Turbocharger Coolant Hoses/Pipes Replacement 6.6L (LLY) Engine - Outlet Pipe

1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement in Engine Mechanical - 6.6L (LLY).
2. Drain the cooling system. Refer to Cooling System Draining and Filling .
3. Disconnect the negative battery cables. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
4. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in Engine Controls - 6.6L (LLY).

Important: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damage. Loosen the hose by twisting.

5. Loosen the charged air cooler outlet duct to intake hose clamp.
6. Remove the charged air cooler duct from the intake.
7. Remove the generator mounting bracket. Refer to Generator Bracket Replacement in Engine Electrical.
8. Remove the exhaust gas recirculation (EGR) cooler tube. Refer to Exhaust Gas Recirculation Valve Cooler Replacement in Engine Controls - 6.6L (LLY).



9. Disconnect the fuel injection control module electrical connectors.



10. Remove the upper fuel injection control module fuel line bolt.
11. Remove and discard the washer from the banjo fitting.



12. Reposition the hose clamp at the bypass pipe.
13. Remove the turbocharger coolant outlet hose from the bypass pipe.



14. Reposition the turbocharger coolant outlet hose clamp.
15. Remove the turbocharger coolant outlet hose from the pipe on the turbocharger.



16. Remove the turbocharger coolant outlet pipe bolt and nut.



17. If necessary, remove the turbocharger. Refer to Turbocharger Replacement in Engine Mechanical - 6.6L (LLY).
18. If necessary, remove the coolant outlet pipe clip bolt (3) from the turbocharger.
19. If necessary, remove the coolant outlet pipe.

1. If necessary, install the coolant outlet pipe.

Notice: Refer to Fastener Notice in the Preface section.

2. If necessary, install the coolant outlet pipe clip bolt (3) to the turbocharger.

Tighten
Tighten the bolt to 9 N·m (80 lb in).

3. If necessary, install the turbocharger. Refer to Turbocharger Replacement in Engine Mechanical - 6.6L (LLY).



4. Install the turbocharger coolant outlet pipe bolt and nut.

Tighten
Tighten the bolt/nut to 9 N·m (80 lb in).




5. Install the turbocharger coolant outlet hose to the pipe on the turbocharger.
6. Position the turbocharger coolant outlet hose clamp.



7. Install the turbocharger coolant outlet hose to the bypass pipe.
8. Position the hose clamp at the bypass pipe.



9. Install a NEW washer to the banjo fitting.
10. Install the upper fuel injection control module fuel line bolt.

Tighten
Tighten the bolt to 35 N·m (26 lb ft).




11. Connect the fuel injection control module electrical connectors.
12. Install the EGR cooler tube. Refer to Exhaust Gas Recirculation Valve Cooler Replacement in Engine Controls - 6.6L (LLY).
13. Install the generator mounting bracket. Refer to Generator Bracket Replacement in Engine Electrical.




Important: Lubricate the end of the duct prior to installation.

14. Install the charged air cooler duct to the intake.
15. Tighten the charged air cooler outlet duct to intake hose clamp.

Tighten
Tighten the clamp to 6 N·m (53 lb in).

16. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in Engine Controls - 6.6L (LLY).
17. Connect the negative battery cables. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
18. Fill the cooling system. Refer to Cooling System Draining and Filling .
19. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement in Engine Mechanical - 6.6L (LLY).

Turbocharger Coolant Hoses/Pipes Replacement 6.6L (LLY) Engine - Inlet Pipe

1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement in Engine Mechanical - 6.6L (LLY).
2. Drain the cooling system. Refer to Cooling System Draining and Filling .

Important: After removing the charged air cooler duct, cover the turbocharger opening with tape in order to prevent entry of objects.

3. Loosen the charged air cooler inlet duct connector to turbocharger clamp (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.

4. Remove the charged air cooler inlet duct connector (4) from the turbocharger.



5. Reposition the turbocharger coolant inlet hose clamp at the bypass valve.



6. Remove the turbocharger coolant inlet hose banjo bolt (1).
7. Remove the inlet hose washer and inlet line.

Notice: Refer to Fastener Notice in the Preface section.




1. Install the inlet hose washer and inlet line.
2. Install the turbocharger coolant inlet hose banjo bolt (1).

Tighten
Tighten the bolt to 25 N·m (18 lb ft).




3. Position the turbocharger coolant inlet hose clamp at the bypass valve.



4. Remove the tape from the turbocharger openings.

Important: Lubricate the end of the duct prior to installation.

5. Install the charged air cooler inlet duct connector (4) to the turbocharger.
6. Tighten the charged air cooler inlet duct connector to turbocharger clamp (1).

Tighten
Tighten the clamp to 6 N·m (53 lb in).

7. Fill the cooling system. Refer to Cooling System Draining and Filling .
8. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement in Engine Mechanical - 6.6L (LLY).