Banks Power Dodge Trucks: (Diesel ’03 - 07 5.9L Cummins) Intake- Big Hoss Intake Manifold System '03-07 235, 250, 305 and 325 HP, Dodge Cummins 5.9L (24-valve) Trucks - Manual (Page 10)

10
96774 v.5.0
1.
if not previously installed, tap
the three (3) 3 ⁄
16
x 3 ⁄
8
dowel pins
into holes on the cylinder head
intake flange face. Dowel pins
must not protrude more than
.200 inch from the milled surface
of the head.
2.
Install the o-ring into the
groove on the intake manifold.
Remove any excess grease
from the o-ring that may be left
from the port-matching imprint
procedure. Take care that the
o-ring does not get stretched or
twisted during installation.
3.
install manifold, bolts and
washers as shown in Figure 4.
Place a 5 ⁄
16
AN washer on each
of the 5 ⁄
16
-18 x 1” upper manifold
bolts. Apply Teflon sealant to
the first 5-6 threads of each bolt
and install manifold with o-ring
against cylinder head, lightly snug
all bolts.
4. Place a 3 ⁄
8
-inch conical
(Belleville) washer on each of the
six 3 ⁄
8
inch lower manifold bolts.
(Dished side faces away from
bolt head). Apply a drop of oil on
the o-ring of each 3 ⁄
8
Stat-O-Seal
washer and slide washers against
the conical washers on the lower
manifold bolts.
5.
Working from the center
outward, install the lower
manifold bolts and torque the
inner bolts to 20 ft. lbs. Torque
the two outer bolts on the longer
side and the outer bolt on the
short side to 30-35 ft. lbs. Torque
upper manifold bolts to 16-18ft.
lbs. See Figure 4.
6.
install fuel rail with three M8 x
40 mm hex bolts. Lightly snug the
bolts.
7.
Install high-pressure injector
nozzle lines and clamp brackets.
Apply Teflon sealant to the first
5-6 threads of the four factory
clamp bracket bolts, install bolts
but leave bolts loose. Tighten
nozzle lines at head and fuel rail,
then tighten bracket bolts and
fuel rail bolts. Torque bolts to
12-14 ft. lbs..
8.
Lightly oil o-ring on factory
MAP/TEMP sensor and install
in bore on top of manifold.
Apply a very small amount of
Teflon sealant to the two factory
mounting screws and tighten.
9.
Install two socket head 1 ⁄
8
NPT pipe plugs in ports on intake
manifold. Both ports are located
near the front of the manifold,
one on the top and one on the
side. A mechanical boost gauge
or other boost-sensing device
may be connected to either port.
Use Teflon sealant on the pipe
threads.
10.
Reconnect electrical wire
looms to injector plugs and
engine sensors. Reroute engine
wire looms if necessary. Unused
intake heater wiring should be
removed. An M6 x 12mm hex
bolt and M6 lock washer is
provided to anchor the factory
wire loom clamp to the front
flange of the intake manifold next
to the head. An additional M6 x
35mm hex bolt, M6 lock washer,
and 1” x 1 ⁄
4
I.D. spacer are
provided to anchor the factory
wire loom clamp to the bottom
of the intake manifold behind the
fuel filter.
11. Mount the fuel filter
assembly bracket to the side of
the manifold using the factory
bolts and reconnect the low
pressure fuel lines. Reinstall the
high-pressure fuel line from the
fuel injection pump to the fuel rail
and tighten.
12.
On vehicles where the
throttle controller was originally
bolted to the cylinder head,
proceed to step 13. On all other
installations, install the coarse
threaded end of a 1 ⁄
4
X 1 1 ⁄
4
stud
in the front “ear” on the 4-inch
diameter inlet hose joint of
the Big Hoss intake manifold.
Temporally use two 1 ⁄
4
-28 hex jam
nuts tightened against each other
on the fine threads to tighten the
stud. once tight, remove the nuts
and proceed to step 17.
13.
Reinstall the throttle
controller assembly on the three
bosses at the top/front of the
intake manifold using the factory
bolts. From inside the cab, check
that the throttle pedal moves
smoothly through its full travel.
14 . Install an M6 spring clip
nut on the upper rear throttle
controller cover tab (see Figure
5). Reinstall plastic throttle
controller cover using all but one
Section 7
INTAke MANIFoLD To CyLINDer HeAD ASSeMBLy
Figure 5