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Profissional Documentos
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manual
with installation
instructions
SIDEWINDER
T UR B O
Dear Customer:
We at Gale Banks Engineering are confident that you will be pleased with
the performance of your turbocharged diesel and hope we may be of
service in the future.
1. Disconnect ground cables from both batteries. Remove and discard air inlet gasket from the
5. intake manifold. Remove air filter mounting
Remove the air filter, housing, intake silencer
2. studs. Install two new pressure chamber studs with
and flexible duct, and bracket from the exhaust two 5 ⁄ ” thick spacers between studs and intake
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adjustment is completed, make sure that the ground to instructions included in Application Kit.
cables from both batteries are disconnected, then
continue with the following steps. Install new air inlet gasket provided on the intake
6. manifold. Install pressure chamber over studs,
1982–1987 models secure with two sealing washers, 5⁄ ” I.D. x 3⁄ ” O.D. flat
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Figure 5
Insert the eight original exhaust manifold and two 3⁄ ” split lock washers. See Figure 9.
8
Figure 7
Figure 8
8
P.N. 96291 V.2.0
between the turbocharger and exhaust manifold. Guide
Figure 9 the turbocharger oil drain tube into the oil drain hose
on the adapter. Secure the turbocharger with four 3⁄ 8
Figure 10
housing so it lines up with the other end of the – 24 stainless collet locknuts. See Figure 10. Tighten
boost tube. Lightly snug one of the six bolts on the the nuts finger tight.
Figure 11
compressor housing to secure this position.
inlet hood. Twist the hood into place. Reinstall the 56. 20 x 3⁄ ” hex bolts and 1⁄ ” I.D. x 1⁄ ” O.D. washers.
4 4 2
grille. NOTE: Cover goes on only one way; make sure the
Temporarily mount the air filter bracket to the cover registers properly on the filter element.
48. battery tray through the battery hold-down
threads using an M8-1.25 x 60mm metric full-thread 57. 1982–1987 MODELS
Install the 1” molded rubber hose between the
bolt and 5⁄ ” I.D. x 3⁄ ” O.D. washer. See Figure 1. Make
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air filter housing and the anti-depression valve on
sure the narrow side of the bracket sits against the the engine. See Figure 13. Adjust the position of the
vertical support section of the battery tray. plastic elbow on the air filter housing as required for
Using the bracket as a template, drill two 11
⁄ ”
32 installation. Secure with two No. 16 hose clamps. Then
49. diameter holes through the battery tray. go to step 67.
Bolt the bracket and the back-up plate (located 1988 AND NEWER MODELS
50. opposite the bracket, see Figure 1) to the 58. Cut off and discard 2” of the hose that connected
battery tray with two 5⁄ ” – 24 x 1” hex bolts, 5⁄ ” I.D.
16 16 the anti-depression valve to the intake manifold
x 3⁄ ” O.D. washers and 5⁄ ” – 24 locknuts. Remove the
4 16
1988 AND NEWER MODELS
metric bolt and washer, apply Loctite to 1⁄ ” of the
2 59. Cut off and discard the 90° bend from one end
threads nearest head of the bolt, reinstall and tighten of the 1” dia. molded rubber hose supplied in the turbo
(see Figure 1 for assembly sequence). kit. See Figure 14.
51. Install two 3⁄ ” x 11⁄ ” studs in the bottom of the air Splice the remaining hose from step 58 to the molded
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Figure 16
reduced. to bring the Allen screw into view in the inspection slot in
the bottom of the pump bowl (see Figure 19). On some
The pump adjustment can easily be set with the pump on
late model trucks, ie: 1986 and later, it may be necessary
the vehicle. If the condition of the pump is in question, or if
to remove the front crankshaft pulley to gain access to the
the pump is to be removed from the vehicle, GALE BANKS
vibration damper bolt. DO NOT ATTEMPT TO ROTATE THE
ENGINEERING can provide the addresses and phone numbers
ENGINE WITH THE STARTER. Using a 5⁄ ” Allen wrench, rotate
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service shops.
NOTE: The Allen-screw turns fairly tightly, and is self-locking.
Turning the screw clockwise adds fuel. Keep track of your
PUMP ADJUSTMENT PROCEDURE
adjustments.
NOTE: The engine must be COLD before starting this
Reassemble the governor spring assembly and guide stud
procedure.
(see Figure 18). Replace the sealing washer, available
NOTE: Utmost cleanliness should be exercised. Do NOT use from GM, if needed. Make sure the upper extension of the
any rags during the adjustment procedure. The lint from the metering valve spring rides atop the guide stud. Torque down
rag can clog an injector. Lay all parts on clean newspaper the guide stud snugly (85 inch-pounds).
during the adjustment procedure.
Using a syringe or similar means, remove as much
VERY IMPORTANT: 4a. diesel fuel as possible from the injector pump housing.
SPECIAL INSTRUCTIONS FOR INJECTOR PUMP ADJUSTMENT This will make it easier to view the Allen-head adjustment
ON LATE MODEL 6.2L ENGINES screw through the slot in the bottom of the pump housing
when it is rotated into position.
Late model (’89 and newer) 6.2L diesel engines may have a
plastic cap over the head of the guide stud. The position of Rotate the engine slowly by hand, IN A CLOCKWISE
the guide stud is pre-set at the factory, and should not be 5a. DIRECTION ONLY, using a breaker bar, a short
altered. On these models, adjust the pump as outlined in this extension and a 15/ ” socket on the vibration damper bolt
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section with the exception of step numbers 4, 5, 6, and 7. For to bring the Allen screw into view in the inspection slot in
these steps, follow the new step numbers: 4a, 5a, 6a, and 7a. the bottom of the pump bowl (see Figure 19). On some
late model trucks it may be necessary to remove the front
Make sure both battery ground cables are
1. disconnected. Disconnect the wiring from the top
crankshaft pulley to gain access to the vibration damper bolt
to turn the engine over. DO NOT ATTEMPT TO ROTATE THE
of the fuel injection pump cover. Note their location for
ENGINE WITH THE STARTER. The Allen head screw may be
reassembly.
hard to see — a flashlight or shop light may help. The screw
Place a drip pan under the rear of the engine to catch will have to be adjusted at an angle from under the guide
2. fuel. Clean the upper portion of the pump and guide stud/spring assembly.
stud (Allen-head bolt at the rear of the pump) with diesel
Using a 5⁄ ” ball-end style Allen wrench, rotate the
6a.
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NOT clean the pump while the engine is hot, as doing so may
fairly tightly, and is self-locking. Turning the screw clockwise
damage the pump.
adds fuel. Keep track of your adjustments.
Remove the fuel return line from the pump cover.
3. Remove the top attaching bolt and loosen the lower 7a. Go to step 8 and continue with pump reassembly.
attaching bolt on the fast solenoid and place the solenoid
Inspect the pump cover and make sure the seal is
14 8.
P.N. 96291 V.2.0
seated in the cover. Replace if questionable. Fill the pump NOT START THE ENGINE!! Remove the pump cover. Ground
bowl with clean diesel fuel. Hold the throttle in the idle the solenoid lead (opposite hot terminal on the cover) and
position. With the bolts removed from the pump cover, connect the pink wire to the cover terminal. With the ignition
position the cover about 1⁄ ” forward, toward the shaft end,
4 switch on, the solenoid in the cover should move the linkage.
and about 1⁄ ” above the pump. Guide the cover downward
8 If not, free the linkage or replace the solenoid. Reinstall the
and rearward into position, being careful not to damage the cover.
cover seal. Reinstall the bolts with the flat washers against
10. Reinstall the fuel return line and fast idle solenoid.
the pump cover.
Purge the air from the system as follows: Remove and
Reconnect battery cables. Turn the ignition switch 11. fill all filters with clean diesel and reinstall the filters.
9. to the “ON” position, and touch the pink solenoid
Detach all fuel supply hoses between the lift pump (fuel pump
wire to the solenoid terminal. A clicking noise should be in the side of the engine) and the injection pump at their
heard. If clicking is heard, proceed to next step. If not heard, highest ends, and fill them with clean diesel fuel using a small
the linkage may be jammed in the wide-open position. DO funnel. Reattach the hoses.
Figure 18
Figure 19
operating characteristics
Your BANKS turbocharged diesel engine should exhibit It is also important to understand that turbocharged
the following operating characteristics: boost pressures are load related, that is the
turbocharger makes boost only when called upon to
Cruise Conditions (constant 60mph on level road):
do so (by load requirements). The turbo will not “make
EGT should be approximately 400°F; boost gauge, if
boost” with the transmission in neutral, but makes
so equipped, should read 1 to 11⁄ pounds.
2