view - Banks Power

Owner’sManual
with Installation Instructions
Banks Power Pack®
System
Compatible with Banks iQ™
Including Stinger® System
and EconoMind
06-07 Dodge Cummins
5.9L Turbo-Diesel Pickups
THIS MANUAL IS FOR USE WITH SYSTEMS 63793, 63795 & 63817-63818
Gale Banks Engineering
546 Duggan Avenue • Azusa, ca 91702
(626) 969-9600 • Fax (626) 334-1743
Product Information & Sales: (888) 635-4565
Customer Support: (888) 839-5600
Installation Support: (888) 839-2700
bankspower.com
©2012 Gale Banks Engineering
09/20/12 PN 96822 v.4.0
Also Available from Banks Power
03-07 Dodge 5.9L
BigHead®
Wastegate
Monster
Exhaust
Banks iQ
Banks Bullet™
Banks Billet™
Torque Converter
DynaFact ®
Instrumentation
®
Monster-Ram
Advanced
Diesel Tuners
Banks Brake®
Banks Ram-Air ®
Intake
Techni-Cooler®
System
Super-Scoop®
Banks iQ System
(P/N 61148-61149)
- 5” touchscreen interface that can
control the Banks Diesel Tuner on
the fly.
- Interchangable gauge display, read
and clear codes, monitor engine
diagnostics, log data, time your
vehicles runs and much more.
Banks Monster® Exhaust System
Single (P/N 48640-48643, 48700,
48701, 48708)
Duals (P/N 48702-48707, 48709)
Sport (P/N 48777-48780)
- Increases exhaust flow, cuts
backpressure, lowers exhaust gas
temperatures (EGTs) and increases
power.
Banks Ram-Air Intake System
(P/N 42145)
- Increases your airflow over stock.
- Adds power, improves fuel
economy,
lowers EGTs and reduces smoke.
Banks Ram-Air Intake SuperScoop
(P/N 42190-42191)
- Adds cooler denser air to the
Ram-Air Intake housing, further
increasing fuel economy, reducing
smoke and lowers EGTs.
2
96822 v.3.0
Banks Monster-Ram
(P/N 42765-42766)
- Increased flow from intercooler
- Raises boost without increasing
backpressure at the turbine
Big Hoss Intake Manifold System
(P/N 42747)
- Increases flow and provides more
uniform air distribution to the
engine for more available power
at a given boost level.
Banks Exhaust Brake
(P/N 55222-55229)
- Increases the stopping power of
your truck and extends the
service life of your brakes
Banks SmartLock
(P/N 55270)
- Reduces wear on transmission
- Locks Torque Converter and
raises trans-line pressure
- Works with Banks Exhaust Brake
Boost and Pyro Gauges
(P/N 64507)
- Keep your engine safe by
monitoring vital engine
parameters.
Banks Billet Torque Converter
(P/N 72515)
- Higher torque capacity over stock
- Lockup clutch is slip-resistant so
transmission fluids stay cooler and
transmission life is prolonged.
Banks Bullet
(P/N 66522-66523)
- Adds power safely to your vehicle
- Displays critical engine functions
- Engine safeguards
- Change power levels on-the-fly
Banks Techni-Cooler® System
(P/N 25980-25981)
- Provides increased air flow to the
engine by increasing air density for
more increased power, lower EGTs
and improved fuel economy.
Thermocouple
- Add a temperature limiting function
to your Diesel Tuner .
Banks Speed-Loader
(P/N 62981)
- Furthers the power output of the
Banks Six-Gun and provides EGT
limiting safety.
Banks BigHead® Actuator
(P/N 24331)
- Achieves a higher peak boost over
stock and gives you precise
boost control that gives you crisp
acceleration and more mid-range
pulling power.
Banks Stinger Systems
(P/N 49692-49699, 49708-49711,
49716-49721)
Contains:
- Ram-Air Intake system
- Monster Exhaust (single or dual)
- EconoMind Tuner w/ Banks iQ
- Big Head Wastegate Actuator
Banks PowerPack Systems
(P/N 49700-49707, 49712-49715,
49722-49727)
Contains:
- Ram-Air Intake system
- Monster Exhaust (single or dual)
- EconoMind Tuner w/ Banks iQ
- Big Head Wastegate Actuator
- Monster-Ram
- Techni-Cooler System
Banks Six-Gun Bundle
(P/N 49728-49735, 49744-49747,
49752-49757)
Contains:
- Ram-Air Intake system
- Monster Exhaust (single or dual)
- Six-Gun Tuner w/ Banks iQ
- Big Head Wastegate Actuator
Banks Big Hoss Bundle
(P/N 49736-49743, 49748-49751,
49758-49763)
Contains:
- Ram-Air Intake system
- Monster Exhaust (single or dual)
- Six-Gun Tuner w/ Banks iQ
- Big Head Wastegate Actuator
- Monster-Ram
- Techni-Cooler System
For More Information please call (888) 635-4565
or Visit us online @ www.bankspower.com
96822 v.3.0
3
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 Installation Practices . . . 5
• Heat gun
Section 1 . . . . . . . . . . . . . . . . . . . . . . 6
Monster Exhaust System Installation
• Foot-pound torque wrench
• Penetrating oil or light lubricant
spray
• Reciprocating saw
• Inch-pound torque wrench
Section 2 . . . . . . . . . . . . . . . . . . . . . 13
Techni-Cooler Assembly Installation
Section 3 . . . . . . . . . . . . . . . . . . . . . 18
Thermocouple Installation
Section 4 . . . . . . . . . . . . . . . . . . . . . 19
Banks Ram-Air Filter Installation
Section 5 . . . . . . . . . . . . . . . . . . . . . 20
Banks EconoMind Diesel Tuner
Installation
Section 6 . . . . . . . . . . . . . . . . . . . . . 24
Mounting the Docking Station and
Connecting the Banks iQ
Section 7 . . . . . . . . . . . . . . . . . . . . 26
Power Selector Switch Installation
Section 8 . . . . . . . . . . . . . . . . . . . . . 29
Optional Gauge Cluster Installation
Section 9 . . . . . . . . . . . . . . . . . . . . . 30
Transmission Learnng
Section 10 . . . . . . . . . . . . . . . . . . . . 30
Troubleshooting, EconoMind
Section 11 . . . . . . . . . . . . . . . . . . . . 33
Clearing Learned Information
Section 12 . . . . . . . . . . . . . . . . . . . . 33
Removal of the EconoMind Diesel Tuner
Section 13 . . . . . . . . . . . . . . . . . . . . 34
Filter Maintance
Section 14 . . . . . . . . . . . . . . . . . . . . 34
Placement of the Banks Power Decals
4
96822 v.4.0
General Installation Practices
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. For ease of installation of your
Banks system, familiarize yourself
with the procedure by reading the
entire manual before starting work.
This manual contains 40 pages of
copy, illustrations and parts listing.
If any pages are missing from this
manual please call Gale Banks
Engineering immediately for a
replacement.
2. The exploded illustrations provide
only general guidance, Refer to each
and section diagram in this manual
for proper instructions.
3. Throughout this manual, the
left side of the vehicle refers to the
driver’s side, and the right side refers
to the passenger’s side of the vehicle.
4. Disconnect the ground cable from
the battery before beginning work. If
there are two batteries, disconnect
both.
5. Route and tie wires and hoses
9. Dual exhaust system only. The
6. During installation, keep the
10. Dual exhaust system only. The
7. When raising the vehicle, support
Warning: Below 32oF (0oC) or
above 140oF (60oC), the Banks iQ
may be susceptible to damage
as a result of extended direct
exposure to sunlight, heat
or extreme cold. It is highly
recommended that Banks iQ
be removed from its mounting
location if the vehicle will be
subjected to high concentrations
of sunlight, heat or cold for
an extended period of time.
Gale Banks Engineering is not
responsible for damage to Banks
iQ resulting from exposure
conditions.
a minimum of 6 inches away from
exhaust heat, moving parts and sharp
edges. Clearance of 8 inches or more
is recommended where possible.
work area clean. If foreign debris
is transferred to any Banks system
component, clean it thoroughly
before installing.
it on properly weight-rated safety
stands, ramps or a commercial hoist.
Follow the manufacturer’s safety
precautions. Take care to balance
the vehicle to prevent it from slipping
or falling. When using ramps, be
sure the front wheels are centered
squarely on the topsides; put the
transmission in park; set the parking
brake; and place blocks behind the
rear wheels.
Caution! Do not use floor jacks to
support the vehicle while working
under it. Do not raise the vehicle
onto concrete blocks, masonry
or any other item not intended
specifically for this use.
8. The Banks iQ displays a GREEN
indicator light when the battery is
fully charged. If an ORANGE light
is displayed the Banks iQ can be
charged with the supplied AC outlet
wall charger. Locate the supplied
AC-outlet wall charger, also located
in your kit and plug the charging cord
into the Banks iQ. Please refer to
the Banks iQ DashBoard PC Owner’s
Manual for additional instructions.
Dual Exhaust System is designed to
accommodate the factory sized spare
tire. If the spare tire is oversized, it
may need to be removed.
tip is located for single rear wheel
applications. Installation on dually
systems is not recommended.
Notification
The Banks Ram-Air Filter comes
pre-oiled and no oiling is
necessary for initial installation.
Service the filter as specified in
the Filter maintenance Section of
this manual.
96822 v.4.0
5
Section 1
Monster Exhaust System Installation
Figure 1a
General Assembly
Banks Monster Exhaust (Single)
Item Description
P/N
Qty
1
Banks Monster Muffler
532831
2
Tailpipe
532751
3
Tip, Tailpipe 5” Dual Wall
523831
4
Extension Pipe
532781
5
4” Exhaust Clamp
524702*
6
Front Muffler Hanger Clamp
532841
7
Rear Muffler Hanger Clamp
532861
*CCLB Models receive three 4”-clamps
5
4
1
6
5
6
96822 v.4.0
3
2
5
7
96822 v.4.0
7
Figure 1a
General Assembly
Banks Split Dual Monster Exhaust
Item Description
1
P/N
Monster Muffler
Qty
532851
2Y-Pipe
532871
3
Tail Pipe Right Passanger Side
53289
1
4
Tail Pipe Left Driver Side 53288
1
5
Extension Pipe Crew Cab Long Bed
53278
1
6
4” Exhaust Clamp
524702*
7
Front Hanger Clamp
532841
8
Rear Hanger Clamp
532861
9
3-1⁄ 2” Exhaust Clamp
524682
10
Rubber Insulator
537321
11
Frame Hanger Bracket
532901
12
7⁄ 16-20
916351
13
7⁄ 16”
14
2”x 2” Hanger Plate
532911
15
7⁄ 16-20
916191
16
Black 5” Cable Ties
x 4” Hex Bolt
SAE Washers
916012
Crimp lock Nuts
620013
*SCLB use one 4”-Clamp
6
8
5
1
7
6
8
96822 v.4.0
12
13
3
11
14
15
10
4
9
2
9
16
96822 v.4.0
9
1. Disconnect the battery ground
cables from each of the batteries.
Secure the cables so that they do
not come in contact with the battery
posts during the installation.
2. Raise the vehicle and support it
with properly weight rated safety
stands, ramps or a commercial hoist.
Follow the manufacturer’s safety
precautions. Take care to balance the
vehicle to prevent it from slipping or
falling. When using ramps, be sure the
front wheels are centered squarely on
the topsides; place the transmission in
park; set the parking brake and place
blocks behind the rear wheels.
CAUTION: DO NOT WORK UNDER
ANY VEHICLE SUPPORTED ONLY
BY A JACK. SEVERE INJURY MAY
RESULT.
WARNING! The following step
requires the use of a torch and/or
saw. Proper safety equipment
should be used. Failure to use
proper safety equipment may
result in severe injury.
3. Starting at the rear of the
vehicle, remove the tailpipe near the
muffler clamps by cutting through
the connection or by removing the
clamps and heating the joints with an
oxyacetylene torch to allow crimped
pipes to separate. Remove the tailpipe
from the vehicle.
4. Remove the clamps on the
catalytic converter to front muffler
or if applicable, the intermediate
pipe connection. TAKE CAUTION TO
NOT CUT OR DAMAGE CATALYTIC
CONVERTER TUBING. Separate the
muffler intermediate pipe to catalytic
converter connection.
Note, the use of an oxy-acetylene
torch may be necessary. Remove
the muffler hanger pins from the
rubber hangers with a pry bar (Spray
lubricant will ease hanger removal)
and remove the muffler/intermediate
pipe or muffler assembly from the
vehicle.
IMPORTANT: If the vehicle
is equipped with a catalytic
converter, it should be inspected.
Diesel catalysts may become
plugged with soot and can cause
a restriction to exhaust flow,
impeding performance. Shine a
powerful flashlight into the inlet
end of the converter. Observe
the light through the other end
of the converter. The full circle
of the flashlight should be visible
10
96822 v.4.0
without any blockage in the grid
work of the catalyst. If excessive
soot is observed, the catalyst
may need to be cleaned. TAKE
PRECAUTIONS to avoid blowing
soot toward the work area
or where it could be inhaled.
ALWAYS use breathing protection.
Also inspect the catalyst for
damage (i.e. chips, bent corners,
etc.) to the grid work. If your
catalytic converter is damaged,
it may be covered under your
vehicle’s emissions warranty.
5. For Crew Cab Long Bed & Mega
Cab models (160.5” wheelbase)
ONLY, install a 4” exhaust clamp onto
the front of the Banks intermediate
pipe. Install the intermediate pipe
onto the catalytic converter outlet.
Install the intermediate pipe hanger
onto the corresponding rubber
hanger. Loosely snug the 4” clamp.
6. For all models, install the Banks
front muffler hanger clamp (single
pin) onto the Monster muffler inlet.
Also install a 4” exhaust clamp onto
the muffler inlet. Install the muffler
inlet (see markings on muffler body)
onto the Banks intermediate pipe /
catalytic converter. Orient the muffler
such that the “Banks Monster” logo is
facing towards the frame and is level
with the ground. Install the hanger
clamp pin into the corresponding
rubber hanger with the hanger pins
facing forward (see Figure 2). With
the muffler inlet fully inserted, loosely
tighten the 4” exhaust clamp on the
muffler inlet swedge.
NOTE: Once the pipe has been
completely engaged in the slip
joint, it should be marked with a
marker, scribe or tape for reference
when tightening clamps later in the
installation. Each slip joint in the
Figure 2
system should be marked in this
fashion. When the exhaust system is
being adjusted to align the hangers,
the slip joints can be adjusted so that
the reference mark is no more than
1⁄ 4” away from its original position.
Step 7 thru 11 for single exhaust
Step 12 thru 23 for split dual
Single exhaust
7. Install a 4” exhaust clamp on the
muffler outlet. Adjust the hanger
clamp to a position that best supports
the muffler.
8. Route the tailpipe over the rear
axle housing and into the muffler
outlet. Install the tailpipe hanger pin
into the corresponding rubber hanger.
Loosely snug the 4” clamp on the
muffler outlet.
9. Install the 5” Monster tailpipe tip
on the exhaust. Keep the wrapping
on until installation is complete. The
tip should be rotated so the drain
hole is facing down. Adjust the tip
past the edge of the body or where
aesthetically pleasing.
10. With everything positioned
properly, begin to tighten the clamps
starting with the ones closest to the
turbo and working your way back.
Evenly torque the exhaust clamps to
35 ft-lbs. Make sure that each slip is
fully inserted (+/- 1⁄ 4 inch).
Note: Whenever possible, tack
weld slip connections to prevent
disengagement is recommended.
11. Remove the protective covering
from the tailpipe tip. Caution: The
protective covering may ignite and
burn if not removed prior to running
the engine.
Proceed to Section 2.
Spilt Dual Exhaust
Figure 3
Y-PIPE
12. Install the rear muffler hanger
clamp with the two pins facing
forward onto the muffler outlet.
Insert the two hanger pins into the
vehicle’s corresponding rubber
hangers.
PASSENGER
SIDE
TAILPIPE
13. Install the Banks Y-pipe into the
muffler outlet such that the outlets
are pointing up. Install two (2) 3-1⁄ 2”
saddle clamps onto each y-pipe
outlet (see Figure 3).
DRIVER SIDE
TAILPIPE
3.5”
CLAMP
14. Install the Banks hanger bracket
REAR
ORIENTATION OF
HANGER CLAMP MONSTER MUFFLER
4“
FRONT CLAMP
HANGER
INTERM
CLAMP
PIPE
FORWARD
Figure 4
DRIVER SIDE
FRAME
15. Install the supplied rubber
HANGER
BRACKET
hanger onto the Banks hanger
bracket.
16. Install the driver-side tailpipe
7/16” BOLT
& WASHER
7/16”
NUT &
WASHER
onto the rear of the driver-side frame
rail. Behind the rear shock cross
member, place the hanger bracket
over the frame rail on the inside.
Align the hole in the center of the
frame with the hanger bracket. Install
the 7⁄ 16 ”x 4” & washer through the
bracket and frame rail. Secure the
bolt on the outside frame rail using
the 2”x2” plate, washer and 7⁄ 16”
nut. Be sure the hanger pin is parallel
with the frame rail and torque 7⁄ 16”
hardware to 48 ft-lb (see Figure 4).
into the top Y-pipe outlet. Install the
driver-side tailpipe hanger into the
vehicle rubber hanger.
17. Install the passenger-side
tailpipe into the lower Y-pipe outlet.
Install the passenger-side tailpipe
hanger into the vehicle rubber
hanger.
2“ X 2”
PLATE
SPARE
TIRE
DRIVER SIDE
TAILPIPE
96822 v.4.0
11
18. Move the spare-tire to the rear
of the vehicle and center between
the dual tailpipes. Tighten the spare
tire with the manufacture tire tool
so that it is retained into place (See
Figure 5).
19. Un-clip the axle vent hose outlet
attached to the bed near the spare
tire. Re-route the vent hose on top of
the fuel tank and attach to the bed.
Zip tie the vent hose and brake line
to the emergency brake cable, away
from the tailpipe.
20. Adjust each of the pipes to
ensure that all of the hanger pins
are parallel with the frame-mounted
pins and fully inserted in the vehicle’s
rubber hangers.
21. Be sure that the two (2) tailpipes
are completely engaged into the
Y-pipe. Rotate the tailpipe until the
hanger pins are parallel with the
frame-mounted pin.
NOTE: Recommended distance
between exhaust tip and body is a
half (1⁄ 2”) inch.
22. Beginning with clamps closest
to the catalytic converter, and
working your way back, align the
saddle clamps to on the radius of
the corresponding pipe slots. Figure
3 illustrates the proper location of
an exhaust clamp on a tubing joint.
Evenly torque the nuts on each of the
exhaust clamps to 35 ft-lb.
Note: Whenever possible, tack
weld slip connections to prevent
disengagement is recommended.
23. Remove the protective covering
from the tailpipe tip. Caution: the
protective covering may ignite
and burn if not removed prior to
running the engine.
-end, section 1-
12
96822 v.4.0
Figure 5
ADJUST SO THAT
SPARE TIRE TO
TAILPIPE CLEARANCE
IS THE SAME
MOVE SPARE
TIRE TOWARDS
REAR OF
VEHICLE
BANKS
DRIVER SIDE
TAILPIPE
ZIP TIE ON
VENT HOSE
& BRAKE LINE
BANKS
PASSENGER SIDE
TAILPIPE
Section 2
Techni-Cooler Assembly Installation
Figure 6
Banks Techni-Cooler
General Assembly
Item Description
P/N
Qty
Item Description
P/N
Qty
1
TECHNI-COOLER ASSEMBLY
255381
13
GROUND STRAP INTAKE HEATER 621821
2
BOOST TUBE LEFT
413321
14
Bracket, L-Lower, Techni-Cooler
255411
3
BOOST TUBE RIGHT 413311
15
Bracket, L-Upper, Techni-Cooler
255421
4
HOSE 3.5” X 3.25” BLACK
942151
16
Bracket, R-Lower, Techni-Cooler
255431
5
HOSE, COMPressor OUT 2.75 X 3.25
942771
17
Bracket, R-Upper, Techni-Cooler
5⁄ 16”-18
255441
1⁄ 2”
6
HUMP HOSE 3.5” X 3.25” BLACK
942932
18
Cap Screw, Button Head,
7
HIGH-RAM INTAKE MANIFOLD
427431
19
HEX BOLT, 8mm-1.25 x 16mm
918121
8
GASKET, High-ram intake
930232
20
NUT, HEX, M6 X 1.0, ZINC
917701
9
STUD, HIGH-RAM INTAKE
5⁄ 16”-24
915322
21
Washer, Thread Sealing 5⁄ 16”
912092
10
STUD, HIGH-RAM INTAKE
5⁄ 16”-24
915332
22
NUT, NYLOCK
11
HOSE CLAMP 2.75” SPRNG LOADED 928932
23
WASHERS, FLAT, ZINC
917002
12
HOSE CLAMP 3.5” SPRING LOADED 928976
24
WASHER, AN, S/S
912019
X 8MM 1.25 X 7.30
X 8MM 1.25 X 7.86
5⁄ 16”-24
x
912224
912114
96822 v.4.0
13
Note: For installation of the
Banks Stinger System proceed to
Section 3.
15. Remove the 4 hex head bolts
1. Disconnect the Inlet Air
16. Swing the A/C condenser
Temperature/ Pressure Sensor
connector located on the air box
cover. The connector is shown in
Figure 7.
2. Remove the nut that fastens the
air filter housing to the radiator cross
brace.
3. Loosen the hose clamp that
secures the air inlet duct to the
turbocharger inlet. Disconnect the
inlet duct from the turbocharger.
4. Remove the air box and inlet
duct as an assembly. The air box is
held in place with re-usable pushin fasteners and can be pulled out
vertically.
that attach the A/C condenser
mounting brackets to the CAC.
upward as shown in Figure 9, then
out away from the vehicle as shown
in Figure 10.
Caution: Minimize the amount of
stress to the A/C condenser fluid
lines to prevent damage.
engine oil dipstick to the intake. Save
the bolt for re-use.
8. Remove the electric heater wire
11. Remove the two upper radiator
attachment bolts.
13. Remove the two upper CAC
attachment bolts.
14. Remove the 4 bolts (2 per
side) that retain the upper radiator
cross brace, then remove the upper
radiator cross brace. The brace is
shown in Figure 8.
14
96822 v.4.0
in the vehicle.
from the condenser, retain the torx
head bolts for reassembly.
22. Place the A/C condenser back in
Figure 7. Location of the Inlet Air Temp/ Pressure Sensor
7. Remove the bolt that holds the
tube.
20. Install the Banks Techni-Cooler
front of the Techni-Cooler.
vehicle.
outlet with a clean rag to prevent
foreign debris from entering these
locations.
10. Remove the driver side boost
isolators from the stock CAC and
install them on the Banks TechniCooler.
17. Remove the stock CAC from the
6. Cover the turbocharger inlet and
at the base of the stock intake.
Remove the stock intake from the
vehicle. Cover the intake manifold
opening with a clean rag to prevent
any foreign debris from entering the
engine through the heater block.
19. Remove the upper rubber
21. Remove all factory brackets
boost tube. The boost tubes are the
charge air ducting that route air from
the turbocharger to the Charge Air
Cooler (CAC) and from the CAC to
the intake manifold.
9. Unbolt and remove the 4 bolts
rubber bushings from the stock CAC
and install them on the Banks TechniCooler.
An assistant could be helpful to hold
the A/C condenser while the stock
CAC is being removed and the Banks
Techni-Cooler is being installed.
5. Remove the passenger side
harness from the stock intake by
pulling the plastic pin out. Remove
the wire harness brackets that are
mounted on the intake by removing
the nut and washer.
18. Remove the lower saddle mount
Figure 8. Upper radiator cross brace
23. Install the R.U. and L.U.
brackets onto the condenser and
assemble the condenser to the banks
intercooler using the 5⁄ 16” button
head bolts and washers provided.
Install the R.L and L.L brackets
onto the condenser such that the
intercooler boss and condenser holes
align. (see Figure 11).
Note: The Banks condenser brackets
are stamped such that “R.U.” means
Right (Passenger Side) Upper and
that the “R.U.” is visible when the
condenser is installed.
24. Tighten the 5⁄ 16” bolts at each
of the A/C mounting brackets and
torque to 19 ft-lbs.
25. Tighten the torx head bolts on
both of the lower and the upper A/C
mounting brackets.
26. Install the upper radiator cross
brace. Leave the bolts loose to aid in
the alignment of the cross brace with
the radiator and Techni-Cooler.
27. Loosely install the upper CAC
mounting bolts.
Figure 9. A/C condenser removal procedure
28. Loosely install the upper radiator
mounting bolts.
29. Tighten the radiator cross brace
bolts and torque to 21 ft-lbs
30. Tighten the upper CAC mounting
bolts and torque to 8 ft-lbs (96 in-lbs).
31. Tighten the upper radiator
mounting bolts and torque to 8 ft-lbs
(96 in-lbs).
32. Install the passenger side boost
tube. The passenger side uses a 2.75
inch diameter straight hose at the
turbocharger connection, and a 3.5
inch diameter hump hose at the CAC
connection. The orientation of the
hose clamps should be as shown in
Figure 12 to avoid clearance issues.
Do not install the straight hose onto
the turbocharger, and keep the hose
clamps at the CAC connection loose
until the thermocouple is installed in
Section 3. Cover the opening of the
boost tube to prevent foreign objects
from entering the boost tube during
the installation.
NOTE: Before slipping any boost
tubes and the corresponding
hoses, into position, ensure that all
connection ends are clean and free
of any oil residue and contaminates.
Clean compressor outlet and all
connection points with a non-oil
based solvent such as Acetone,
Mineral Spirits, Denatured Alcohol or
Lacquer Thinner. Read and follow the
manufactures operation instruction
for non-oil based solvent cleaner.
Figure 10. A/C condenser removal procedure
33. Install the driver side boost
tube. The driver side tube uses a
3.5 inch diameter straight hose at
the intake manifold and a 3.5 inch
diameter hump hose at the CAC.
96822 v.4.0
15
Figure 11. Relocation of the upper driver side A/C condenser mounting bracket
The orientation of the hose clamps
should be as shown in Figure 13
to avoid clearance issues. Keep the
hose clamps loose until the High Ram
is installed. Cover the opening of the
boost tube to prevent foreign objects
from entering the boost tube during
the installation.
34. Remove the three wires on the
electric heater block at the intake
manifold, then remove the heater
block. Save the fasteners for re-use.
Caution: Cover the opening in the
intake manifold with a clean rag
to prevent foreign objects from
entering the engine.
35. Completely remove the stock
gaskets from both sides of the heater
block and intake manifold. Take care
not to scratch or gouge any of these
surfaces when removing the gasket
material.
Figure 12. Orientation of the passenger side hose clamps to avoid clearance issues.
36. Remove the rag that was used
to cover the intake. Reinstall the
electric heater block onto the intake
manifold with one of the supplied
gaskets. Reattach the three electrical
connections to the heater element.
37. Caution: The High Ram studs
have different threads on each
end. Make sure the M8 ends go
into the engine intake manifold.
The shorter studs are placed inboard
closest to the valve cover. Apply the
supplied thread locking compound
to the M8 threaded end of the studs.
Hand tighten the studs to the intake
manifold.
38. Using the two 5⁄ 16”-24 nuts
supplied, tighten the studs into
the intake by threading both nuts
onto the stud, then tighten the nuts
against each other with two 1⁄ 2” open
end wrenches. Tighten and torque
the stud to 2 ft-lbs by turning the top
nut. Remove the nuts from the stud
by using two open-end wrenches to
loosen the nuts in relation to each
other. Repeat the process for each
stud. The process
is shown in Figure 14.
16
96822 v.4.0
Figure 13. Orientation of the hose clamps on the driver side.
Figure 14. High-Ram stud installation.
/
12
39. If your vehicle is NOT equipped
FACTORY NUTS
GROUND STRAP
LARGER
DIAMETER
TERMINAL
Figure 15. Exploded view of the High-Ram assembly
INTAKE HEATER
M6 NUT & M6
WASHERS (2)
M8 X 1.25 BOLT
SAE WASHER
with a factory ground strap on the
intake heater, install the supplied
ground strap from the intake heater
to the engine. Put a 6-mm washer
onto the bottom intake heater
stud, leaving the factory heater nut
installed. Next, install the smaller
diameter ground strap terminal over
the stud and retain with a 6-mm
washer and nut. Route the other end
of the ground strap to the threaded
section on the engine and retain with
a SAE washer and M8- 1.25x 16 bolt.
See Figure 14.
40. Slide the supplied intake gasket
over the four studs, then slide the
High-Ram over the studs.
41. Install the supplied Stat-O-Seal
washers on the two driver side
(longer) studs. Driver side studs are
longer than passenger side studs.
The washers should be installed in
a twisting motion to prevent tearing
their sealing element. Install the
supplied 5⁄ 16” flat washer on all
studs, then fasten with the supplied
5⁄ 16-24 nylock nuts. The nuts should
be tightened to 12 ft-lbs (144 in-lbs).
An exploded view of the High-Ram
assembly is shown in Figure 15.
42. Gently bend the engine oil
dipstick tube to it’s mounting location
on the High Ram as shown in Figure
15. Secure the dipstick tube with
the factory bolt that was previously
removed.
43. Remove rag that was used to
cover the boost tube opening. Make
the connection between the driver
side boost tube and the High-Ram.
Tighten all the driver side hose
clamps to 5 ft-lbs (60 in-lbs).
-end, section 2-
96822 v.4.0
17
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 outlet of the manifold
adjacent to the turbine housing.
For this reason it is essential that
the turbocharger be removed from
the engine in order to clean out any
metal chips from drilling that could
cause turbine blade damage.
NOTE: The Cummins ISB engine uses
a divided exhaust manifold. The
thermocouple may be installed to
sample exhaust temperature in either
exhaust passage. We recommend the
rear passage (toward the firewall).
2. If not already done, remove the
factory air intake system as described
in Section 2 Steps 1-4.
3. Loosen the upper hose clamp on
the turbocharger oil drain-tube hose
that is located between the two
sections of the oil drain tube.
4. Disconnect the oil supply hose
at the turbocharger. Disconnect the
compressor outlet hose that goes to
the intercooler.
5. Disconnect the turbine outlet pipe
by loosening the V-band. Save V-band
for re-installation.
6. Remove the turbocharger
mounting nuts/bolts and the
turbocharger from the exhaust
manifold. Clean and inspect the
Figure 16
exhaust flange mounting surfaces on
the exhaust manifold. Make sure the
surface is clean and dry.
CAUTION: Anytime the
turbocharger is removed from
the engine, take care that no
foreign objects enter any of the
turbocharger connections on
the engine or the turbocharger.
Foreign objects entering air,
exhaust, or oil connections may
cause major damage to the engine
and/or turbocharger and is not
covered under any warranty.
Cover the open end of the
intercooler pipe with a clean rag,
as this pipe is very susceptible to
foreign object entry.
7. Stuff clean shop towels into the
compressor outlet and inlet hoses
to prevent contamination from
entering the pipes. Cover the turbo oil
drainpipe to avoid contamination.
8. Stuff a small clean shop towel
or rag 4 to 5 inches into the rear
exhaust manifold passage through
the turbocharger mounting flange.
This is to prevent chips from entering
the manifold while drilling and
tapping.
9. Use a 7⁄ 16” drill, keeping the drill
perpendicular to the manifold surface
and drill through the exhaust manifold
into the rear passage as shown in
Figure 16.
10. Tap the drilled hole with a 1⁄ 4”
NPT pipe tap. Check the thread
depth as you tap by periodically
removing the tap and screwing the
pipe coupling into the tapped hole.
The coupling should thread in 3 to 3
1⁄ 2 turns hand tight. Do not install the
probe in place at this time.
11. Remove all loose chips from the
exhaust manifold. A shop vacuum or
small brush will help. Now remove
the rag using a welding rod or coat
hanger bent into a hook.
Caution! Make sure rags are
removed from exhaust manifold
prior to reinstalling turbocharger!
12. Install the pipe coupling into
the manifold using anti-seize on the
threads. Install the thermocouple and
tighten.
CAUTION: Remove all the rags that
are inside the compressor outlet
and inlet hoses and the exhaust
manifold before re-installing the
turbocharger.
13. Install the new turbine inlet
gasket provided and apply a dab
of anti-seize compound to the
four turbo mounting studs. Install
the turbocharger on the exhaust
manifold. As the turbocharger is
reinstalled, slip the oil drain tube
into the drain hose. Tighten the
turbocharger mounting nuts to 24
ft-lbs. Tighten the oil drain hose
clamp.
14. Reconnect and tighten the turbo
oil supply hose.
15. Reconnect the turbine outlet
pipe to the turbocharger and secure it
with the V-band.
16. Re-install the air box and inlet
tube assembly. Secure the air box
at the radiator cross brace with
the factory nut that was previously
removed. Re-connect the Air Inlet
Temperature/ Pressure sensor at the
air box cover. Re-connect the air inlet
duct to the turbocharger inlet. Tighten
the hose clamp at the turbocharger
inlet to 8 ft-lbs (96 in-lbs).
17. Re-connect the compressor
outlet hose that goes to the
intercooler and tighten all hose
clamps to 5 ft-lbs.
-END, SECTION 3-
18
96822 v.4.0
Section 4
Banks Ram-Air Filter Installation
Notification
The Banks Ram-Air Filter comes
pre-oiled and no oiling is
necessary for initial installation.
Service the filter as specified in
the Filter maintenance Section of
this manual.
1. Locate the engine air filter box on
the passenger’s side of the vehicle.
Remove the cover by releasing
the four (4) clips on the side of the
housing and slide the cover toward
the engine.
2. Remove the old air filter element
from the filter housing and replace
it with the Banks Ram-Air filter
element. Place the Banks filter
element in the right orientation
and check the filter seal is seating
properly around the housing to
ensure no leakage.
3. Slide the tabs on the cover into
the slots on the air filter box. Press
the cover down gently and re-attach
the four (4) clips on the side to
securely clamp the cover.
-end, section 4-
Figure 17 EconoMind and supplied wiring harnesses
96822 v.4.0
19
Section 5
Banks EconoMind Diesel Tuner Installation
1. Place the EconoMind Diesel
Figure 18
Tuner box on top of the fuse box
located in the left front side in the
engine compartment. See Figure
18. The in-cab cable with the three
small connectors will be routed into
the cabin via the grommet on the
firewall. The other two harnesses
will be routed under the intake to
their respective locations listed in the
following steps.
2. Locate the rubber grommet on
the drivers side firewall. Using a
utility knife, make a 1.5-inch-long
slit in the grommet next to the wire
harness. Be careful not to cut or
damage the harness. See Figure
19 for the proper location of the
required cut. Insert a screwdriver
from the engine compartment into
the cut hole and gently thrust it
through the grommet.
3. Inside the vehicle, remove the
Figure 19
lower dash panel beneath the
steering column by removing the
two (2) screws at the bottom of
the panel. Retain the screws for
reinstallation.
NOTE: There are also two (2) clips
located at the top corners of the
panel, which hold the panel in place.
These clips can be released by gently
pulling on the corners of the panel.
Use caution to avoid damaging the
panel during removal.
4. Remove the electrical connector
bracket on the left hand side of the
support below the steering column
in front of the firewall by removing
the two (2) bolts. This will allow
access to the inner grommet. See
Figure 20.
5. Cut the grommet on the firewall
inside the vehicle along the hole
created by the screwdriver in Step
2.
6. Locate the in-cab cable with the
three connectors. From the engine
compartment, push the in-cab cable
through the hole cut in the firewall
grommet.
NOTE: Taping the end of the cable to
a piece of stiff wire (i.e. coat hanger)
may make routing the cable through
the firewall a simpler task. The stiff
wire should be pushed through the
slit in the grommet and then the
wires can be attached to the stiff
wire and pulled through the hole in
the grommet.
20
96822 v.4.0
Figure 20
Figure 21
CAUTION: Pull gently to avoid
damage to the cable connectors.
Always pull on the cable sheath
rather than the wires themselves.
7. From inside the vehicle, continue
to pull the in-cab cable through the
firewall until it is approximately 22”
inside the cab. Secure the cable
to the lower access panel area.
Take precaution to leave the three
connectors accessible for usage
further in the installation process.
8. Locate the OBD II connector and
remove it from the sheet metal panel
by pressing the outer tabs in. Now,
push the connector out. See Figure
21.
Figure 22
9. Locate the Banks OBDII Interface
Cable and 11” cable tie in your kit.
Connect the OBDII Interface Cable to
the vehicle OBDII connector. Use the
11” cable tie as shown in Figure 22
to secure the Banks interface cable
to the vehicle OBDII connector. Now,
connect the 8-pin connector from the
Banks OBDII Interface Cable to the
8-pin connector on the EconoMind
Tuner in-cab cable.
Note: If you are not installing the
optional Banks IQ then coil up and
secure the cable with the RJ12
(telephone style) connector end.
10. In the engine compartment find
Figure 23
the Fuel Rail Pressure (FRP) sensor
on the fuel rail. It is located on the
drivers side of the engine. Unplug
the factory connector and plug it
into the corresponding male FRP
sensor connector on the EconoMind
harness. Plug the EconoMind’s
female FRP sensor connector into the
sensor. See Figure 23.
11. Locate the Manifold Pressure
(MAP) sensor on top of the intake
manifold. Unplug the factory
connector and plug it into the
corresponding male MAP sensor
connector on the EconoMind
harness. Plug the EconoMind’s
female MAP sensor connector into
the sensor. See Figure 23.
96822 v.4.0
21
Figure 24
CAUTION: The Camshaft Position
(CMP) sensor and the Crankshaft
Position (CKP) sensor have the
same type of connectors and
they are in close proximity to
one another. Make sure the
right connectors are used when
installing these connections.
Refer to Figure 24 for their
locations on the EconoMind
Diesel Tuner wire harness.
12. Locate the Crankshaft Position
(CKP) sensor on the lower front left
side of the engine. It is behind the
engine crankshaft pulley (engine
harmonic balancer). Unplug the
factory connector and plug it into
the corresponding male CKP sensor
connector on the EconoMind
harness. Plug the EconoMind’s
female CKP sensor connector into
the sensor. Take care to route the
wire harness away from the power
steering pump pulley and secure
it with the supplied cable ties. See
Figure 25.
Figure 25
13. Locate the Camshaft Position
(CMP) sensor below the fuel
injection pump between the timing
gear cover and the ECM. Unplug
the factory connector and plug it
into the corresponding male CMP
sensor connector on the EconoMind
harness. Plug the EconoMind’s
female CMP sensor connector into
the sensor. See Figure 26.
Figure 26
22
96822 v.4.0
Figure 27
14. Remove the fuse box cover,
located in left front side of the engine
compartment. Locate the mini-fuse
#28 and remove it. Install the miniauto blade tap onto the removed
mini fuse as shown in Figure 27.
Re-install the mini fuse with the
attached blade tap into location #28
as shown in Figure 28. Plug in the
terminal to the mini-auto blade.
Note: Install the mini-auto blade tap on
the terminal leg closest to the engine.
This is the “hot” side of the circuit.
Figure 28
Caution: It is very important that
you select the proper fuse. The
Banks EconoMind Diesel Tuner
will not function properly if
installed incorrectly.
15. Connect the Red and Yellow
thermocouple wires on the
EconoMind wire harness with the
Red and Yellow lead wires on the
thermocouple.
Note: Go over the entire installation as
a precautionary check to ensure that
all clamps are tight, wiring and hoses
are properly routed, and connections
are correct and tight. Make sure that
the EconoMind wire harness is not
lying in the way of the brake and gas
pedals, or any moving parts.
16. Make sure the fuse box cover
surface is clean and free of dirt and
oil before mounting the EconoMind
Diesel Tuner. Clean and dry as
required using a cloth dampened
with rubbing alcohol or a similar
cleaning solution.
CAUTION: Do not spray fluid
directly onto any electrical
equipment, or equipment damage
may result. Mount the EconoMind
Diesel Tuner on the top of the
fuse box cover as shown in Figure
1, by peeling the protective
backing off the adhesive tape on
the back of the EconoMind Diesel
Tuner.
17. Hold the EconoMind Tuner
against the fuse box cover for
approximately 1 minute while applying
pressure to allow the adhesive to
properly adhere to the surface.
-end, section 5-
96822 v.4.0
23
Section 6
Mounting and Connecting the Banks iQ
If not installing the optional Banks
iQ, skip to Section 7.
6. Next, remove and set the side
WARNING: Below 32oF (0oC) or
above 140oF (60oC), the Banks iQ
may be susceptible to damage
as a result of extended direct
exposure to sunlight, heat
or extreme cold. It is highly
recommended that the Banks iQ
be removed from its mounting
location if the vehicle will be
subjected to high concentrations
of sunlight, heat or cold for
an extended period of time.
Gale Banks Engineering is not
responsible for damage to Banks
iQ resulting from exposure
conditions.
7. Locate the RJ12 Cable (similar
dash access panel aside.
to telephone connector) previously
secured behind the knee panel.
Remove the knee panel to gain
access to the RJ12 cable. See Figure
32.
8. Locate Banks iQ Bridge Module and
connect the RJ12 connector into the
bridge module. See Figure 33.
Figure 30
9. Route the Banks iQ USB interface
cable from the Banks iQ bridge
module under the dash and out
through the side access panel
opening. The cable can be slid under
the door frame’s seal and run up
to the top of the dash. Pull enough
cable to reach the Banks iQ and
connect it to the USB receptacle on
the left side of Banks iQ. See Figure
31. Snap the side access panel back
in place making sure not to pinch the
wire.
Attaching Banks iQ to window mount
CAUTION: Do not use force when
working on plastic parts. Permanent
damage to the part might result.
1. Locate the Window Mount
Assembly in your kit.
2. Assemble the Banks iQ docking
station to the Universal mount by
inserting and sliding the Universal
mount tab into the docking station
groove. Hand tighten the nut behind
the docking station to hold the
docking station in place.
3. Attach the window mount to your
Banks iQ. See Figure 30. Align and
place the two (2) lower tabs on the
window mount to the corresponding
slots on the bottom of Banks iQ first
then snap the top of Banks iQ into
place.
Note: There may be a snug fit when
installing the Banks iQ into the window
mount. Take care not to force this
process.
4. Find a suitable place on the
windshield for ease of access and
viewing of Banks iQ. Use location
shown in Figure 31 as a reference
for mounting Banks iQ in your
vehicle. Loosen the knob and move
the swivel suction plate to achieve
desired viewing angle of the Banks
iQ screen. Do a test fit and note
the angle necessary to achieve the
correct viewing angle.
5. Make sure the suction cup and
the mounting area on the windshield
are clean and dry. With the suction
lever in the up position, ensure
the suction cup is flat against the
windshield, and then push the
suction lever down to secure in
place.
24
96822 v.4.0
Figure 31
Mounting location for Banks iQ
Figure 32 Banks iQ System
WARNING: THE CHARGING CABLE
CONNECTED TO THE BANKS
iQ IS DESIGNED TO SUPPLY
A CONSTANT LOW-VOLTAGE
POWER SOURCE (+5VDC) TO
THE BANKS iQ AND IS “LIVE”
AS LONG AS THE SYSTEM’S
OBD II INTERFACE CABLE OR
BANKS WIRING HARNESS IS
COMPLETELY INSTALLED AND
THE USB CABLE CONNECTOR
IS PLUGGED INTO BANKS iQ.
ALTHOUGH THIS CHARGING CABLE
IS SHORT AND ITS CIRCUITRY IS
FUSE-PROTECTED, THE USER IS
EXPECTED TO TAKE APPROPRIATE
MEASURES TO PREVENT SMALL
CHILDREN AND/OR PETS FROM
CONTACT WITH ANY PART OF THIS
SYSTEM.
10. Secure Banks iQ bridge module
Figure 33 Banks Bridge Module
under the dash to any dash frame
support using the supplied cable ties.
Use the cable tie support loops on the
side of the bridge module to securely
fasten it under the dash.
11. Route all wiring away from any
pedals or other moving components.
Using the cable ties supplied, secure
the wiring under the dash.
12. Reinstall the lower knee panel
back in place with the factory
hardware. Tuck any excess cable
behind it for a clean appearance.
-END, SECTION 6-
96822 v.4.0
25
Section 7
Power Selector Switch Installation
Figure 34
Installation not needed if optional
Banks iQ is installed.
Caution: Do not use force
when working on plastic parts.
Permanent damage to the part
might result.
Two holes must be drilled into the
instrument cluster bezel that will
require the removal of the instrument
cluster bezel, cup holder / storage
tray, vertical panel and instrument
panel center bezel. Alternatively,
two holes can be drilled with the
instrument cluster still in place if a
right angle drill and 1⁄8 Uni-drill bit is
used.
• Step 1 thru 9 to install the power
level selector switch on the
instrument cluster bezel without a
right angle drill.
• Step 10 thru 14 to install the
power level selector switch on the
instrument cluster bezel using a
right angle drill.
• Step 15 thru 18 to install the
power level selector switch in the
accessory switch cutout.
Note: Some vehicles are equipped
with an electric pedal adjustment
switch. If your vehicle is equipped
with this switch then do not install
the Banks power level selector
switch in this location.
• Step 19 thru 21 to install power
level selector switch in location of
your choice.
Drilling Instrument Cluster Bezel
without a right angle dill Step 1
thru 9.
1. Remove the screws and unclip the
knee dash panel located under the
steering wheel and set aside.
2. Remove the cup holder / storage
tray. The screws are located under
the rubber inserts. Remove the
rubber inserts then remove the
screws and set the cup holder /
storage tray aside. See Figure 35.
3. Remove the screws to the
remainder of the cup holder / storage
tray and set aside.
NOTE: The cup holder / storage tray
is a two-piece item.
4. Remove the screws to the vertical
panel directly beneath the instrument
panel center bezel then remove the
vertical panel and set aside.
5. Remove the instrument panel
center bezel screw.
26
96822 v.4.0
Figure 35
Figure 36
NOTE: Only the left corner of
the instrument cluster bezel will
be unclipped and lifted off the
instrument panel. The right side of
the instrument cluster bezel will
be attached with screws that are
not accessible for removal unless
additional steps are taken to remove
them.
13. Obtain a piece of sheet metal or
similar material.
14. Place the piece of sheet metal
behind the instrument cluster bezel
as shown in Figure 36.
Note: The piece of sheet metal is
intended to be used as a safety
barrier in the prevention of over
drilling.
15. Skip to Step 23 to continue.
Installing the Power Level
Selector Switch in the accessory
cutout panel.
Figure 37 Power level selector switch, orientation of the tab on the washer
16. Remove the screws and unclip
the knee dash panel located under
the steering wheel and set aside.
17. Remove the accessory cutout by
pressing the retaining tabs located
on the backside of the part and set
aside.
18. Cut out the supplied template
(see Figure 38-B) and align the
template onto the front of the
accessory cutout by centering it
to the part. Use masking tape to
securely hold down the template.
NOTE: Do not tape over the markings
on the template.
19. Skip to Step 24 to continue.
Installing power level selector
switch in custom location.
6. Remove the instrument panel
center bezel by unclipping the
retainer clips that secure the
instrument panel center bezel to the
instrument panel.
Note: The instrument panel center
bezel can be unclipped by prying with
your fingers on a corner. Avoid using
metal tools to pry off the instrument
panel center bezel or cosmetic
damage may occur.
7. Remove the screws that secure
the instrument cluster bezel then
unclip the instrument center bezel by
prying off with your fingers.
8. Remove the instrument cluster
bezel and set aside.
9. Skip to Step 23 to continue.
Alternate Method- Drilling
Instrument Cluster Bezel Using a
Right Angle Drill
10. Remove the screws and unclip
the knee dash panel located under
the steering wheel and set aside.
11. Remove the (3) screws at the
bottom of the instrument cluster
bezel.
12. Gently pry on the upper left
corner of the instrument cluster
bezel and unclip the left corner only.
CAUTION: Make sure that that
area of your choice can be
drilled without damaging any
components located behind the
surface. Remove panel as needed
to ensure no drilling interference.
20. Locate an area of your choice
where you would like to install the
power level selector switch.
21. Cut out the supplied template
(see Figure 38-B) and align the
template onto the front of the area of
your choice. Note: use the template
to align hole to be drilled. Use
masking tape to securely hold down
the template.
96822 v.4.0
27
NOTE: Do not tape over the markings
on the template.
22. Skip to Step 24 to continue.
23. Cut out the supplied template
(see Figure 39-A) and align the
template onto the front of the cluster
bezel by placing its left edge against
the cluster rib, and its bottom edge
against the cluster bottom edge. Use
masking tape to securely hold down
the template.
NOTE: Do not tape over the markings
on the template.
24. Using a 3⁄ 8” Uni-drill, center the
bit onto the 3⁄ 8” drill location on the
template and slowly drill through the
panel. 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.
NOTE: It is important that the hole is
drilled at the recommended location.
The switch may not clear the
instrument panel structure if the hole
is shifted to another location.
25. Align the Banks power level
selector label onto the previously
drilled hole. Make sure the entire
mounting surface is clean and free of
dirt and oil before mounting the label.
Clean and dry as required using a
cloth dampened with rubbing alcohol
or similar cleaning solution.
Figure 38-A
28
96822 v.4.0
CAUTION: Do not spray fluid
directly onto any electrical
equipment, or equipment damage
may result.
Mount the Banks power level selector
switch label onto the drilled panel
by peeling the protective backing
off the adhesive tape on the back
of the switch label. Hold the label
against the panel for approximately
20 seconds while applying pressure
to allow the adhesive to properly
adhere to the surface.
26. Remove the nut and internal
tooth washer from the power level
selector switch. Rotate the shaft
counter clockwise until the shaft
stops. Verify that the locating washer
tab is inserted into the #6 position on
the switch (see Figure 37).
NOTE: If the washer is in any position
other than the #6, your EconoMind
Diesel Tuner will not select power
levels correctly.
27. After confirming the locating
washer is in the #6 location, install
the switch through the 3⁄ 8” hole
on the backside of the bezel. The
alignment pin should rest in the 1⁄ 8”
hole and with the switch fully rotated
counter clockwise; the shaft’s flat
side should be facing the steering
column. Secure switch with internal
tooth washer and nut. Snug the nut.
Be careful not to over torque the nut
and damage the plastic threads.
28. Install the knob onto the shaft
facing the #1 Level on the power
level selector label. On the knob,
snug the two (2) set screws with the
supplied 0.050” hex key wrench.
29. Reinstall the removed panels.
Make sure to reconnect all electrical
connecters disconnected previously.
30. Route the power level selector
switch wires down to the steering
column.
31. Route the power level selector
switch’s cable to the wire harness
that was routed into the passenger
compartment from the EconoMind
module, and plug the 2-pin connector
into the corresponding connector on
the EconoMind wiring harness.
32. Re-install the electric connector
bracket that was removed in Step
4 of Section 5 below the steering
column in the front of the firewall
with the original two (2) bolts.
-end, section 7-
Figure 38-B
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.
Figure 39
2. Using the panel as a template,
drill two 3⁄ 16” diameter holes in the
dash and mount the panel with the
supplied machine screws, nuts and
star washers provided.
3. Locate the supplied EconoMind
wire loom with the 4-pin connector.
Connect the 4-pin connector on
the EconoMind wire loom to the
connection labeled DYNAFACT
Gauges on the EconoMind wiring
harness. See Figure 17.
4. Install the DynaFact boost and
pyrometer gauges in the mounting
panel using the clamps and
thumbnuts provided. Plug the BLACK
wire lead to the male spade terminal
on the BLACK wire of each gauge
wire harness. Plug the YELLOW wire
into the Yellow wire of the boost
gauge wire harness and the RED wire
into the RED wire of the pyrometer
gauge wire harness. The ORANGE
wire remains unused.
5. Connect the 4-pin connector
of each gauge into the back of its
corresponding gauge.
a.Crimp the remaining Black and RED
wires from each 4-pin connector
gauge harness to the butt
connectors as shown in Figure 39.
b.Strip one end of the RED wire and
crimp it to the butt connector
containing the RED wires from step
‘a’.
c.Strip one end of the BLACK wire
and crimp it to the butt connector
containing the BLACK wires from
step ‘a’.
d.Route the RED wire to the fuse
box. Locate the appropriate fuse
for instrument lighting in the
owner’s manual. Cut the RED wire
as required and strip the end.
Crimp the push on connector
to the RED wire and connect to
the fuse as shown in Figure 39.
Alternatively, locate power wire to
dimmer switch and install T-tap.
Cut the RED wire as required and
strip the end. Crimp the push on
T-tap connector to the RED wire
and connect to T-tap on dimmer
power wire.
e.Locate a metal surface that will
serve as an acceptable chassis
ground. Cut the BLACK wire to a
sufficient length that will allow it to
reach the chassis ground and strip
the end. Crimp the ring terminal
to the BLACK wire as shown in
Figure 39.
f. Drill a 1⁄ 8” hole, if required, to
attach the ring terminal to the
chassis ground. Caution: If
drilling, check the backside
to make sure there are no
components that may be
damaged by drilling.
g.Use the supplied self-tapping
screw to secure the ring terminal
to the chassis ground.
-end, section 896822 v.4.0
29
Section 9
Transmission Learning
Your EconoMind Diesel Tuner displays
the “4,3” diagnostic code (refer to
TROUBLESHOOTING in Section
10 on how to read codes) when it
needs to learn your transmission
configuration. This always occurs
when the EconoMind Diesel Tuner
is first installed on the truck. The
EconoMind Diesel Tuner is equipped
with advanced safety features to
preserve your automatic transmission.
One of them is the capability to detect
the occurrence of transmission slip,
and it will automatically de-rate the
engine output power accordingly.
Before this safety feature can take
effect, the EconoMind Diesel Tuner
needs to learn that your truck
is equipped with an automatic
transmission.
1. The following driving test shall
be performed in an area where
speeds over 55mph are safe and
traffic is light. For a vehicle with a
manual transmission, follow Step
2. For a vehicle with an automatic
transmission, follow Step 3. While
driving, listen for any exhaust leaks or
rattles, or intake boost leaks. After the
engine cools, re-tighten clamps and
hoses if leaks are detected.
2. (Manual Transmission) To
teach the EconoMind Diesel Tuner
that your truck is equipped with a
manual transmission, drive the truck
at a speed over 55 mph for at least
2 minutes. The “4,3” diagnostic code
will be eliminated.
3. (Automatic Transmission) To
teach the EconoMind Diesel Tuner
that your truck is equipped with an
automatic transmission drive the
truck at a speed over 55mph until
the torque converter is locked (the
torque converter is usually locked at
speeds over 55mph). With the torque
converter locked and with turbo boost
below 10psig (ie, light load), maintain
the attained speed steadily for at least
30 seconds. Once the transmission is
learned, the “4,3” diagnostic code will
be eliminated. Repeat if necessary to
eliminate code.
-end, section 9-
Repeat if necessary to eliminate code.
Proceed to Section 10.
Section 10
Troubleshooting, EconoMind
EconoMind Troubleshooting Using
The Banks iQ
Check the Banks iQ’s Status indicator
for the “OK” icon on the upper left
corner of the iQ screen. Any Tuner
fault will be indicated by the “Banks
Engine” icon (see Figure 40) and
its cause can be investigated by
running a ‘Tuner Diagnostic’ from the
Diagnostic menu.
Figure 40
Banks Engine
Icon
Figure 41
30
96822 v.4.0
1. In the Environment select menu
press on the ‘Diagnostics’ button.
See Figure 41.
2. In the Diagnostics menu press on
the ‘Tuner Diagnostics’ button to run
a tuner diagnostics. See Figure 42.
3. The ‘Self Diagnostic’ screen
displays a log of diagnostic events
related to the Power Tuner. The
‘Logged Events’ list takes a moment
to update each time this screen
is opened (as indicated by a slight
flickering of the list). Once the list is
updated, the most current event will
appear at the bottom of the list. Each
event has an associated timestamp
and description, which will be
displayed below the list when that
event is highlighted. Each key cycle
of the vehicle produces a minimum
of two logged events. See Figure 43.
Table 1 lists the common diagnostic
codes and the suggested course of
action for each.
4. Use the arrow buttons to scroll
through the recorded events.
5. Touch the Banks iQ icon on the
lower left of the screen to return to
the environment screen or the return
icon to return to the Diagnostics
menu.
6. A pop-up “Log-File” screen will
appear asking you if you want to
erase the contents of the log. Press
‘No’ to keep the contents on Log-file
or ‘Yes’, to erase the Log-files.
• No LEDs will illuminate if the fuse
on the EconoMind wiring harness is
blown or the wiring harness is not
properly connected. If the fuse and all
connections are okay, contact Banks
Technical Service.
Figure 42
• The RED LED will flash in a certain
sequence if a connection is incorrect
of if there is a problem with the
system – this sequence will identify
one or more diagnostic codes. A
Banks EconoMind Diesel Tuner’s
diagnostic code is comprised of 2
digits. Each code is expressed in a
sequence of 2 sets of the flashing
red LED separated by a brief flashing
of the green LED in between. Each
set of a number of red LED flashes
represents a digit. A longer flashing
of the green LED separates the
sequences. The LEDs will continue
to flash to display all the errors,
and then repeat. Table 1 lists the
common diagnostic codes. For
example, if a faulty thermocouple
is detected (code “2,3”) by the
Banks EconoMind Diesel Tuner, the
following red and green LED flashing
sequence is observed when the key
is on:
Figure 43
(1) Two times flashing RED LED
(2) One time quick flashing GREEN
LED
(3) Three times flashing RED LED
Diagnosing EconoMind error
codes without the Banks iQ.
If you feel that your Banks EconoMind
Diesel Tuner is not functioning
properly, some diagnostics can be
performed. Your EconoMind Diesel
Tuner is equipped with diagnostic
features that will detect and display
certain errors.
Remove the Banks EconoMind Diesel
Tuner from its mounting location
while keeping all connectors plugged
in, and position it in such a way
that you can view the top of the
EconoMind housing that contains the
LEDs . Turn the vehicle key to the
ON position. Observe the two LEDs
mounted on the end of the Banks
EconoMind Diesel Tuner:
• A steady GREEN LED will illuminate
if all wire connections are correct,
the engine is running, and the engine
coolant temperature is within its
normal operating range.
• The GREEN LED will flash if all wire
connections are correct, the engine
is running, but the engine coolant
temperature is not within its normal
operating range. The GREEN LED will
stop flashing once the engine coolant
temperature is within its normal
operating range.
(4) One time longer flashing GREEN
LED
The above flashing sequence will
repeat continuously. When the
problem is corrected, the diagnostic
code will be eliminated and replaced
by a steady green light.
NOTE: If multiple codes are set, they
will be displayed in a series separated
by the longer flashing green LED.
When reading codes, make sure to
watch the entire series until you see
the first code repeat.
-end, section 10-
96822 v.4.0
31
Table 1 Banks EconoMind Fault Codes
Code
Event
Course of Action
1,1
Fuel Rail Pressure (FRP) Input Turn ignition OFF and check 3-pin FRP sensor connections. Turn ignition back
Voltage Out of Range.
ON and re-check for presence of code.
1,2
Manifold Absolute Pressure
(MAP) Input Voltage Out of
Range.
Turn ignition OFF and check 4-pin MAP sensor connections. Turn ignition back
ON and re-check for presence of code.
1,3
Power Level Selector Switch
Input Value Out of Range.
Turn ignition OFF and make sure either Banks IQ or Power Level Selector switch
is connected to EconoMind tuner. If Power Level Selector switch is connected
(no Banks IQ), check 2-pin connection on tuner’s in-cab cable. Turn ignition back
ON and re-check for presence of code.
2,1
Fuel Rail Pressure (FRP)
Turn ignition OFF and check 3-pin FRP sensor connections. Turn ignition back
Output Voltage Out of Range. ON and re-check for presence of code.
2,2
Manifold Absolute Pressure
(MAP) Output Voltage Out of
Range.
Turn ignition OFF and check 4-pin MAP sensor connections. Turn ignition back
ON and re-check for presence of code.
2,3
Exhaust Gas Temperature
(EGT) Sensor Open Circuit
Turn ignition OFF and check thermocouple ring-terminal connections (2). Turn
ignition back ON and re-check for presence of code.
3,1
Crankshaft Position (CKP)
Signal Fault or Intermittent
Power.
Turn ignition OFF and check 3-pin CKP and CMP sensor connections and fusetap power connection to EconoMind tuner (in engine compartment fuse box).
Start engine and re-check for presence of code.
3,2
Internal Module Malfunction.
Turn ignition OFF and check all EconoMind tuner connections. Turn ignition
back ON and re-check for presence of code.
3,3
Low Battery Voltage or
Internal Module Malfunction.
Turn ignition OFF and check fuse-tap power connection to EconoMind tuner (in
engine compartment fuse box). Turn ignition back ON and re-check for presence
of code.
3,4
OBDII CAN Communication
Error.
Turn ignition OFF and check in-cab OBD II and 8-pin cable connections. Turn
ignition back ON and re-check for presence of code.
4,2
Transmission Slippage
Detected.
Transmission is slipping excessively. Code will automatically clear once
transmission stops slipping (repaired).
4,3
Perform Transmission Learning procedure in Section 9. Code will automatically
Unlearned Transmission Type
clear once transmission type and gear ratios (auto trans. only) have been
and Gear Ratios.
learned successfully.
5,1
Internal Module Malfunction.
Turn ignition OFF and check all EconoMind tuner connections. Turn ignition
back ON and re-check for presence of code.
If problem persists, call Gale Banks Engineering Tech Support.
32
96822 v.4.0
Section 11
Clearing Learned Information
NOTE: If clearing the EconoMind’s
learned parameters then all Banks
iQ tunable settings will be reset to
factory defaults. (Refer to the Banks
IQ Owners Manual for more detail.)
This procedure should only be
performed if:
- A ”4,2” code for transmission slip
detection is repeatedly set or will
not clear and the transmission is not
actually slipping; or
to clear the information related to
the learned transmission type and
gear ratios. The diagnostic code “4,
3” will reappear after the procedures
are carried out correctly. Follow
the steps below to unlearn the
transmission on your EconoMind
Diesel Tuner.
CAUTION: The following
procedures can only be carried
out with the engine not running.
- The EconoMind Diesel Tuner is
moved to a new vehicle; or
1. Turn the vehicle key to the ON
- The vehicle’s speedometer has
been factory recalibrated for different
gearing or tire size; or
2. Fully depress the accelerator
- Instructed to do so by Banks
Technical Staff. Your EconoMind
Diesel Tuner also has the capability
position but DO NOT start the engine.
pedal and then release it completely.
Repeat for 5 times. The GREEN LED
will flash when this is completed
successfully.
3. Turn the key OFF. Wait 10
seconds, or until the GREEN LED goes
off and stays off. Turn the key to the
ON position but DO NOT start the
engine.
4. Fully depress the accelerator
pedal and then release it completely.
Repeat for 5 times. The “4,3”
diagnostic code will flash when this
is completed successfully. NOTE:
When the transmission type and gear
ratios are cleared (with code “4,3”
displayed), the engine power returns
and remains in stock level until the
EconoMind Diesel Tuner re-learns the
transmission and the “4,3” code is
eliminated. Follow the procedures in
”Transmission Learning” (Section 9)
to eliminate the “4,3”.
-end, section 11-
Section 12
Removal of the EconoMind Diesel Tuner
If the EconoMind Diesel Tuner should
ever need to be removed from the
vehicle, perform the following:
5. Disconnect the EconoMind’s
Crankshaft Position (CKP)
connections from the vehicle’s CKP
sensor and harness.
Note: The ignition must remain in the
OFF position throughout the removal
process.
6. Re-connect the vehicle’s CKP
1. Disconnect the EconoMind’s Fuel
7. Disconnect the EconoMind’s
Rail Pressure (FRP) connections from
the vehicle’s FRP sensor and harness.
2. Re-connect the vehicle’s FRP
connector back into the FRP sensor.
3. Disconnect the EconoMind’s
connector back into the CKP sensor.
Camshaft Position (CMP) connections
from the vehicle’s CMP sensor and
harness.
8. Re-connect the vehicle’s CMP
connector back into the CMP sensor.
Manifold Absolute Pressure (MAP)
connections from the vehicle’s MAP
sensor and harness.
9. Unbolt the EconoMind’s ground
4. Re-connect the vehicle’s MAP
10. Unplug the EconoMind’s RED/
connector back into the MAP sensor.
ring terminal from the fender stud
and retighten the stud’s 10mm nut.
WHT power wire from the mini-fuse
tap and remove the tap.
11. Disconnect the 2 ring terminals
nearest the EconoMind from the EGT
thermocouple lead wire.
12. Disconnect the 3 small
connectors on the EconoMind’s
in-cab cable and gently pull the cable
back through the firewall.
13. Remove the EconoMind Diesel
Tuner.
NOTE: Failure to follow the above
instructions when removing the
EconoMind Tuner will result in a
“Check Engine” light on the dash
and a Diagnostic Trouble Code being
stored in the factory computer, in
addition to the engine not running.
-end, section 12-
96822 v.4.0
33
Section 13
Filter Maintance
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 44.
Figure 44 Typical air-filter restriction gauge
2. 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. No gasoline cleaning, No
steam cleaning, No caustic cleaning
solutions, No strong detergents, No
high pressure car wash, No parts
cleaning solvents. Any of these No’s
can cause harm to the cotton filter
media plus SHRINK and HARDEN the
rubber end caps.
CAUTION! Extremely fine dust
from agriculture or off-road
use will pull the oil from the
element. Frequent re-oiling of
the element’s clean side might
be required. Completely service
when practicable. For extra
protection use an air-filter sealing
grease on rubber ends of the
element. Service only with Banks
Ram-Air-filter cleaner and Banks
Ram-Air-filter oil.
-end, section 13-
Section 14
Placement of the Banks Power Decals
Figure 45
Gale Banks Engineering
546 Duggan Avenue • Azusa, ca 91702
(626) 969-9600 • Fax (626) 334-1743
Product Information & Sales: (888) 635-4565
Customer Support: (888) 839-5600
Installation Support: (888) 839-2700
bankspower.com