Banks Power Chevy_GMC Trucks: Duramax LB7 (Diesel ’01 - 04 6.6L) Intake- Big Hoss Intake Manifold System '01-07 - Manual (Page 15)

96775 v.2.0
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Note: Normally manifolds install with
their inlet flanges facing forward, how-
ever they may be reversed for special
applications.
1.
Two balance tube spools with o-ring
seals interconnect the manifold ple-
nums. These spools are supplied blank
(no drilled thru-hole) and may be drilled
out as desired. Different turbocharger
performance characteristics may
require different balance hole sizes to
dampen intake pulsation and maintain
the same boost levels in both banks
of the engine. We suggest you start by
drilling a ½ diameter hole through each
spool and enlarge the hole if testing
dictates.
2.
Install two 3 ∕
32
“ x 1.612” diameter
and three 3 ∕
32
“ x 2.487” diameter o-rings
in the groves on each manifold mount-
ing flange. The small o-rings go in the
grooves around the end runners of
each manifold.
Note: Dow-Corning III, or a small dab of
gasket sealant or RtV may be used to
hold the o-rings in place in the manifold
flange grooves. See Figure 7.
3.
Install two 1 ∕
8
“ x 1.109” diameter
o-rings in the grooves on each balance
tube spool. Apply a light oil on all four
o-rings and insert both balance tubes
into the machined bosses on one of the
two manifold plenums. See Figure 7.
4.
Engage the free ends of the bal-
ance tube spools into the bosses on
the opposite side manifold and push
the manifolds together until the spools
seat in the manifolds. Carefully set the
paired manifolds on the cylinder head
faces while guiding loose fuel and oil
lines through the openings between
the manifold runners. This works best
with an assistant helping. See Figure
7. Check that the o-rings stayed in
place.
5.
Install eleven M8 x 1.25 x 30mm
socket head bolts through each mani-
fold base flange into heads. Leave bolts
finger tight. Balance tube spools will be
free to slide within their bores, but not
to the extent that their o-rings will not
seal.
6.
Tighten the bolts on the right hand
manifold first. A ball-drive hex wrench
and L-hex wrench work best in tight
places. An 8mm box wrench around
the shaft of a long 8mm ball handle
can be used to feed through the run-
ners on the manifolds for more torque.
Once the right manifold bolts are tight,
tighten the left side.
7.
Install the right and left fuel rails on
the intake manifold base flanges using
the original M8 bolts. Fuel rails mount
on the rear set of the double bolt pat-
tern. The right hand rail has the fuel
pressure sensor.
8.
Install the new high-pressure fuel
crossover line by feeding it through the
opening just behind the front-runners
on each manifold. Thread the tube
nuts onto each fuel rail, and leave the
nuts finger tight. The tube may be bent
slightly if necessary to line up the end
connections. See Figure 1.
9.
Install the original high-pressure
fuel line between the outlet connec-
tions on top of the fuel pump and front
of the left hand fuel rail. The line feeds
through the opening behind the front-
runner on the left hand manifold and
under the crossover fuel line. The line
must be reversed end-for-end to clear
the manifold runners. Tighten the tube
nuts on both fuel lines. It may be easi-
est to loosen the nuts and disengage
the ends of the long fuel line before
first tightening the short line, then the
long line.
Section 6
INSTALL MANIFOLDS ON CYLINDER HEADS