Removal Procedure
- Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
- Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
- Loosen the charged air cooler outlet duct clamp (1).
- Remove the charged air cooler outlet duct.
- Loosen the charged air cooler inlet duct to turbocharger clamp (1).
- Remove the charged air cooler inlet duct from the turbocharger .
- Remove the engine wiring harness. Refer to Engine Wiring Harness Assembly Replacement .
- Remove the water outlet tube. Refer to Water Outlet Tube Replacement in Engine Cooling.
- Disconnect the fuel feed and return pipes from the chassis pipes. Refer to Metal Collar Quick Connect Fitting Service .
- Remove the air conditioning (A/C) compressor/power steering pump bracket. Refer to Air Conditioning (A/C) Compressor and Power Steering Pump Bracket Replacement in Engine Mechanical - 6.6L.
- Remove the heater pipe bolt and pipe.
- Remove the fuel pipe clip bolt and clip.
- Remove the fuel pipe clip bolts and clips on the intake.
- Remove the fuel feed front pipe bracket nuts.
- Remove the fuel feed front hose from the fuel feed front pipe.
- Remove the fuel feed front pipe (1).
Important: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
Important: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
Installation Procedure
- Install the fuel feed front pipe (1).
- Install the fuel feed front hose to the fuel feed front pipe.
- Install the fuel feed front pipe bracket nuts.
- Install the fuel pipe clips and bolts to the intake.
- Install the fuel pipe clip and bolt.
- Install the heater pipe and bolt.
- Install the A/C compressor/power steering pump bracket. Refer to Air Conditioning (A/C) Compressor and Power Steering Pump Bracket Replacement in Engine Mechanical - 6.6L.
- Connect the fuel feed and return pipes from the chassis pipes. Refer to Metal Collar Quick Connect Fitting Service .
- Install the water outlet tube. Refer to Water Outlet Tube Replacement in Engine Cooling.
- Install the charged air cooler inlet duct to the turbocharger.
- Align the mark on the duct (2) with the mark on the turbocharger.
- Position the clamp (1) as shown for proper clearance.
- Install the charged air cooler outlet duct to the intake.
- Align the mark on the duct (3) with the mark on the turbocharger.
- Position the clamp (1) as shown for proper clearance.
- Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
- Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
Tighten
Tighten the nuts to 25 N·m (18 lb ft).
Tighten
Tighten the bolts to 16 N·m (11 lb ft).
Tighten
Tighten the bolt to 16 N·m (11 lb ft).
Tighten
Tighten the bolt to 20 N·m (15 lb ft).
Tighten
Tighten the clamp to 6 N·m (53 lb in).
Tighten
Tighten the clamp to 6 N·m (53 lb in).
