Banks Power Chevy_GMC Trucks: Duramax LB7 (Diesel ’01 - 04 6.6L) Intake- Techni-Cooler Intercooler '01-05 - Manual (Page 3)

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1.
Disconnect the ground cables from
both the driver and passenger side
batteries. Position the loose cables so
that they do not come into contact
with their respective battery posts
during the installation.
2.
Disconnect the mass airflow (MAF)
sensor’s connector at the air box
assembly. Loosen the hose clamp
at the inlet tube to the turbocharger
and disconnect the tube from the
turbocharger. Pull the air box out of
the vehicle. It’s held in place by plastic
fasteners that snap in place. Cover
the turbocharger inlet with a clean
rag to prevent debris from entering
the turbocharger that could result in
damage upon start-up.
3.
Remove the upper grill baffle that
mounts between the grill and radiator
cross brace. The baffle is held in place
by 7 push-in retainers. The retainers
are removed by pulling up on the
center pin, then prying the retainer out
of it’s hole as shown in Figure 1.
4.
Remove the grill
a. 2001 to 2002 vehicles: The grill is
retained by (4x) 1 ⁄
4
turn fasteners, (1x)
screw at the latch support, and (2x)
snaps at the outboard ends of the grill.
Depress the snaps at the ends of the
grill before attempting to remove the
grill from the vehicle.
b. 2003 to 2005 vehicles: Disengage
the snaps at the outboard ends of the
grill. Pull the grill from the vehicle.
5.
Rotate the headlamp-retaining
pin, then remove the pin as shown in
Figure 2.
Note: Figure 2 shows a 2004 model
year vehicle; earlier model years may
have two vertical pins per headlamp
assembly.
6.
Disconnect the connectors from the
backside of the headlamp assembly,
and remove from the vehicle. Repeat
for the driver and passenger side
headlamp assemblies.
intercooler assembly installation
Figure 1: Removal of push-in retaining pins