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96824 v.4.0

Section 2

TECHNI-COOLER ASSEMBLY INSTALLATION

Figure 8

General Assembly

Banks Techni-Cooler Intercooler System

Item Description

P/N

Qty

Techni-Cooler Assembly

25536 1

Boost Tube, Left

41324 1

Boost Tube, Right

41325 1

Hose, 3.5”x 3.25”, Black

94215 1

Hose, 2.5”x 2.5”, 5-ply, Black

94273 1

Hump Hose, 3.5”x 3.25”, Black

94293 2

High-Ram Intake Manifold

2003-04

42745

2005-07

42746

Gasket, High-Ram Intake

93038 1

Stud, High-Ram Air Intake M6-1.0 x

⁄

-20 x 4.365 (03-04)

91534 3

Stud, High-Ram Air Intake M6-1.0 x 1⁄4-20 x 6.185 (05-07)

91536

Stud, High-Ram Air Intake M6-1.0 x

⁄

-20 x 6.725 (03-04)

91535 1

Stud, High-Ram Air Intake M6-1.0 x 1⁄4-20 x 6.595 (05-07)

91537

Nut, Nylock

⁄

”-20

91110 4

Washer, SAE Flat, Zinc

⁄

”

91102 4

Washer, Thread Sealing

⁄

”-20

91106 2

O-Ring. High-Ram

93606 2

Spacer, Battery Box

91890 1

Hex-Bolt, Washer Head, Black 8mm-1.25 x 30mm

91810 2

Hose clamp, 3.5” Spring Loaded

92897 6

Hose clamp, 2.5” Spring Loaded

— *

* These are stock components that will be re-used with the Banks Techni-Cooler System

Содержание Power Stinger

Страница 1: ...WITH SYSTEM 63743 63745 63747 63748 For iDash 1 8 instructions see iDash 1 8 manual 97654 Gale Banks Engineering 546 Duggan Avenue Azusa CA 91702 626 969 9600 Fax 626 334 1743 Product Information Sale...

Страница 2: ...P N 42750 42751 Increases flow and provides more uniform air distribution to the engine for more available power at a given boost level Banks Techni Cooler System P N 25974 25975 Provides increased ai...

Страница 3: ...limiting function to your Diesel Tuner OttoMind Programmer P N 66064 Contains Banks tunes that boost your vehicles HP Torque and MPG Displays a host of critical engine functions Provides service techn...

Страница 4: ...t moving parts and sharp edges Clearance of 8 inches or more is recommended where possible 6 During installation keep the work area clean If foreign debris is transferred to any Banks system component...

Страница 5: ...t lubricant spray Reciprocating saw Inch pound torque wrench Table of Contents General Installation Practices 4 Banks Powerpack System Section 1 8 Installation of Banks Monster Exhaust System Section...

Страница 6: ...6 96824 v 4 0 General Assembly Diagram BANKS POWERPACK SYSTEM...

Страница 7: ...96824 v 4 0 7...

Страница 8: ...Cab Short Bed 53528 1 Rear Intermediate Pipe Regular Cab Long Bed 53527 1 Rear Intermediate Pipe Excursion 53534 1 5 Extension Pipe Crew Cab Long Bed 53531 1 6 Monster Tailpipe Truck 53512 1 Excursion...

Страница 9: ...96824 v 4 0 9 8 5 12 16 10 15 14 13 1 11 6 7...

Страница 10: ...1 Extended Cab Long Bed 53558 1 Extended Cab Short Bed 53556 1 Crew Cab Long bed 53559 1 5 Y Pipe 2003 2007 53574 1 6 Monster Tailpipe Pass Side 2003 2007 53575 1 7 Monster Tailpipe Drvr Side 2003 200...

Страница 11: ...96824 v 4 0 11...

Страница 12: ...llow for T O P removal installation Retain all hardware and parts for reassembly 9 For Manual Transmissions only The transmission will need to be lowered to allow for removal and installation of the T...

Страница 13: ...cation see Figure 3 Note spacers are to be installed between the hanger pin and the inside of the frame rail Torque factory nuts to 20 ft lbs 21 Using a pry bar completely remove the rubber hanger fro...

Страница 14: ...Figure 4 33 Install the Banks rubber insulator onto the supplied hanger bracket Locate the two slots on the rear driver side frame and install the hanger bracket assembly using the 7 16 Hardware see...

Страница 15: ...45 ft lbs 38 Remove the protective covering from the tailpipe tip Caution The protective covering may ignite and burn if not removed prior to running the engine 39 Tighten the exhaust clamps as necess...

Страница 16: ...9 Stud High Ram Air Intake M6 1 0 x 1 4 20 x 4 365 03 04 91534 3 9 Stud High Ram Air Intake M6 1 0 x 1 4 20 x 6 185 05 07 91536 2 10 Stud High Ram Air Intake M6 1 0 x 1 4 20 x 6 725 03 04 91535 1 10...

Страница 17: ...a c condenser mounting brackets that are attached to the upper radiator support as shown in Figure 9 6 Remove the 2 bolts that attach the upper Charge Air Cooler CAC mounts to the upper radiator supp...

Страница 18: ...et For 2005 07 4 wheel drive equipped vehicles only A small bracket used to mount an electronic module will also be removed with the plastic battery tray 18 Remove both the driver and passenger side b...

Страница 19: ...E ROOM FOR THE BANKS TECHNI COOLER SYSTEM 23 For 2005 07 4 wheel drive equipped vehicles only Remove the two retaining clips that attach the wire harness to the metal battery tray 24 Remove the driver...

Страница 20: ...mm socket 31 Remove the passenger side battery tray 32 Trim the bracket below the battery tray as shown in Figure 16 Note Be careful not to cut the a c lines that are in close proximity to the bracket...

Страница 21: ...upper radiator air deflector with pushpins HIGH RAM INSTALLATION 47 Apply the supplied thread locker to the M6 threaded side of the High Ram studs The M6 thread length is shorter than the 1 4 20 threa...

Страница 22: ...rmly against the hose stops provided on the CAC and High Ram Allow a minimum 1 8 air gap between CAC High Ram and boost tubes Note The a c line on the passenger side may need to be bent to provide cle...

Страница 23: ...ead depth as you tap by periodically removing the tap and screwing the pipe coupling into the tapped hole The coupling should thread in 3 to 31 2 turns hand tight Do not install the probe in place at...

Страница 24: ...nder the power steering fluid reservoir towards the EconoMind Diesel Tuner 2005 07 model year vehicles Route the previously disconnected middle connector in the most direct path towards the EconoMind...

Страница 25: ...ll to the passenger compartment When passing through the firewall either make a hole in a factory grommet or drill a hole and use a new grommet If drilling check the backside to make sure there are no...

Страница 26: ...e sure not to pinch the RED single terminal wire Mounting The EconoMind Diesel Tuner 19 2003 04 model year vehicles only Remove the clip shown in Figure 37 to create adequate room to mount the EconoMi...

Страница 27: ...he fuse box cover as shown in Figure 28 32 23 Re install the plastic driver side battery box Torque the attachment bolts to 12 ft lbs 24 Re install the driver s side battery battery hold down clamp an...

Страница 28: ...28 96824 v 4 0 Figure 38 Figure 37...

Страница 29: ...e angle necessary to achieve the correct viewing angle 5 Make sure the suction cup and the mounting area on the windshield are clean and dry With the suction lever in the up position ensure the suctio...

Страница 30: ...EVENT SMALL CHILDREN AND OR PETS FROM CONTACT WITH ANY PART OF THIS SYSTEM 11 Secure Banks iQ Bridge Module under the dash to any dash frame support using the supplied cable ties Use the cable tie sup...

Страница 31: ...96824 v 4 0 31 Figure 45 Banks Bridge Module Figure 44 Banks iQ System Figure 43...

Страница 32: ...locate the Six Gun selector switch For 2003 04 model year vehicles skip to Step 9 to finish the selector switch installation procedure 7 2005 07 Automatic Transmission vehicles Set the vehicle s parki...

Страница 33: ...wn in Figure 49 Note All of the power settings ma y not be usable if the tab is not in slot 6 13 Install the switch through the 13 32 hole on the backside of the bezel The alignment pin should rest in...

Страница 34: ...aining Black and RED wires from each 4 pin connector gauge harness to the butt connectors as shown in Figure 52 b Strip one end of the RED wire and crimp it to the butt connector containing the RED wi...

Страница 35: ...ransmission learning procedure will need to be repeated when switching back to the higher power settings once the transmission adapts to the lower power settings It will be apparent when the transmiss...

Страница 36: ...and all connections are okay contact Banks Technical Service The RED LED will flash in a certain sequence if a connection is incorrect of if there is a problem with the system this sequence will ident...

Страница 37: ...ror or Internal Module Malfunction Turn ignition OFF and check fuse tap power connection to EconoMind Diesel tuner under dash panel Turn ignition back ON and re check for presence of code 3 3 Internal...

Страница 38: ...and harness Re connect the vehicle s MAP connector back into the MAP sensor 4 Disconnect the 2 ring terminals from the EGT thermocouple 5 Disconnect the 3 small connectors on the In Cab Cable and gent...

Страница 39: ...96824 v 4 0 39 Template 2 fan shroud step 35 CUT LINE BOOST TUBE FAN SHROUD TEMPLATE FRONT Template 1 fan shroud step 34...

Страница 40: ...40 96824 v 4 0 This page left blank intentionally...

Страница 41: ...Template 4 Templates for locating the power level switch on the dash panel Template 3 Templates for locating the power level switch on the dash panel 2003 04 model year vehicles only 2005 07 model yea...

Страница 42: ...le Banks Engineering 546 Duggan Avenue Azusa CA 91702 626 969 9600 Fax 626 334 1743 Product Information Sales 888 635 4565 Customer Support 888 839 5600 Installation Support 888 839 2700 bankspower co...

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