04/19/06 PN 96800 v.1.0

Banks Twin Turbofor Small Block Chevrolet

THIS MANUAL IS FOR USE WITH KITS 21101, 21102, 21103, 21104, 21107,21108, 21109, 21110 21112, 24008, 24085, 24090, 24092, 24714, 24715, 24717, 42442, 51103, 51104

Gale Banks Engineering 546 Duggan Avenue • Azusa, CA 91702 (626) 969-9600 • Fax (626) 334-1743

Product Information & Sales: (800) 438-7693Customer Support: (888) 839-5600 Installation Support: (888) 839-2700

bankspower.com

©2006 Gale Banks Engineering

Owner’sManualwith Installation Instructions

2 96800 v.1.0

Dear Customer,

If you have any questionsconcerning the installation ofyour Banks Twin Turbo System,please call our Technical ServiceHotline at (888) 839-2700between 7:00 am and 5:00 pm(PT). If you have any questionsrelating to shipping or billing,please contact our CustomerService Department at (888) 839-5600.

Thank you.

1. Before starting work, familiarizeyourself with the installationprocedure by reading all of theinstructions.

2. Throughout this manual, the leftside of the vehicle refers to thedriver’s side, and the right side to thepassenger’s side.

3. Before installing any components,inspect them for any foreign materialthat may have entered during shippingand handling, machining or assembly.Remove any burrs, machining chipsand polishing compound fromcastings. Rinse all hoses and tubeassemblies with solvent and blow dry,especially braided hoses afterassembly of hose-end fittings.

4. Teflon paste has been providedwith this kit for pipe threadassemblies. We recommend it overTeflon tape to eliminate the possibilityof tape fragments getting into thelubrication and fuel systems. Flaredfittings, hose and tube assembliesrequire no sealant.

5. Plastic or fiberglass parts, rubberhoses, brake lines, wiring, etc. in closeproximity to hot exhaust componentswill need to be shielded from heat. Wedo not recommend that the exhaustsystem be covered with any kind ofheat wrap or blanket, as this mayoverheat it causing warpage, cracks,or burnout. We recommend placingheat shielding on or between adjacentcomponents. This may be in the formof reflective blanket material, or sheetmetal forming air gaps, such as on ourturbo exhaust manifold. On vehicleswith low hood lines, it is advisable tomount heat shielding on the undersideof the hood over the turbos andexhaust piping.

6. Check valves may need to beinstalled in-line with any accessoriesnormally operated by manifoldvacuum. (e.g. power brake booster,automatic transmission modulator,heater or A/C dampers)

7. When connecting MAP sensor,reference line should be connected tomanifold vacuum/pressure below thethrottle blades. No check valve shouldbe used.

8. During installation, keep the workarea clean. Do not allow anything tobe dropped into intake, exhaust, orlubrication system components whileperforming the installation, as foreignobjects will cause immediate enginedamage upon start-up.

9. These instructions describe thefinal assembly of the turbo system ona finished engine. We suggest youmake a dry-run assembly of allcomponents finger-tight to verify anyissues of fit and to familiarize yourselfwith the procedure.

General Installation Practices

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Table of Contents

Section 1 . . . . . . . . . . . . . . . . . . . . . . .4Engine Support Systems

Section 2 . . . . . . . . . . . . . . . . . . . . . . .6Exhaust Manifold Installation

Section 3 . . . . . . . . . . . . . . . . . . . . . . .8Turbocharger Assembly Installation

Section 4 . . . . . . . . . . . . . . . . . . . . . .12Turbocharger Oil Feed Line Installation

Section 5 . . . . . . . . . . . . . . . . . . . . . .17Turbocharger Oil Drain Line Installation

Section 6 . . . . . . . . . . . . . . . . . . . . . .20Turbocharger Wastegate Installation

Section 7 . . . . . . . . . . . . . . . . . . . . . .23Pressure Chamber Installation

Section 8 . . . . . . . . . . . . . . . . . . . . . .29Shuttle Valve Installation

Section 9 . . . . . . . . . . . . . . . . . . . . . .33Wastegate Actuation Kit Installation

Section 10 . . . . . . . . . . . . . . . . . . . . .36Boost Tube Installation

Section 11 . . . . . . . . . . . . . . . . . . . . .39Braided Hose and End Fitting Assembly

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Your Banks Sidewinder Twin-Turbosystem has the potential to makeconsiderable power, but only if thevehicle’s support systems are upgradedto match. We recommend you considermaking the following modifications ifyou have not already done so.

FUEL SYSTEMA quality high-performance EFI fuelpump capable of producing therecommended injector pressure andfuel flow volume for the anticipatedpower level will be required. Checkwith your EFI manufacturer for theirnozzle flow rates and pressures. As ageneral rule, an engine at WOT underload will use 1⁄2 pound of gasoline perhorsepower per hour.

Thus, an 800-horsepower engine willrequire a fuel-flow capacity of 400pounds per hour total flow from theeight injectors. This is a minimumrequirement, as the pump should havesome additional flow and pressurereserve to allow for pressureregulation and high demandconditions. Install a fuel pressuregauge to monitor pressure whiletuning. Pressure is ÆP injector. If yourinjector needs a ÆP of 45 psi and youwill be running 10 psi of boostpressure, the pump will need to make55 psi of pressure at the necessaryfuel flow rate, plus 5 psi for regulation.

The fuel tank pick-up line or outletfitting should be at least as large asthe fuel pump inlet, typically a –10 or–12 line size. If at all possible, mountthe pump in the rear of the vehicle,close to the fuel tank. A high-flow finemesh fuel filter should be installed atthe fuel pump inlet. Check with thepump manufacturer for filter micronsize.

High-volume/high-pressure electricpumps must be supported by an

electrical system capable of providingthe rated pump amperage and supplyvoltage. Check that the wire gaugeand fuse amperage is appropriate forthe pump selected. Most ECUs switchthe pump on and off through a relaytied to the ECU’s ignition circuit.

EXHAUST SYSTEMTurbochargers respond quicker andwill produce more boost withminimum backpressure. If possible,use a 3-inch-diameter outlet pipe fromeach turbocharger. In a minimumspace situation, you may reduce to21⁄2-inch-diameter off of each turbo,increasing to 3 inches as soon aspossible, but power will be reduced. Ina racing application, keep the pipe size3 inches or larger, and as short aspractical. On a street vehicle, mufflersshould be a low restriction chambereddesign (no glass packs) with inlet andoutlet sizes at least 3 inches. Keep thenumber of bends to a minimum, andas free flowing as practical. Stainlesssteel tubing is not necessary, but willlast a lot longer.

The wastegates are provided with V-band outlet connections for welding to13⁄4” tubing. On a street driven car, thewastegates’ outlet tubes can bemerged into the turbocharger outlettubes 12”-24” downstream of theturbos. When doing this werecommend some kind of slip joint orbellows be placed in the wastegateoutlet tubes to minimize tubedistortion or cracking from differentthermal expansion rates.

Our turbo system is designed with thewastegate outlets pointing out towardeach side. If necessary for the vehicleapplication, the wastegates may berotated to another position, but newactuation hard-line tubes will have tobe made.

Section 1ENGINE SUPPORT SYSTEMS

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The turbochargers are supplied withheat shields, outlet gaskets, 3” tubeoutlet flanges, and eight 3⁄8-16 x 1” 12pt. bolts. One outlet gasket is used oneach side of the heat shield. Whenbuilding the exhaust system, have theheat shields and all gaskets in place soyour final stack-up of parts will becorrect.

IGNITIONA high-energy multiple spark or CDignition system is required to provideadequate spark energy during highboost operation. Check with your ECUmanufacturer to determine what typeof ignition triggering is compatible withthe ECU circuitry. Distributor cap,rotor, and plug wires must be in topcondition to prevent miss firing underboost. Spiral-core, low-resistance plugwire is recommended for use withmost electronic ignition systems.

Sparkplug selection will varysomewhat with the system applicationand cylinder heads used. In general,plugs will need to be several heatranges colder than stock to preventthe plug from becoming a source ofpre-ignition. Do not use projected tipplugs that extend the center insulatorinto the combustion chamber.

LUBRICATIONAny oil suitable for lubricating theengine will lubricate the turbos. Oilcontaminated by dirt or debris, or alack of oil, will cause rapid turbobearing failure. Anytime new turbosare installed, or a new engine isstarted for the first time, the turbosshould be oil-primed prior to enginestart-up. Disconnect the turbo oil drainlines at the oil-pan fittings and crankthe engine with the ignition off until oil

is observed flowing from the drainlines, then reconnect lines and startthe engine. An alternative method is topump several shots of clean engine oilinto each turbo oil inlet fitting, thencrank the engine with the turbo feedlines disconnected and ignition offuntil oil flows from the feed lines.Reconnect the lines and start theengine. Oil priming ensures that theturbos will not be spinning beforeengine oil reaches them, as in anunprimed engine with empty oilpassages.

When a turbocharged engine is shutoff after a period of operation,especially when it has been run undermoderate or high boost, it isrecommended that it be allowed toidle for 30-60 seconds before shutdown. This allows engine oil to coolthe turbo bearings and to prevent thehot turbo from baking the engine oilinto sludge on the turbo bearings. Donot shut a turbocharged engine offimmediately following high RPM/boostoperation, as the turbos will spin for anumber of seconds with no oilpressure, causing bearing damage.Never place a restrictor in the inlet oroutlet turbocharger oil line. Theturbocharger bearing clearancesprovide the necessary restriction to oilflow. A restricted or blocked turbo oildrain line will cause oil to back up intothe turbo, pushing past the seals andentering the intake or exhaust systemresulting in oil burning. Restricted oilinlet flow may result in damaged turbobearings. If the engine will not producenormal oil pressure, steps must betaken to upgrade the engine’s oilsystem, or reduce oiltemperature/increase viscosity.

-END, SECTION 1-

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1. Apply a small amount of anti-seizeonto the threads of the twelve 3⁄8-16 x3" bolts. See Figure 1. Install two lockwashers on each bolt.

Note: Lock washers may be suppliedalready cemented together. If not,install two washers per bolt with thecourse serrations facing each other.

2. Install each manifold with the heatshield between the manifold and the

cylinder head using the two outsidebolts. Peel the protective covering offof the heat shield before installation.See Figure 2.

3. Install the remaining 10 bolts, fingertight.

4. Make an initial pass torqueing eachbolt to 15 ft-lbs. Then make a finalpass torqueing each bolt to 35 ft-lbs.

-END, SECTION 2-

Section 2EXHAUST MANIFOLD INSTALLATIONFigure 1

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Figure 2

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1. Apply a small amount of anti-seizeonto the course threads of the eight3⁄8" studs. Note: Two of the studs areshorter.

2. Install four studs into the turbineinlet flange on each exhaust manifold.The short studs are used in the rightfront corner of each manifold. SeeFigure 3.

3. Thread two 3⁄8” fine thread hexnuts onto one of the studs.

4. Lock the nuts together by turningthem in opposite directions towardeach other. See Figure 4.

5. Once the nuts are locked togetheruse a wrench to snug the stud into theexhaust manifold flange by turning theupper nut. (Approx 5-8 ft-lbs).

6. Loosen the nuts by turning them inthe opposite direction and removethem from the stud.

7. Repeat Steps 3 – 6 for theremaining seven studs.

8. Each exhaust manifold is providedwith a 1⁄4" NPT pipe port for anexhaust gas temperature gauge probe(pyrometer). These ports are on theside of the manifold below the turboflange. If a pyrometer probe is notinstalled, make sure a provided 1⁄4"pipe plug is installed in this port oneach manifold. Use Anti-seize on thepipe threads. See Figure 5.

9. Remove the turbochargers fromtheir packaging. Carefully check theturbochargers for any packing debris.Remove any debris found in theassembly.

Note: Debris in the turbocharger candamage it and the engine if notremoved.

10. Install the two turbochargers ontothe two exhaust manifolds. Theturbine outlet should face the rear of

Section 3TURBOCHARGER ASSEMBLY INSTALLATION

Figure 3

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Figure 4

Figure 5

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the engine. See Figure 6. Note: Nogasket is used between theturbocharger and manifold.

11. Install a 3⁄8" AN washer over thesix longer studs. Note: Due to castingclearance, washers cannot be used onthe two shorter studs.

12. Apply a small amount of anti-seize onto the threads.

13. Install a 3⁄8" collet-lock nut ontoeach of the 8 studs with the roundcollet side of the nut against the ANwasher and tighten to approximately15 - 20 ft-lbs. Start the first nut on theshort stud of each turbo flange. Note:This torque value is just for reference.A torque wrench cannot be used totighten these studs due to the limitedclearance. The nuts must be tightenedwith an end wrench. See Figure 7.

14. Loosen the six compressor andsix turbine housing bolts on each

turbocharger so the housing may berotated. Rotate the turbo centersections so that each oil inlet flangefaces up. Note: The oil inlet port isround and the oil drain port is square.

15. Lay a straightedge on top of theoil inlet flanges of the center sections.

16. Rotate the center sections untilthe top surface of each oil inlet flangeis flush with the straightedge. SeeFigure 8.

17. Tighten all six bolts that hold thecenter section to the exhaust turbinehousing on each turbocharger to 12-15ft-lbs. (For reference only, use an endwrench)

18. Bend over the lock tabs for eachof the bolts tightened. Note: Leave thebolts that hold the compressorhousing to the center section looseuntil later.

-END, SECTION 3-

Figure 6

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Figure 7

Figure 8

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1. Install an aluminum turbo oil inletflange adapter and o-ring onto thecenter section of each turbochargerusing a pair of M8x1.25 12-point bolts.Torque bolts to 15-18 ft. lbs. SeeFigure 9.

2. Apply liquid Teflon to the 1⁄4" NPTthread of the two 1⁄4" NPT -4 AN 90ºelbow fittings.

3. Install one of these fittings into thetop of each aluminum adapter on thecenter section. Using a 9⁄16" wrench,rotate both fittings until they are tightand the -4 AN male ends point directlyat each other See Figure 10.

4. Apply liquid Teflon to the 1⁄4" NPTthread of the 1⁄4" x -6 AN male fittingand install it into the 1⁄4" NPT femalethread of the 1⁄4" x -4 male T-fitting.See Figure 11.

If installing on an aftermarket blockfollow Steps 5 and 6. If installing on astock block skip to Step 7.

5. If installing on an aftermarket block,apply liquid Teflon to the 1⁄2" NPTthread of the 1⁄2" x -6 AN male fittingand install it into the 1⁄2" NPT port onthe back of the block. See Figure 12

6. Install the 3⁄8" tube onto the -6 ANfitting on the back of the block androute forward to the front of the intakemanifold. (See Figure 13). Install T-fitting assembly on the end of thetube. Only tighten finger tight. Skip toStep 9.

7. If installing on a stock block, applyliquid Teflon to the 1⁄4" NPT thread ofthe 90° 1⁄4" NPT x -6 AN male fittingand install it into the 1⁄4" NPT port onthe oil filter flange of the block. Aimfitting so it points up. See Figure 14

Section 4TURBOCHARGER OIL FEED LINE INSTALLATION

Figure 9

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Figure 10

Figure 11

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Figure 12

Figure 13

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8. Install the 3⁄8" tube onto the elbowfitting in the block and route forwardto the front of the intake manifold.Install the T-fitting assembly on theend of the tube. Only tighten fingertight.

9. Install the long tube onto the -4male fitting on the right sideturbocharger and route to the T-fitting.

10. Install the short tube onto the -4

male fitting on the left sideturbocharger and route to the T-fitting.

Note: Lines may be sprung apart orbent slightly with light thumb pressureto install the T-fitting. All hardlineassembly tube nuts should be leftfinger tight until all tubes are in placeand final adjustments for best tube fitis complete. See Figure 15.

-END, SECTION 4-

Figure 14

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Figure 15

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1. Oil drain threaded bungs must bewelded to the oil pan prior to installingfittings. Two 1⁄2” NPT bungs areprovided for welding to a steel oil pan(for an aluminum pan, installer mustprovide aluminum weld bungs). Locatethe center of each bung 11⁄2 inchesbelow the pan rail flange adjacent tothe center main cap, check for panbolt clearance. This location preventsreturn oil from being slung by thecounterweights or rod caps, and isrequired for proper alignment with theoil drain tubes. With the pan off theengine, punch or drill a 5⁄8 -inch-diameter hole through the pan wall ateach center mark. Center each bungover the hole, check that thechamfered thread side of the bungfaces out, then weld or braze thebungs to the pan. See Figure 16

2. Install 1⁄2" NPT x 5⁄8 hose 45º elbowfitting into the oil pan with the end

pointing straight up. See Figure 17

3. Apply anti-seize to the four 8mm x1.25 x 20mm hex bolts.

4. Install a pair of circle lock washersover each 8mm bolt and insert thebolts from below the oil drain tubeflanges. Place the gaskets over thebolts and install onto the underside ofthe turbocharger center sections. Onlytighten finger tight at this time. SeeFigure 18

Note: Lock washers may be suppliedalready cemented together. If not,install two washers per bolt with thecourse serrations facing each other.

5. Measure and cut a piece of the 5⁄8”rubber hose long enough to engage 1”of the right drain tube when installedon the hose fitting on the oil pan. Theelbow fitting in the pan may be rotatedslightly for best alignment.

Section 5TURBOCHARGER OIL DRAIN LINE INSTALLATION

Figure 16

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Figure 17

Figure 18

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6. Unbolt the drain tube from theturbocharger. Slide two spring bandclamps onto the hose. Install the hoseon the pan fitting and then push thedrain tube into the hoses.

7. Reinstall drain tubes. After bolts areinstalled, torque each bolt to 15-18 ft-lbs.

8. Use pliers to expand the springband clamps and locate each clamp1⁄4” in from each end of the hose.When completed, repeat step 6 and 7and install hose and clamps on leftside drain tube. See Figure 19

-END, SECTION 5-

Figure 19

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1. Remove the wastegate assembliesfrom their cartons. There is a right andleft wastegate, identified byorientation of the logo and the outletflange. The outlet flanges should faceto the outside of the engine with thelogos right-side-up when viewed fromthe front of the engine.

2. Install the right wastegate onto thefront of the right exhaust manifoldwith the V-band clamp, bolt, and locknut provided. Use a small dab of Anti-seize on the bolt threads. Make surethe wastegate valve seat ring isbetween the wastegate and themanifold with the tapered side againstthe wastegate valve. Tighten the boltto the point that the wastegate issecure but can still be rotated toposition by hand. Repeat thisprocedure for the left wastegate. SeeFigure 20 and Figure 21

Note: When installing wastegates with

high boost springs, it may be easier fortwo people to perform the clamping /bolting procedure.

3. Adjust the two wastegates so thefront logo lettering is level on eachone; this will make the side ports level.See Figure 22 . Torque eachwastegate clamp bolt/nut to 5-7 ft. lbs.Install a 10 mm banjo bolt, - 4ANfitting body, and two crush washers(found in the wastegates partspackage) in the 10mm side port ofeach wastegate with the –4 threadpointing straight up, and tighten. Note:washers go on either side of the fittingbody. See Figure 23.

4. Install the remaining 10 mm banjobolts, barbed hose fitting bodies andcrush washers in the front of eachwastegates with the fitting pointeddown. These are the cover vents. SeeFigure 24.

-END, SECTION 6-

Section 6TURBOCHARGER WASTEGATE INSTALLATION

Figure 20

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Figure 21

Figure 22

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Figure 23

Figure 24

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1. A 1⁄2-inch NPT female pipe threadport must be provided at the rear ofthe intake manifold plenum area forthe shuttle valve vacuum line. Drill andtap into the manifold at theapproximate location of the elbowfitting shown in Figure 25. Check thatyour proposed location will allow the45° 1⁄2" NPT x –10AN elbow to berotated 360° when tightened. If anyadditional vacuum/boost componentsare to be connected to the rear of themanifold plenum (MAP sensor, boostgauge, fuel pressure regulator ref.,etc.), drill and tap the necessary pipethread ports as shown in Figure 25above the elbow fitting. Many EFIthrottle bodies provide alternativeports to connect these components.Install pipe plugs (not supplied) in anyports not used.

Note: This operation is best performedwith the manifold removed. Alwaysproperly clean before installation.

2. Apply liquid Teflon to the pipethreads of the 1⁄2" x -10 AN 45º fittingand install into the back of the intakemanifold. Aim the fitting approximatelyas shown in Figure 25.

3. Install the four 5⁄16" x 6.5” studsinto the manifold until bottomed.

4. Thread two 5⁄16" fine thread hexnuts onto one of the studs.

5. Lock the nuts together by turningthem in opposite directions towardeach other. See Figure 26

6. Once the nuts are locked togetheruse a wrench to snug the stud into theintake manifold by turning the uppernut. (Approx 5-8 ft-lbs).

7. Loosen the nuts by turning them inthe opposite direction and removethem from the stud.

8. Repeat Steps 4 – 7 for theremaining three studs.

Section 7PRESSURE CHAMBER INSTALLATION

Figure 25

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9. Install the throttle body gasket andthen the throttle body.

Note: The stud length, spacer tubelength, and spacer ring height havebeen established to work with anAccel DFI intake manifold and 1-5/8”tall throttle body. This combination ofparts will place the pressure chamberat the correct elevation to line up theturbo boost tubes and provide aproper seal of the o-rings. If you areusing a different combination of intakemanifold and/or throttle body, you willneed to alter the spacer heights asnecessary to seal the o-rings andmake boost tubes line up. If shorteningthe spacer tubes is required, makesure you remove material from thenon-chamfered end of the tubes.

10. Slide a pressure chamber spacertube over each of the four previouslyinstalled studs so it rests on thethrottle body mounting ear. The

chamfered end of each tube must beup. Slide a 5⁄16" x 1⁄16" o-ring overeach stud so it rests in the chamfer oneach tube. See Figure 27

11. Set a 5" x 1⁄16" o-ring onto theinlet flange surface of the throttlebody. See Figure 28. Install thepressure chamber spacer ring onto thethrottle body inlet flange and o-ring.Note: The spacer ring has a step cutinto one end and a grove in the other.The end with the step faces down. Thering may be a tight fit on some throttlebodies. Set a 5 1⁄4" x 1⁄16” o-ring in thegroove on the top edge of the spacerring. See Figure 29.

12. Apply liquid Teflon to the pipethreads of a 1⁄4" x – 4 AN 90° fittingfrom the wastegate actuation parts kit.Install this fitting in the 1⁄4" pipe porton the bottom of the pressurechamber body near the right front studhole. Tighten the fitting so it will point

Figure 26

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Figure 27

Figure 28

26 96800 v.1.0

forward in the vehicle. Apply liquidTeflon to a 1⁄8" pipe plug and install itin the 1⁄8" port near the other frontstud hole. See Figure 30.

13. Install the pressure chamber overthe four studs and seat it against theo-ring. Install the pressure chambercover over the four studs. No sealantor gasket is used between thepressure chamber and cover. Installeleven, 5⁄16-18 x 3⁄4" button head boltsand lightly snug the bolts. See Figure31.

14. Install four 5⁄16” thread sealwashers over the studs and push themdown until they contact the cover.Install four 5⁄16” AN washers and 5⁄16”-24 Nylock nuts on the studs andtorque evenly to 5-7 ft-lb. Now torquethe eleven cover bolts to 8-10 ft. lbs.

15. Place one 2 1⁄2” x 1⁄16” o-ring intothe grove of each of the two 2-1⁄2”hose nipples. Install the hose nipplesonto the front of the pressurechamber using eight 1⁄4-20 x 1⁄2”socket head cap screws. Torque to 5-7ft-lbs. See Figure 32.

16. Check the operation of thethrottle lever on the throttle body toensure that the lever or installedthrottle cable or linkage cannot hit thepressure chamber or othercomponents causing a stuck throttleor run-away open throttle condition.Take whatever actions are required toprovide necessary clearance. This mayrequire a modified lever or leverextension.

-END, SECTION 7-

Figure 29

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Figure 30

Figure 31

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Figure 32

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Note: This installation may requireassistance from a second person.Ensure shuttle valve bore is clean andfree of debris. Temporarily install thevalve piston to ensure that it movesfreely through the bore.

1. Install the shuttle valve cap andgasket onto the right side of thepressure chamber using four 1⁄4-20 x1⁄2” socket bolts. Torque the 1⁄4" boltsto 30-36 in-lbs (2.5-3 ft-lbs). SeeFigure 33.

2. Place the shuttle valve piston intothe bore with the tapered end first.See Figure 34.

3. Obtain four 1⁄4-20 x 1⁄2" sockethead bolts and have the necessarytools handy for their installation.

4. Slide the spring into the valveinside the bore. Insert the spring guideinto the spring. See Figure 35.

5. Push on the spring guide tocompress the spring until the springguide flange is seated against thepressure chamber. See Figure 36.Install the four 1⁄4-20 x 1⁄2" bolts tohold the spring guide. Make sure tohave at least two bolts (oppositecorners) installed before releasing thespring guide to avoid damage to thecomponents or personal injury. Torquethe 1⁄4" bolts to 5-7 ft-lbs. Note: Thisstep is much easier with two people.

6. Apply liquid Teflon to the 1⁄2" NPTthreads of the 1⁄2" NPT x -10 AN 90ºfitting.

7. Install the 1⁄2" NPT x -10 AN 90ºfitting into the spring guide. Tightenthe fitting leaving the -10 end facingstraight back. See Figure 37

8. Assemble the -10 hose with thestraight hose end on one end and the90º hose end on the other to route

Section 8SHUTTLE VALVE INSTALLATION

Figure 33

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Figure 34

Figure 35

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Figure 36

Figure 37

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from the intake manifold to thepressure chamber. The straight hoseend connects to the intake manifoldand the 90º hose end connects to thepressure chamber. See Figure 38.Carefully measure the necessarylength of hose and cut to size. See

“Hose and End Fitting Assembly” onpage 39 for instructions on how toassemble the hose.

9. Install the hose and tighten thefittings.

-END, SECTION 8-

Figure 38

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1. Install the boost reference tube(shortest hard-line tube) onto thefitting under the right front corner ofthe pressure chamber. Leave tube nutfinger tight. Install the -4 AN T-fittingon the end of the boost referencetube. Leave tube nut finger tight. SeeFigure 39.

2. Install the left and right wastegatefeed tubes between the –4 AN T-fittingand the –4 AN banjo 90° fittings on thewastegates. See Figure 40. Leavetube nuts finger tight. Note: Tube frompressure chamber to T-fitting is madeto fit Accel/DFI pressure chamberheight.

3. Tighten all of the tube nuts on thewastegate and oil hardline tubeassemblies while adjusting the tubesfor best fit. To avoid twisting the

tubing, use two wrenches whiletightening the tubing on the T-fitting.See Figure 41. Hardline tubeassemblies may be bent slightly usingmoderate thumb pressure and adapterfittings rotated slightly as required foralignment. Wastegate tubes should runabove oil tubes across the front of theengine.

4. Once tubes are adjusted, installthree tube spacer clamps on the tubeassemblies as shown in Figure 42.Readjust the tubes if necessary toallow the tubes to run one aboveanother through the clamps. Whentube adjustment is final, tighten thebolts in the tube clamps. See Figure43 for the look of the finishedinstallation.

-END, SECTION 9-

Section 9WASTEGATE ACTUATION KIT INSTALLATION

Figure 39

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Figure 40

Figure 41

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Figure 42

Figure 43

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1. Test fit boost tubes between turbocompressor covers and hose nippleson pressure chamber. Rotate thecompressors to align with the boosttubes and pressure chamber hosenipples. There should beapproximately 1⁄8"of an air gapbetween the boost tube and the turboor nose nipple. See Figure 44. Note:There is a right-hand and left-handboost tube. Try different orientationsto find the best fit.

2. Install the boost tubes using fourpieces of 2 1⁄2" x 2 1⁄2" silicone hoseand eight T-bolt hose clamps. SeeFigure 45 and 46.

3. Make sure hose clamps areproperly positioned behind hosebeads, then tighten clamps. Tightenthe six bolts securing each turbocompressor cover to 10-12 ft-lbs, thenbend lock tabs against bolt heads.(This is a reference torque figure).

4. Installation of the turbocomponents is now complete. Refer tothe notes at the beginning of thismanual for engine support systemrecommendations and operation. SeeFigure 47 for a view of the completedengine assembly.

-END, SECTION 10-

Section 10BOOST TUBE INSTALLATION

Figure 44

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Figure 45

Figure 46

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Figure 47

1. Wrap hose tightly with tape atcutting point. Using a fine toothhacksaw, cable cutters or radiacwheel, cut the hose in the middle ofthe tape. Remove tape after cutting,being careful not to fray the braid.

2. Twist hose into socket to the depthindicated by the hose insertion markon the outside of the socket. Thisshould be just short of the back of thethreads.

3. VERY IMPORTANT— Mark hose withtape or suitable marking device at rearof socket. This mark will later indicateto you if the hose has pushed out ofthe socket during assembly.

4. Using motor oil or assembly lube,liberally lubricate inside of hose insocket and threads on nipple end ofhose fitting.

5. Clamp socket and hose in a smoothjaw vise as shown in the illustration in

Figure 48. Do not over tighten, as thiscan easily deform the socket. A layerof masking tape can be wrappedaround the socket to protect thefinish.

6. Push the nipple portion of thefitting into the socket and hose whileturning to engage the threads.Continue tightening by hand as far aspossible to make sure that the threadsare properly mated with no crossthreading.

7. Using a wrench, completetightening until a 1⁄16” gap or lessexists between the hex portions of thesocket and nipple.

8. Check mark made on hose in step3 for any evidence of hose push-out.Rinse the completed hose assemblywith solvent and blow dry.

-END, SECTION 11-

Section 11BRAIDED HOSE AND END FITTING ASSEMBLY

Figure 48

96800 v.1.0 39

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