Banks Power Dodge Trucks: (Diesel ’03 - 07 5.9L Cummins) Intake- Techni-Cooler Charge Air Cooler ('03-07) - Manual (Page 5)

1.
Disconnect the negative battery
cables from both batteries
2.
Disconnect the inlet air
temperature/ pressure sensor
connector located on the air box
cover. the connector is shown in
Figure 1.
3.
Remove the nut that fastens the air
filter housing to the radiator cross brace.
4.
Loosen the hose clamp that
secures the air inlet duct to the
turbocharger inlet. Disconnect the inlet
duct from the turbocharger.
5.
Remove the air box and inlet duct
as an assembly. The air box is held in
place with re-usable push-in fasteners
and can be pulled out vertically.
6.
Remove the passenger side 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.
7.
cover the turbocharger inlet and
outlet with a clean rag to prevent
foreign debris from entering these
locations.
8.
Remove the bolt the holds the
engine oil dipstick to the intake. save
the bolt for re-use.
9.
Remove the electric heater wire
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.
10.
Unbolt and remove the 4 bolts 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.
11.
Remove the driver side boost
tube.
12.
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 2.
Intercooler Assembly Installation
Figure 1. Location of the Inlet Air Temp/ Pressure Sensor
96785 v.7.0
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