Banks Power Chevy_GMC Trucks: Duramax LB7 (Diesel ’01 - 04 6.6L) Intake- Techni-Cooler Intercooler '01-05 - Manual (Page 18)

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49.
Install the driver and passenger
side boost tubes. New clamps are
provided for the intake manifold hose
to boost tube connection and the
turbo hose to boost tube connection.
All other locations reuse the factory
clamps. Tighten the clamps to 75
in-lbs. The following hoses are used at
each location:
2001 vehicles:
Turbocharger outlet: 3 inch to 2 3 ⁄
8
inch ID straight reducer
CAC inlet (driver side): Re-use
factory hose
CAC outlet (passenger side):
Uniform 3 inch ID with 145-degree
bend
Intake manifold: 3 inch to 2 3 ⁄
8
inch
ID with 120-degree bend
2002 to 2004 LB7 vehicles:
Turbocharger outlet: 3 inch to 2 3 ⁄
8
inch ID straight reducer
CAC inlet (driver side): Re-use
factory hose
CAC outlet (passenger side): Re-use
factory hose
Intake manifold: 3 inch to 2 3 ⁄
8
inch
ID straight reducer
Note: the a/c line that runs near
the intake manifold will need to
be bent downward to provide
clearance for the boost tube.
the line can be bent by placing a
wooden block on the a/c line, then
lightly tapping the block with a
hammer.
Rotate self-tightening spring hose
clamps on fuel filter away from
Banks turbo charge outlet boost
hose. See Figure 16.
2004.5 to 2005 LLY vehicles:
Turbocharger outlet: 3 inch to 2 3 ⁄
8
inch ID straight reducer
CAC inlet (driver side): Re-use
factory hose
CAC outlet (passenger side): Uniform
3 inch ID with 145-degree bend
Intake manifold: 3 inch to 2
3 ⁄
8
inch
ID with 120-degree bend
50.
Install the driver side fenderwell.
The charge air temperature before the
CAC approaches 400˚F at full load. So,
take care to route wiring away from
the driver side boost tube and
re-install the factory wire retainers
on the fenderwell cover.
51.
Install the lower air cleaner
support bracket. Tighten the bolts
to 80 in-lbs. Install the air cleaner
mounting tray. Tighten the bolts to
80-in-lbs.
52.
Install the air box assembly on it’s
mounting tray. Install the air duct on
the turbocharger inlet and tighten it’s
hose clamp.
53.
Re-install the connector on the
MAF sensor at the air box assembly
54.
Re-connect the ground cables on
both batteries.
55.
Clean an area that is easily visible
on the upper radiator core support
with a non-oil based solvent, such as
Acetone, Mineral Spirits, Denatured
Alcohol or Lacquer Thinner. Allow to
dry and then attach the Banks E.O.
sticker to the upper radiator core
support.
Note: For 2001 models, attach Banks
e.o. label D-161-82. For all other models,
attach Banks e.o. label D-161-83