Banks Power Chevy_GMC Trucks: Duramax LLY-LBZ (Diesel ’06 - 07 6.6L) Power Systems- PowerPack & Stinger Systems w Economind (LLY & LBZ) '06-07 (PDA) Compatible w_ Optional PowerPDA - Manual (Page 22)

22
96506 v.8.0
INSTaLL BaNkS TECHNI-
CooLEr
28.
Locate the supplied Banks
charge air cooler and transfer both
top and bottom rubber grommets
and corresponding metal sleeve into
position on the Banks charge air
cooler.
29.
Install the Banks cAc into
the vehicle. Align the lower cAc
mounting pegs with the rubber
mounts in the vehicle’s frame. There
is a significant amount of play in
the rubber mounts that can allow
them to be aligned with the cAc as
required.
30.
Reinstall the radiator cross
brace. Leave the attachment bolts
loose to aid in aligning the cAc with
the support.
31.
Reinstall the radiator onto cAc.
Secure the radiator to the Banks cAc
with 5 ∕
16
”-18 by 1 1 ∕
8
long bolts and
large OD washers supplied in the
Banks system. Tighten to 10-12 ft-lbs.
Note: Install the top two bolts 1st
then install bottom two bolts. It may
be helpful to use a pry bar or similar
to assist in aligning the screw holes
between the radiator and the Banks
charge air cooler.
32.
Install the upper cAc
attachment bolts that were
previously removed. There is enough
play in the lower mounting pads, that
the cAc can be positioned to align
with the upper cross brace. Tighten
the bolts.
33.
check that the engine-cooling
fan can freely spin without contacting
the lower fan shroud. If the fan
contacts the shroud, the shroud must
be realigned with the radiator.
34.
Tighten the 6 radiator-cross
brace bolts to 80 in-lbs. Install the
diagonal fender support brace and
tighten the bolts.
35.
Install the upper fan shroud.
The push-in retainers that secure the
upper shroud to the lower shroud are
secured by inserting the retainer with
the center pin pulled out. Once the
retainer is inserted, press the center
pin down to secure the retainer.
Install and upper fan shroud bolts.
The stock upper fan shroud bolts are
reused and should be tighten to 80
in-lbs.
36.
Install the transmission control
module to the upper fan shroud.
37.
Install the a/c condenser and
tighten it’s upper mounting bolts to
80 in-lbs.
38.
Install the latch support. Tighten
it’s six attachment bolts to 80 in-lbs.
39.
Install the hood latch. Position it
so that it aligns with the marks that
were previously made on the latch
support prior to it’s removal. Tighten
it’s bolts to 80 in-lbs.
40.
Install the driver and passenger
side plastic headlamp support
structures. Tighten the screws to 80
in-lbs.
41.
Install the light bulbs into the
park/turn signal lamp assemblies.
These are held in place by turning
them clockwise. Install the park/
turn signal lamp assembly onto
the vehicle for both the driver and
passenger side.
42.
Install the electrical connectors
to the headlamp assembly. Install
the headlamp assemblies and secure
them with their retaining pins.
43.
Install the grill by snapping in
the tabs into the retainer clips.
44.
Install the upper grill baffle
and secure with the seven push-
in retainers that were previously
removed. The push-in retainers that
secure the grill baffle are secured by
inserting the retainer with the center
pin pulled out. Once the retainer is
inserted, press the center pin down
to secure the retainer.
45.
Install the driver and passenger
side boost tubes. Tighten the driver
side hose clamps to 75 in-lbs. Make
sure when reinstalling the passenger
side boost tube that the hose coupler
fits tight and flush to its respective
mounting location, then reinstall the
wire retaining clip.
Note: Before slipping any boost
tubes and the corresponding
hoses, into position, ensure that all
connection ends are clean and free
of any oil residue and contaminates.
Clean compressor outlet and all
connection points with a non-oil
based solvent such as Acetone,
Mineral Spirits, Denatured Alcohol or
Lacquer Thinner. Read and follow the
manufactures operation instruction
for non-oil based solvent cleaner.
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 a/c line can be
bent by placing a wooden block on
the a/c line, then lightly tapping the
block with a hammer.
46.
Install the driver side and
passenger 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.
47.
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.
48.
Install the air box assembly on
it’s mounting tray. Install the air duct
on the turbocharger inlet and tighten
it’s hose clamp.
49.
Re-install the connector on the
MAF sensor at the air box assembly
50.
Re-connect the ground cables
on both batteries
-END, SEcTION 2-