Owner’sManual with Installation Instructions Banks Bullet™ Diesel Tuner 2003-2007 Ford Power Stroke 6.0L Turbo-Diesel THIS MANUAL IS FOR USE WITH KITS 66524 & 66525 Gale Banks Engineering 546 Duggan Avenue • Azusa, ca 91702 (626) 969-9600 • Fax (626) 334-1743 Product Information & Sales: (888) 635-4565 bankspower.com ©2012 Gale Banks Engineering 05/14/12 PN 96584 v.5.
Products available from Banks Power for the 2003-2007 Ford 6.0L Banks iQ System (P/N 61151-61152) - 5” touchscreen interface that can control the Banks Diesel Tuner and/or SpeedBrake on the fly. - Interchangable gauge display, read and clear codes, monitor engine diagnostics, log data, time your vehicles runs and much more.
Banks Billet Torque Converter (P/N 72522) - Higher torque capacity over stock - Lockup clutch is slip-resistant so transmission fluids stay cooler and transmission life is prolonged. Banks Stinger Systems (P/N 46465-46486) Contains: - Ram-Air Intake system - Monster Exhaust (single or dual) - EconoMind Tuner w/ Banks iQ Banks SpeedBrake iQ Compatible (P/N 55455-55456) PDA Compatible (P/N 55457-55458) - Allows for controlled hill decent at a user defined vehicle speed.
THIS IS A HIGH PERFORMANCE PRODUCT. USE AT YOUR OWN RISK. Do not use this product until you have carefully read the following agreement. This sets forth the terms and conditions for the use of this product. The installation of this product indicates that the BUYER has read and understands this agreement and accepts its terms and conditions. Disclaimer of Liability Gale Banks Engineering Inc.
Please see enclosed warranty information card, or go to www.bankspower.com/warranty, for warranty information regarding your product. All products that are in question of Warranty must be returned shipping prepaid to the SELLER and must be accompanied by a dated proof of purchase receipt. All Warranty claims are subject to approval by Gale Banks Engineering Inc.
Dear Customer, If you have any questions concerning the installation of your Banks Bullet Diesel Tuner, please call our Technical Service Hotline at (888) 8392700 between 7:00am and 5:00pm (PST). If you have any questions relating to shipping or billing, please contact our Customer Service Department at (888) 839-5600. Thank you. The Banks Bullet Diesel Tuner has 3 power levels adjustable via controls on the interface module. Level 1 is stock, Level 2 is towing and Level 3 is sport.
Bullet and Supplied Wiring Harness 96584 v.5.
General Installation Practices 1. Before starting work, familiarize yourself with the installation procedure by reading all of the instructions. 2. The exploded views provide only general guidance. Refer to each step and section diagram in this manual for proper instruction. 3. Throughout this manual, the left side of the vehicle refers to the driver side, and the right side to the passenger side. 4.
Recommended Airflow Improvements Banks Monster® Exhaust ‘03 F-250/350 Pickup Ext cab, short bed........................48764 ‘04-07 F-250/350 Pickup Ext cab, short bed........................48784 ‘03 F-250/350 Pickup Ext cab, long bed.........................48766 ‘04-07 F-250/350 Pickup Ext cab, long bed.........................48786 ‘03 F-250/350 Pickup Crew cab, short bed....................48765 ‘04-07 F-250/350 Pickup Crew cab, short bed....................
Section 1 Exhaust Gas Thermocouple Installation Instructions NOTE: If not installing or connecting an EGT thermocouple to the Banks Bullet Diesel Tuner then install the supplied EGT thermocouple bypass plug. The bypass plug is installed on the two-pin connector attached to the backside of the Banks Bullet. -If your vehicle has a Banks DynaFact EGT probe installed, please skip to step 11. -If your kit does not have EGT sensing and limiting functions, please skip to Section 2. INSTALLATION 1.
Figure 2: Location to drill and tap the driver side exhaust manifold for the thermocouple 7. Remove all metal chips from the 8. Re-install the exhaust manifold. Note: Failure to remove all metal chips could result in catastrophic damage to the turbocharger’s turbine wheel or interfere with the operation of the variable geometry vane mechanism. 9. Tighten the turbocharger adapter exhaust manifold.
Section 2 Installation of Wiring Harness, Connections and Banks Bullet Diesel Tuner 1. Disconnect the battery ground of the engine must be removed. The heat shield is accessible from beneath the vehicle. The heat shield is secured with one, 13mm and two, 10mm bolts. See Figure 6. 2. Locate the Manifold Absolute 4. Once the heat shield is removed, cables from each of the batteries. Secure the cables so that they do not come in contact with the battery posts during the installation.
Figure 6 2003 Model TURBOCHARGER HEAT SHIELD BOLTS Figure 7 2003 Model CONNECTOR INJECTION CONTROL PRESSURE SENSOR HEAT WRAP 96584 v.5.
Figure 8 2004-2007 Model 7. Unplug the factory connector and plug it into the corresponding male ICP sensor connector on the Banks Bullet harness. Plug the Banks Bullet’s female ICP sensor connector into the sensor. 8. Route the harness from the MAP and ICP sensor as shown in Figure 9. Use the supplied zip ties to secure the harness to the factory harness. Note: Failure to follow the recommended harness routing may result in a melted harness. 9.
Figure 9: MAP/ICP sensor harness routing Figure 10 96584 v.5.
Figure 11 control panel should push easily in and snap back into place – if it does not, look for kinked or pinched wiring.) 14. Remove the fuse box cover, located in the cabin compartment. Locate mini-fuse #22 and remove. Install the mini-auto blade fuse tap onto the removed mini fuse as shown in Figure 12. Re-install the mini fuse with the attached blade tap into location #22 as shown in Figure 13. Figure 12: Fuse tap 15.
Figure 13 Figure 14 96584 v.5.
. If using a module mounting method other than the supplied bracket, complete the mount installation per the supplied directions. Double-check all wire harness routing for proper clearance around moving and sharp objects as well as heat sources, then use the supplied nylon tie straps to secure the wire harnesses safely away from any control linkages and the operator’s feet underneath the dashboard. 19.
Section 3 Operation of the Banks Bullet Diesel Tuner Figure 15: Banks Bullet module controls If your Banks Bullet Diesel Tuner module has been properly installed as outlined in the previous section, it will power up and briefly scroll ‘Banks Power’ across the screen, then display the current power level setting after you switch your ignition key on.
Setting Desired Power Level: To set the desired power level from the normal display mode, press the ‘Menu’ button until ‘PWR’ is displayed, then press the ‘Select’ button. The current power level setting will be displayed – press the ‘Select’ button to continue operating at this power level and return to normal operating mode (the module will display a ‘SAVED’ message confirming your selection), or press the ‘Menu’ button to cycle through power levels ‘STK’ (stock), ‘TOW’ (tow) and ‘SPT’ (sport).
Always carefully monitor your EGT when running stacked performance modules. Setting Default Display Options: To set the desired default display parameter from the normal display mode, press the ‘Menu’ button until ‘DISP’ is displayed, then press the ‘Select’ button.
Section 4 Troubleshooting The Bullet Diesel Tuner is equipped with self-diagnosing features that automatically check for proper sensor and module operation. Error codes that your module may display, either upon startup or after accessing the Diagnostics submenu, are listed below. must be connected to the six-pin MAP/ ICP harness in place of the module.
Section 5 Placement of the Banks Power Decals Figure 16: Placement of the Banks decals -end, section 5- 96584 v.5.
Gale Banks Engineering 546 Duggan Avenue • Azusa, ca 91702 (626) 969-9600 • Fax (626) 334-1743 Product Information & Sales: (888) 635-4565 bankspower.
