GM Service Manual Online
For 1990-2009 cars only

Turbocharger Coolant Hoses/Pipes Replacement 6.6L (LB7) Engine

Tools Required

J 43181 Heater Line Quick Connect Release Tool

Removal Procedure


    Object Number: 813243  Size: SH
  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 cooling system. Refer to Cooling System Draining and Filling .
  5. Disconnect the negative battery cables. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.

  6. Object Number: 813244  Size: SH

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

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

  9. Object Number: 877275  Size: SH
  10. Loosen the charged air cooler outlet duct to intake hose clamp (1).
  11. 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.

  12. Remove the charged air cooler duct from the intake.

  13. Object Number: 666693  Size: SH
  14. Remove the generator positive cable nut.
  15. Remove the positive cable from the generator.

  16. Object Number: 674573  Size: SH
  17. Disconnect the generator electrical connector (1).

  18. Object Number: 669244  Size: SH
  19. Remove the ribbed idler pulley from the generator bracket.
  20. Remove the generator bracket and position to the side.
  21. • The generator does not require removal.
    • The drive belt tensioner does not require removal.

    Object Number: 744247  Size: SH
  22. Disconnect the fuel injection control module electrical connectors (2).

  23. Object Number: 744237  Size: SH
  24. Remove the fuel line bolts.
  25. Remove the fuel lines (2) from the fuel injection control module.

  26. Object Number: 362171  Size: SH
  27. Using J 43181 , disconnect the inlet heater hose from the heater core inlet.
  28. Remove the fuel injection control module wiring harness conduit from the heater pipe.

  29. Object Number: 699325  Size: SH
  30. Remove the heater inlet pipe to fuel filter bolt.
  31. Remove the heater inlet pipe to thermostat housing bolt.
  32. Remove the heater inlet pipe with O-ring seal from the thermostat housing.

  33. Object Number: 699335  Size: SH
  34. Remove the turbocharger coolant feed pipe bracket bolts.
  35. Remove the turbocharger coolant return hose clamps and hose.

  36. Object Number: 668428  Size: SH
  37. Disconnect the turbocharger coolant feed hose from the turbocharger.

  38. Object Number: 699333  Size: SH
  39. Remove the turbocharger coolant feed pipe nut.
  40. Remove the coolant feed pipe.

  41. Object Number: 668427  Size: SH
  42. Disconnect the turbocharger coolant return hose from the turbocharger coolant bypass valve.
  43. Disconnect the turbocharger coolant return hose from the turbocharger.

Installation Procedure


    Object Number: 668427  Size: SH
  1. Connect the turbocharger coolant return hose and clamp to the turbocharger coolant bypass valve.
  2. Connect the turbocharger coolant return hose and clamp to the turbocharger.

  3. Object Number: 699333  Size: SH
  4. Install the turbocharger coolant feed pipe.
  5. 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.

  6. Install the turbocharger coolant feed pipe nut.
  7. Tighten
    Tighten the nut to 9 N·m (80 lb in).


    Object Number: 668428  Size: SH
  8. Connect the turbocharger coolant feed hose and clamps to the turbocharger and the coolant pipe.

  9. Object Number: 699335  Size: SH
  10. Install the turbocharger coolant return hose and clamps.
  11. Install the turbocharger coolant feed pipe bracket bolts.
  12. Tighten
    Tighten the bolts to 21 N·m (15 lb ft).


    Object Number: 699325  Size: SH
  13. Install a NEW O-ring seal to the heater inlet pipe.
  14. Install the heater inlet pipe to the thermostat housing.
  15. Install the heater inlet pipe to thermostat housing bolt.
  16. Tighten
    Tighten the bolt to 21 N·m (15 lb ft).

  17. Install the heater inlet pipe to fuel filter bolt.
  18. Tighten
    Tighten the bolt to 21 N·m (15 lb ft).


    Object Number: 651356  Size: SH
  19. Connect the inlet heater hose to the heater inlet.
  20. Install the fuel injection control module wiring harness conduit to the heater pipe.

  21. Object Number: 669244  Size: SH
  22. Install the generator bracket and bolts.
  23. Tighten
    Tighten the bolts to 50 N·m (37 lb ft).

  24. Install the ribbed idler pulley and bolt.
  25. Tighten
    Tighten the bolt to 43 N·m (32 lb ft).


    Object Number: 744237  Size: SH
  26. Install the fuel lines (2) to the fuel injection control module.
  27. Install the fuel line bolts.
  28. Tighten
    Tighten the bolts to 35 N·m (26 lb ft).


    Object Number: 744247  Size: SH
  29. Connect the fuel injection control module electrical connectors (2).

  30. Object Number: 666693  Size: SH
  31. Install the generator positive cable and nut.
  32. Tighten
    Tighten the nut to 9 N·m (80 lb in).


    Object Number: 674573  Size: SH
  33. Connect the generator electrical connector (1).

  34. Object Number: 877275  Size: SH
  35. Remove the tape from the turbocharger openings.
  36. Install the charged air cooler outlet duct to the intake.
  37. Align the mark on the duct (3) with the alignment mark on the intake.
  38. Position the clamp (1) as shown for proper clearance.
  39. Tighten
    Tighten the clamps to 6 N·m (53 lb in).


    Object Number: 813246  Size: SH
  40. Install the outlet duct to the turbocharger.
  41. Align the outlet duct alignment indicator (1) to the turbocharger alignment indicator (2).

  42. Object Number: 813244  Size: SH

    Important: The outlet duct must be fully seated against the MAT/IAT sensor with the edge of the seal in the vertical position.

  43. Install the outlet duct to the MAT/IAT sensor.
  44. Tighten the outlet duct clamps at the turbocharger and the MAT/IAT sensor.
  45. Tighten
    Tighten the clamps to 6 N·m (53 lb in).


    Object Number: 813243  Size: SH
  46. Install the upper intake manifold cover.
  47. Install the upper intake manifold cover to the outlet duct.
  48. Tighten the outlet duct clamp at the upper intake manifold cover.
  49. Tighten
    Tighten the clamp to 6 N·m (53 lb in).

  50. Fill the cooling. Refer to Cooling System Draining and Filling .
  51. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.

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

Removal Procedure


    Object Number: 1334381  Size: SH
  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).
  5. 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.

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

  10. Object Number: 1334881  Size: SH
  11. Disconnect the fuel injection control module electrical connectors.

  12. Object Number: 1334883  Size: SH
  13. Remove the upper fuel injection control module fuel line bolt.
  14. Remove and discard the washer from the banjo fitting.

  15. Object Number: 1335429  Size: SH
  16. Reposition the hose clamp at the bypass pipe.
  17. Remove the turbocharger coolant outlet hose from the bypass pipe.

  18. Object Number: 1335578  Size: SH
  19. Reposition the turbocharger coolant outlet hose clamp.
  20. Remove the turbocharger coolant outlet hose from the pipe on the turbocharger.

  21. Object Number: 1335600  Size: SH
  22. Remove the turbocharger coolant outlet pipe bolt and nut.

  23. Object Number: 1367360  Size: SH
  24. If necessary, remove the turbocharger. Refer to Turbocharger Replacement in Engine Mechanical - 6.6L (LLY).
  25. If necessary, remove the coolant outlet pipe clip bolt (3) from the turbocharger.
  26. If necessary, remove the coolant outlet pipe.

Installation Procedure


    Object Number: 1367360  Size: SH
  1. If necessary, install the coolant outlet pipe.
  2. Notice: Refer to Fastener Notice in the Preface section.

  3. If necessary, install the coolant outlet pipe clip bolt (3) to the turbocharger.
  4. Tighten
    Tighten the bolt to 9 N·m (80 lb in).

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

  6. Object Number: 1335600  Size: SH
  7. Install the turbocharger coolant outlet pipe bolt and nut.
  8. Tighten
    Tighten the bolt/nut to 9 N·m (80 lb in).


    Object Number: 1335578  Size: SH
  9. Install the turbocharger coolant outlet hose to the pipe on the turbocharger.
  10. Position the turbocharger coolant outlet hose clamp.

  11. Object Number: 1335429  Size: SH
  12. Install the turbocharger coolant outlet hose to the bypass pipe.
  13. Position the hose clamp at the bypass pipe.

  14. Object Number: 1334883  Size: SH
  15. Install a NEW washer to the banjo fitting.
  16. Install the upper fuel injection control module fuel line bolt.
  17. Tighten
    Tighten the bolt to 35 N·m (26 lb ft).


    Object Number: 1334881  Size: SH
  18. Connect the fuel injection control module electrical connectors.
  19. Install the EGR cooler tube. Refer to Exhaust Gas Recirculation Valve Cooler Replacement in Engine Controls - 6.6L (LLY).
  20. Install the generator mounting bracket. Refer to Generator Bracket Replacement in Engine Electrical.

  21. Object Number: 1334381  Size: SH

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

  22. Install the charged air cooler duct to the intake.
  23. Tighten the charged air cooler outlet duct to intake hose clamp.
  24. Tighten
    Tighten the clamp to 6 N·m (53 lb in).

  25. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in Engine Controls - 6.6L (LLY).
  26. Connect the negative battery cables. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  27. Fill the cooling system. Refer to Cooling System Draining and Filling .
  28. 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

Removal Procedure


    Object Number: 1334380  Size: SH
  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. Important: After removing the charged air cooler duct, cover the turbocharger opening with tape in order to prevent entry of objects.

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

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

  7. Object Number: 1335386  Size: SH
  8. Reposition the turbocharger coolant inlet hose clamp at the bypass valve.

  9. Object Number: 1367360  Size: SH
  10. Remove the turbocharger coolant inlet hose banjo bolt (1).
  11. Remove the inlet hose washer and inlet line.

Installation Procedure

    Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1367360  Size: SH
  1. Install the inlet hose washer and inlet line.
  2. Install the turbocharger coolant inlet hose banjo bolt (1).
  3. Tighten
    Tighten the bolt to 25 N·m (18 lb ft).


    Object Number: 1335386  Size: SH
  4. Position the turbocharger coolant inlet hose clamp at the bypass valve.

  5. Object Number: 1334380  Size: SH
  6. Remove the tape from the turbocharger openings.
  7. Important: Lubricate the end of the duct prior to installation.

  8. Install the charged air cooler inlet duct connector (4) to the turbocharger.
  9. Tighten the charged air cooler inlet duct connector to turbocharger clamp (1).
  10. Tighten
    Tighten the clamp to 6 N·m (53 lb in).

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