Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement 6.6L (LLY) Engine

Important: After removing the air cleaner outlet duct, cover the turbocharger openings with tape in order to prevent entry of objects.

1. Remove the air cleaner. Refer to Air Cleaner Replacement in Engine Controls - 6.6L (LLY).
2. Remove the charged air cooler outlet duct from the intake and the charged air cooler. Refer to Charged Air Cooler Hoses/Pipes Replacement in Engine Mechanical - 6.6L (LLY).
3. Unclip the engine harness from the retainer and remove the engine wiring harness from the retainer.
4. Remove the wiring harness clamp nut at the air intake pipe.
5. Remove the nut, bolt, and the 2 wiring harness brackets and reposition the wiring harness.
6. Reposition the engine harness from the air inlet tube.
7. Remove the air inlet pipe nuts.
8. Remove the air inlet tube.
9. Remove the air intake pipe. Refer to Air Intake Pipe Replacement in Engine Controls - 6.6L (LLY).



10. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
11. Reposition the exhaust gas recirculation (EGR) coolant pipe hose clamp.
12. Remove the EGR coolant pipe hose.



13. Remove the EGR coolant pipe bolts.
14. Remove the EGR coolant pipe.
15. Remove and discard the coolant pipe O-ring seal.

1. Install a NEW O-ring seal onto the coolant pipe. Lubricate the seal with engine coolant.
2. Install the EGR coolant pipe.

Notice: Refer to Fastener Notice in the Preface section.

3. Install the EGR coolant pipe bolts.

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




4. Install the EGR coolant pipe hose.
5. Position the EGR coolant pipe hose clamp.
6. Connect the ECT sensor electrical connector.
7. Remove all covers on the turbocharger.
8. Install the air intake pipe. Refer to Air Intake Pipe Replacement in Engine Controls - 6.6L (LLY).



9. Install the air inlet tube.
10. Install the air inlet tube nuts.

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

11. Position the engine harness to the retainer and secure the retainer.
12. Install the engine wiring harness clamps to the thermostat housing and the air intake pipe with nut and bolt.

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

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

13. Install the charged air cooler outlet duct to the intake. Refer to Charged Air Cooler Hoses/Pipes Replacement in Engine Mechanical - 6.6L (LLY).
14. Install the air cleaner. Refer to Air Cleaner Replacement in Engine Controls - 6.6L (LLY).