phases of the installation before starting any work. 2. Inspect all components supplied for any foreign material that may have entered during shipping & handling. 3.
INSTALLATION PROCEDURE 5. Loosen compressor discharge hose clamp at 1. Disconnect both batteries. turbocharger. Remove connecting strap between turbocharger and air inlet casting. 2. Pull crankcase vent hose out of turbocharger air inlet hose, then loosen air intake hose clamp at turbo compressor. Remove air cleaner assembly from vehicle to expose hole in inner fender panel. 6. Remove decorative cover from top of engine. Unbolt and remove air inlet casting from top of intake manifold.
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FIGURE 2 where the extension pipe will stop to the end of the intermediate pipe. Add 23⁄4" to the measurement to compensate for the slip joint on the extension pipe. Cut the extension to this length (Crew cab applications may not need trimming). Install the trimmed pipe onto the intermediate pipe and into the muffler. Install the 3" hanger clamp into the rubber hanger on the frame and lightly clamp it to the extension pipe. 13. Wire and plumb gauges as shown in instructions included with gauges.
OTTOMIND INSTALLATION 19. The Banks Ottomind PROM is keyed such that it will 16. In order to access the vehicle’s Powertrain Control only install one way. With the PCM positioned as mentioned in the previous step, the Banks Ottomind will install with the label reading properly. Install the Banks Ottomind in the socket left vacant by the factory prom. DO NOT FORCE THE INSTALLATION. If the Ottomind does not engage the pins with a slight downward pressure, recheck the orientation of the Ottomind.
OPERATING CHARACTERISTICS Your Banks Stinger will allow your GM 6.5L factory turbocharged engine to produce more power and respond quicker well within the safe operating range of the engine as long as the following guidelines are adhered to. Use your pyrometer (exhaust temperature gauge) and boost gauge to monitor your engine’s operation. At idle, EGT (exhaust gas temperature) will be very low, perhaps only 150°F. As the throttle is opened for higher speeds and greater loads, the EGT will rise.
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CLEANING AND OILING THE BANKS RAM-AIR FILTER PRE-CLEANING Tap the element to dislodge any large embedded dir t, then gently brush with a soft bristle brush. NOTE: If complete cleaning is not practical at this time, reoil the element and reinstall in your vehicle. AEROSOL OILING After cleaning air filter always reoil before using. Spray Banks Ram-Air filter oil down into each pleat with one pass per pleat. Wait 10 minutes and re-oil any white spots still showing. 1. 6.
PARTS LIST Stinger GM 6.5 Factory-Turbo Suburban 49044 QTY. DESCRIPTION 4 1 4 1 1 1 1 1 1 1 1 1 1 4 2 1 1 1 1 1 2 2 1 10 1 4 2 BOLT, ⁄16" 20 x 1 ⁄2" Hex . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91629 CARD, Product Registration. . . . . . . . . . . . . . . . . . . . . . . . . . . 96392 CLAMP, Exhaust, 3" HD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52465 DUCT, Super-Scoop Air Inlet. . . . . . . . . . . . . . . . . . . . . . . . . . 42590 FASTENER, Push-In, Inlet Duct . . . .
