Banks Power Dodge Trucks: (Diesel ’03 - 07 5.9L Cummins) Intake- Techni-Cooler Charge Air Cooler ('03-07) - Manual (Page 9)

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 passenger side tube is
most easily installed by placing the 2.75
inch straight hose as it will normally
reside on the boost tube when installed
on the vehicle. Then slide the 3.5 inch
diameter hose all the way onto the
boost tube. install the boost tube in the
vehicle, make the attachment to the
turbocharger, then slide the 3.5 inch
diameter hose towards the techni-
cooler to complete the installation.
Note: Applying a silicon lubricating
spray to inside of the hoses will
temporarily assist in sliding the hose on
the boost tube. install the hose clamps
on the passenger side boost tube as
shown in Figure 6 to avoid clearance
issues. the clamps should be tightened
to 5 ft-lbs (60 in-lbs).
33.
install the driver side boost tube.
The driver side tubes uses a 3.5 inch
diameter straight hose at the intake
manifold and a 3.5 inch diameter hump
hose at the cac. the orientation of
the hose clamps should be as shown
in Figure 7 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.
Figure 6. Orientation of the Passenger Side Hose Clamps to Avoid Clearance Issues.
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