Sapo

TST POWER KIT INSTALLATION INSTRUCTIONS
Insure you have the tools/items listed below before disabling vehicle
TST Power Kit Fender covers to protect paint 7/16 inch deep barrel socket 3/8’s drive with ratchet 10 mm six point socket, 3/8’s drive with 3” extension Tape or clean towels to cover openings 7 mm and ¼ inch six point sockets, ¼ drive with 3” extension 19mm socket, 3/8’s or ½ driveCenter punch 8-10 inches long Hammer to strike punch and hand impact tool Hand impact tool, 3/8’s or ½ drive T15 & T20 TORX bits ¼” drive with ¼” extension 6” long ¼ to 3/8’s and or ½ adapter to hand impact tool 8mm 6point ¼”drive socket Large standard screw driver bit with 6” adapter for impact tool Large screwdriver or small pry bar Pliers 7/16 inch open end wrench 5/8 inch open end wrench Torquewrench capable of at least 30 pound-feet RTV silicon sealant 8 mm allen wrench Park vehicle in a suitable work location, set parking brake, place automatic transmissions in park, manual transmissions in neutral, and open hood. Disconnect both battery negative battery cables. Clean engine if necessary to keep debris and foreign objects from entering engine Place fender cover or protective covering toprotect paint and batteries. Using a 7/16 inch deep barrel socket, loosen lower clamp on upper intake connection hose and slide lower clamp off of hose and down the steel tube out of the way. (FIGURE 1) Remove the six bolts holding the air intake connection and dipstick tube in place using a 10 mm 6 point socket. NOTE: Observe that these bolts are of different lengths so they can be installed incorrect location during assembly. (FIGURE 1) Remove intake manifold connection and hose as a unit, taking care not to damage gasket. This gasket can normally be reused however if it is torn, replace with a new gasket, Cummins part number 3913352. NOTE: Hold electrical grid heater in place while lifting the air connection so that the gasket joint under the grid heater is not disturbed. Cover theair tube and manifold openings with tape or towels to keep foreign objects out. Determine where your vehicle obtains its wastegate pressure signal. Some vehicles pick up this signal at an elbow on the front of the turbo as shown in FIGURE 2 while others get this signal at a tee connected to the rear of the injection pump as shown in FIGUREs 3 & 4. If your vehicle is like FIGURE 2 proceed to step 11below. If your vehicle gets the wastegate signal from the tee at the rear of the injection pump, loosen the hose clamps on the AFC housing to turbo wastegate tube air hose using a 7 mm socket. Disconnect the hose from the barbed fitting on the top of the fuel pump Air Fuel Control (AFC) housing. Slide the hose as far as possible onto the steel turbo wastegate tube. Remove the barbed fitting fromthe AFC housing using a 7/16 inch deep barrel socket. NOTE: Save this fitting in case you want to convert your engine back to stock, this fitting is not used with the Power Kit. Remove injection pump fuel supply tube banjo bolt using a 19 mm socket. NOTE: A few ounces of fuel will drain out which could wash the sealing washers away. Take care NOT to loose sealing washers as they are reused. If lostor damaged replace with Cummins part number 3918192. NOTE: The fuel supply tube is not removed , loosening it on the injection pump end allows access to get to the AFC housing screws. OPTIONAL: You can avoid removing the banjo bolt if you bend the fuel supply line slightly so as to make access to the break off screw. (See FIGURE 4) This option saves some time, eliminates breaking into the fuelline, and make engine restart more quickly. Next remove front passenger side AFC housing break off screw. NOTE: This screw is a factory break off screw with rounded head and no screw driver, allen head or TORX slot. Use a hand impact tool with a 6 inch long ¼” extension and a T15 TORX bit to remove this screw. A center punch may be required to start a hole in the center of this screw. Set the hand...