Banks Power Pack® System For use with Palm® Tungsten™ E2 only Including Stinger® System and EconoMind 2001-2005 Chevy/GMC 6.6L Duramax Turbo-Diesel Pickups THIS MANUAL IS FOR USE WITH SYSTEM 48950-48994, 61073-61079, 63713-63715, 63762-63765 Gale Banks Engineering 546 Duggan Avenue • Azusa, ca 91702 (626) 969-9600 • Fax (626) 334-1743 Product Information & Sales: (888) 635-4565 bankspower.com ©2009 Gale Banks Engineering 12/14/09 PN 96776 v.11.
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.
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 Assembly Diagram . . . . . .
General Assembly Diagram Banks Power Pack System 4 96776 v.11.
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Section 1 Installation of Banks Monster Exhaust System Figure 1a General Assembly Banks Monster Exhaust (Single Tailpipe) 1 Description Qty. Ext./Crew Cab Short Bed/Std Cab Long Bed 53800 1 Ext./Crew Cab Long Bed 53801 1 2 Intermediate pipe Standard Cab Long Bed 53718 1 Ext./Crew Cab Short Bed 53719 1 Ext./Crew Cab Long Bed 53720 1 3 Tailpipe Ext./Crew Cab Short Bed/Std Cab Long Bed 53708 1 Ext.
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Figure 1b General Assembly Banks Split-Dual Monster Exhaust, Split-Dual Description Part # Qty. 1 Monster muffler 53800 1 2 Intermediate pipe Standard Cab Long Bed 53721 1 Ext. Crew Cab Short Bed/Crew Cab Short Bed 53724 1 Ext. Crew Cab Long Bed/Crew Cab Long Bed 53725 1 3 Passenger side tailpipe 53743 1 4 Driver side tailpipe 53744 1 53727 1 5 Y-pipe, Split dual 6 Flanged Intermediate extension pipe Standard Cab Short Bed/Ext.
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Exhaust System Installation Use the Bill of Materials Chart and Figure 1a or 1b to reference component nomenclature and location. Use caution when working in the engine compartment. Make sure the engine has been OFF for several hours and cool. Figure 2 1. Disconnect the ground of the battery (if there is more than one battery, disconnect both). 2. Raise the vehicle and support it with properly weight rated safety stands, ramps or a commercial hoist. Follow the manufacturer’s safety precautions.
1⁄ 4” Figure 4 away from its original position. Step 14 thru 21 applies only to single tailpipe systems. Skip to Step 22 if installing Banks Split-Dual Monster Exhaust System. Single Tailpipe System (Step 14 thru 21) 14. Slide one (1) of the supplied 4-inch exhaust clamps over the Banks intermediate pipe. Note: On extended cab long-bed and crew-cab long-bed vehicle, the clamp that is used between the intermediate pipe and muffler is a combination hanger/clamp.
20. Tighten the exhaust clamp at each of the three (3) joints. Figure 4 illustrates the proper location of an exhaust clamp on a tubing joint. Torque the nuts on each of the exhaust clamps to 35 ft-lb. Note: If a combination hanger/clamp is utilized, evenly torque nuts to 35 ft-lb. The clamps only need to be tight enough to form a seal and hold the pipes together. Over tightening the clamps may cause the system to leak due to the pipe being crimped.
Section 2 Techni-Cooler Assembly Installation Figure 7 General Assembly Banks Techni-Cooler Intercooler System Item 1 2 3 4 5 Description Techni-Cooler Intercooler P/N Qty 25537 1 Boost Tube, Right (2001) 42326 1 Boost Tube, Right (2002-2004) 42327 1 Boost Tube, Right (2004.5-2005) 42329 1 Boost Tube, Left (2001-2004) 42325 1 Boost Tube, Left (2004.5-2005) 42328 1 1 Hose, Compressor Outlet to Boost Tube (2001, 2004.
Figure 8 Air box mounting tray REMOVE STOCK COMPONENTS 1. Make sure the previously removed ground cables from both batteries are still disconnected. 2. Disconnect the mass airflow (MAF) sensor’s connector at the air box assembly. Note: MAF will be installed after Ram-Air intake installation. Loosen the hose clamp that joins the inlet air transfer tube to the molded plastic compressor inlet duct. Pull the air box out of the vehicle. It’s held in place by plastic fasteners that snap in place.
Figure 10a Headlamp assembly removal, Chevy 5. Remove the grill a. 2001 to 2002 vehicles: The grill is retained by (4x) 1⁄ 4 turn fasteners, (1x) screw at the latch support, and (2x) snaps at the outboard ends of the grill. Depress the snaps at the ends of the grill before attempting to remove the grill from the vehicle. b. 2003 to 2005 vehicles: Disengage the snaps at the outboard ends of the grill. Pull the grill from the vehicle. 6.
9. Remove the bulbs from the turn Figure 12 Removal of headlamp/parking lamp assembly support structures signal lamp assembly by turning the lamp sockets a quarter turn counterclockwise. 10. Remove the plastic headlamp mounting structure on the driver and passenger side of the vehicle shown in Figure 12. There are (6) bolts, (2) torx head bolts, (1) pushin retainer and (1) large clip that must be disconnected to remove the piece from the vehicle, per side.
Figure 14 Latch support moved out of the way 15. Remove the two bolts that attach the latch support to the radiator cross brace and the 4 lower attachment bolts (2 per side). The two bolts that attach the upper support to the radiator cross brace are accessed from the engine compartment side of the vehicle. 16. Remove the oil-cooler-line retaining clip as shown in Figure 13. 17. Swing the latch support forward as shown in Figure 14. 18.
Figure 16 Air box support bracket TRIM BRACKETS 20. Remove the 6 bolts (3 per side) that secure the radiator cross brace. The bolts are on the bottom side at each end of the support. Remove the cross brace from the vehicle. 21. Remove the air box support bracket shown in Figure 16. There is an a/c condenser line retaining clip and a plastic fastener that attaches to the inner fenderwell that must be removed before the bracket can be liberated from the vehicle. 22.
Figure 18 Trim template for the air box-mounting bracket. 96776 v.11.
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Figure 19 Radiator attachment bolt and lower clamp 26. Lift the radiator out of it’s lower saddle mounts and position it towards the engine so that it is no longer attached to the charge air cooler. Take care not to damage the radiator cooling fins. 27. Remove the charge air cooler from the vehicle. Check that the lower mounting peg grommets remained in the vehicles frame. Return them to their home on the vehicles frame, if they came out with the charge air cooler. 28.
35. Check that the engine cooling Figure 21 Lower fan shroud fitment with the radiator fan can freely spin without contacting the lower fan shroud. If the fan contacts the shroud, the shroud must be realigned with the radiator. The correct alignment is shown in Figure 21. Each side of the shroud should overlap the radiator headers, and the mounting tabs should fit into their respective bosses as shown in Figure 21. 36. Secure the radiator to the Banks CAC with the 5⁄ 16”-18 by 1.
40. Install the upper fan shroud. The supplied gasket is used to fill the gap between the shroud and the cross brace. The push-in retainers that secure the upper shroud to the lower shroud are secured by inserting the retainer with the center pin pulled out. Once the retainer is inserted, press the center pin down to secure the retainer. Install the gasket and upper fan shroud bolts. The stock upper fan shroud bolts are reused and should be tighten to 80 in-lbs. 41.
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 manifold outlet. It is recommended that the manifold be removed from the engine to thoroughly clean out all metal chips from drilling. If manifold is not removed from the vehicle, all chips must be removed from the manifold.
14 13 1 3 7 2 11 P/N 6 42138 SCREW, TRUSS HEAD, PHILLIPS, 6-32 X 3⁄ 8 12 * These are stock components that will be re-used with the Banks Ram-Air System.
RAM-AIR INSTALLATION Figure 25 Use the Bill of Materials Chart and the General Assembly Drawing to reference component nomenclature and location. See Figure 24. Use caution when working in the engine compartment. Make sure the engine has been OFF for several hours and cool. Make sure to complete Steps 1 thru 3 of Section 2 before proceeding. 2001 thru 2004 LB7 Duramax engine 1. You will have either a decorative cover or a resonator covering the intake manifold.
Figure 27 2. Locate your Banks Ram-Air filter housing from your kit and install as shown in Figure 27. The cutout on Banks Ram-Air filter housing must face passenger side fender. Align the Banks Ram-Air filter housing holes with bolt holes in engine compartment. Install the previously removed stock air box bolts to secure the Banks Ram-Air filter housing. Do not tighten the bolts at this time. 3. Locate your Banks Torx tool,T20H in your Banks Ram-Air kit.
5. Locate your Banks Ram-Air intake Figure 29 tube in your kit. Install the stock MAF sensor (with the additional Banks o-ring) to MAF sensor mounting boss as shown in Figure 29. Tighten screws to 3 in/lbs. Note: Ensure correct alignment as shown otherwise screw holes will not align with screw holes in the Banks Ram-Air intake tube. Caution: DO NOT OVER TIGHTEN SCREWS 6. Locate the Banks compressor inlet hose and hose clamps from your Banks Ram-Air kit.
Figure 31 9. Locate the Banks Ram-Air filter housing cover. Install the previously removed air filter minder rubber grommet into the Banks Ram-Air filter housing cover. Once rubber grommet is installed flush into the Banks Ram-Air cover, then locate the previously removed air filter minder and install into the rubber grommet. Make sure air filter minder is installed flush to rubber grommet. 10. Locate the Banks Ram-Air filter and the Banks filter hose clamp.
16. Tighten the Banks Ram-Air filter Figure 34 housing bolts to vehicle frame. 17. Install the Banks bellows hose and hose clamp onto the Banks RamAir intake tube. 18. Loosely fit the hose clamp to the other end of the bellows. 19. Install the Banks Ram-Air cover into bellows. 20. Install Banks Ram-Air cover w/ filter into the Banks Ram-Air filter housing. Note: a slight resistance in pressing in the Banks bellows is normal. 21.
Section 5 Banks EconoMind Diesel Tuner Installation Figure 36 General Assembly Banks EconoMind Diesel Tuner INSTALLATION OF WIRING HARNESS, CONNECTIONS AND EconoMind DIESEL TUNER 1. From the engine compartment, locate the rubber grommet high on the driver’s side of the vehicle firewall. The grommet is about 3” in diameter. Make a 1” x 1” crossshaped incision in the grommet (see Figure 37). 2.
3. Locate the two black wire harness locking connectors between the brake fluid reservoir and the air conditioning compressor. Lift the gray connector locks and disconnect the 38-pin connector pair and the 24-pin connector pair (see Figure 38). Figure 38 4. Insert the male 38-pin connector on the EconoMind harness into the female 38-pin connector on the factory harness. Insert the female 38-pin connector on the EconoMind harness onto the male 38-pin connector of the factory harness.
Section 6 Mounting the Docking Station and Connecting the Banks PowerPDA Vehicle Command Center Section 6 not needed if installing the Power Level Selector Switch. Please proceed to Section 7. Note: This system has been designed for use with the Palm Tungsten E2 PDA. Warning: The PDA may be susceptible to damage as a result of extended exposure to sunlight, heat or extreme cold.
11. Connect the RJ12 cable into the Figure 42 left-most receptacle on the bottom of the Docking Station. Warning: The charging cable on the Docking Station is designed to supply a constant lowvoltage power source (+5VDC) to the Banks PowerPDA Vehicle Command Center and is “live” as long as the system’s OBD II interface cable is completely installed and the RJ12 connector is plugged into the Docking Station.
Section 7 Installation of the Power Level Selector Switch Section 7 not needed if Banks PowerPDA will be installed. Please proceed to Section 8. Figure 45 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 driver’s side of the instrument panel (IP) next to the steering column (see Figure 45).
2. Cut out the supplied template (see Figure 46) and align the template onto the rear of the IP, squarely seating it on the top of the IP mounting pin (see Figure 47). 3. Using a 3⁄ 8” Uni-bit, center the 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. 4.
Figure 48 5. Remove the nut and internal tooth washer from the Power Level Selector Switch. Rotate the shaft counter clockwise until the shaft stops. Verify the locating washer tab is inserted into the #6 position on the switch (see Figure 49). NOTE: If the washer is in any position other then the #6, your EconoMind Tuner will not select power levels properly. 6.
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. 2.
Section 9 Automatic Transmission Learning NOTE: Please refer to the Banks PowerPDA Software & Installation Kit, Owners Manual for software installation and operation instruction before beginning Section 9, Automatic Transmission Learning. The 6.6L GM Duramax Trucks equipped with the Allison 1000 5-speed automatic overdrive transmission use adaptive shift control logic. This will require the transmission to adapt to the additional power created by the Banks Power products before it will shift properly.
Section 10 Troubleshooting, EconoMind Using The Banks PowerPDA Vehicle Command Center Check the Banks PowerPDA’s Status Indicator for the “OK” icon. Any EconoMind Tuner fault will be indicated by the “Banks Engine” icon (see Figure 51) and its cause can be investigated by going to the ‘Self Diagnostics’ screen and scrolling through the list of logged tuner events. that event is highlighted. Each key cycle of the vehicle produces a minimum of two logged events.
Table 1 Banks EconoMind Diagnostic Codes Code Event Course of Action 1,1 Fuel Rail Pressure (FPR) Input Voltage Out of Range Turn ignition OFF and check the 24-Pin and 38-Pin connectors. 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 the 24-Pin and 38-Pin connectors. Turn Ignition back ON and re-check for presence of code.
Section 11 Clearing Learned Parameters If the Banks EconoMind Diesel Tuner has been moved to a different vehicle, or you are instructed to do so by Banks Technical Staff, it is possible to reset all of the parameters that the EconoMind has ‘learned’. 1. Turn the vehicle key to ON but DO NOT start the engine. CAUTION: The following procedures can only be carried out with the engine OFF! 3. Turn the key OFF. Wait 30 2. Fully depress the throttle pedal and then release it completely. Repeat 5 times.
Section 14 Filter Maintenance 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 54.
Section 15 Placement of the Banks Power Decals Figure 55 TYPICAL LEFT FENDER PLACEMENT TYPICAL LEFT FENDER PLACEMENT TYPICAL RIGHT FENDER PLACEMENT TYPICAL RIGHT FENDER PLACEMENT 44 96776 v.11.
Gale Banks Engineering 546 Duggan Avenue • Azusa, ca 91702 (626) 969-9600 • Fax (626) 334-1743 Product Information & Sales: (888) 635-4565 bankspower.
