Banks Power Chevy_GMC Trucks: Duramax LLY-LBZ (Diesel ’06 - 07 6.6L) Intake-Techni-Cooler Intercooler '06-10 - Manual (Page 22)

22
96786 v.4.0
27.
Remove the charge air cooler
from the vehicle. Check that the lower
mounting peg grommets are removed
from the stock intercooler and place
to the side. The lower rubber grommet
will be transferred to the Banks
intercooler in the next step.
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.