Turbocharger Coolant Hoses/Pipes Replacement 6.6L Engine

Tools Required

J 43181 Heater Line Quick Connect Release Tool

1. Loosen the outlet duct clamp at the upper intake manifold cover.
2. Remove the upper intake manifold cover from the outlet duct.
3. Remove the upper intake manifold cover.
4. Drain the engine coolant. Refer to Cooling System Draining and Filling .
5. Disconnect both battery negative cables. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.




Important: After removing the charged air cooler ducts, cover the turbocharger openings and the ducts with tape to prevent entry of objects.

6. Loosen the outlet duct clamps at the turbocharger and the mass air flow/intake air temperature (MAF/IAT) sensor.
7. Remove the outlet duct from the turbocharger and MAF/IAT sensor.



8. Loosen both of the charged air cooler outlet duct to intake hose clamps.

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

9. Remove the charged air cooler duct to intake hose.



10. Remove the nut retaining the positive cable to the generator.
11. Remove the positive cable from the generator.
12. Disconnect the generator electrical connector.



13. Remove the ribbed idler pulley from the generator bracket.
14. Remove the generator mounting bracket and secure to the side.

•	The generator does not require removal.

•	The drive belt tensioner does not require removal.

15. Disconnect the wiring harness connector to the fuel injection control module. Refer to Fuel Injector Control Module Replacement in Engine Controls - 6.6 L.
16. Remove the fuel lines to the fuel injection control module. Refer to Fuel Injector Control Module Replacement in Engine Controls - 6.6 L.



17. Use the J 43181 in order to disconnect the inlet heater hose from the heater core inlet.
18. Remove the fuel injection control module wiring harness conduit from the heater pipe.



19. Remove the bolt retaining the heater pipe to the fuel filter assembly.
20. Remove the bolt retaining the heater pipe to the thermostat housing.
21. Remove the heater pipe with O-ring seal from the thermostat housing.



22. Remove the bolt retaining the turbocharger outlet coolant pipe to the turbocharger coolant pipe bracket.
23. Remove the hose and clamp from the turbocharger outlet coolant pipe to thermostat bypass pipe.



24. Disconnect the turbocharger outlet coolant hose from the turbocharger.



25. Remove the nut retaining the turbocharger outlet coolant pipe.
26. Remove the coolant pipe from the engine.



27. Disconnect the turbocharger inlet coolant hose from the turbocharger coolant bypass valve.
28. Disconnect the turbocharger inlet coolant hose from the turbocharger.

1. Connect the turbocharger inlet coolant hose and clamp to the turbocharger coolant bypass valve.
2. Connect the turbocharger inlet coolant hose and clamp to the turbocharger.



3. Install the turbocharger outlet coolant pipe to the engine.

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.

4. Install the nut retaining the turbocharger outlet coolant pipe.

Tighten
Tighten the turbocharger outlet coolant pipe nut to 9 N·m (80 lb in).




5. Connect the turbocharger outlet coolant hose and clamps to the turbocharger and the coolant pipe.



6. Install the hose and clamp to the turbocharger outlet coolant pipe to thermostat bypass pipe.
7. Install the bolt retaining the turbocharger outlet coolant pipe to the pipe bracket.

Tighten
Tighten the turbocharger outlet coolant pipe bracket bolt to 21 N·m (15 lb ft).




8. Install a new O-ring seal to the heater pipe.
9. Install the heater pipe to the thermostat housing.
10. Install the bolt retaining the heater pipe to the thermostat housing.

Tighten
Tighten the heater pipe bolt to 21 N·m (15 lb ft).

11. Install the bolt retaining the heater pipe to the fuel filter assembly.

Tighten
Tighten the heater pipe bracket bolt to 21 N·m (15 lb ft).




12. Connect the inlet heater hose to the heater inlet.
13. Install the fuel injection control module wiring harness conduit to the heater pipe.



14. Install the generator mounting bracket and bolts.

Tighten
Tighten the generator mounting bracket bolts to 50 N·m (37 lb ft).

15. Install the ribbed idler pulley and bolt.

Tighten
Tighten the idler pulley bolt to 43 N·m (32 lb ft).

16. Install the fuel lines to the fuel injection control module. Refer to Fuel Injector Control Module Replacement in Engine Controls - 6.6 L.
17. Connect the wiring harness connector to the fuel injection control module. Refer to Fuel Injector Control Module Replacement in Engine Controls - 6.6 L.



18. Install the generator positive cable and the retaining nut to the generator.

Tighten
Tighten the generator positive cable nut to 9 N·m (80 lb in).

19. Connect the generator electrical connector.



20. Install the charged air cooler outlet duct to intake hose.

The hose is marked DUCT which connects to the charged air cooler outlet duct.

The hose is marked ENG which connects to the turbocharger.

Align the marks on the hose with the alignment marks on the pipe and duct.

21. Position the clamps as shown for proper clearance.

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




22. Install the outlet duct to the turbocharger.
23. Align the outlet duct alignment indicator (1) to the turbocharger alignment indicator (2).



24. Install the outlet duct to the MAF/IAT sensor.
25. Tighten the outlet duct clamps at the turbocharger and the MAF/IAT sensor.

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




26. Install the upper intake manifold cover.
27. Install the upper intake manifold cover to the outlet duct.
28. Tighten the outlet duct clamp at the upper intake manifold cover.

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

29. Fill the engine coolant. Refer to Cooling System Draining and Filling .
30. Connect both battery negative cables. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.