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

1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
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 .

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

1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
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 .
4. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
5. Using a pick or a small flat-bladed screw driver, remove and discard the quick connect fitting clip from the charged air cooler outlet duct.
6. Remove the charged air cooler duct from the intake.
7. Remove the generator mounting bracket. Refer to Generator Bracket Replacement .
8. Remove the exhaust gas recirculation (EGR) cooler tube. Refer to Exhaust Gas Recirculation Valve Cooler Replacement .



9. Reposition the hose clamp at the bypass pipe.
10. Remove the turbocharger coolant outlet hose from the bypass pipe.



11. Reposition the turbocharger coolant outlet hose clamp.
12. Remove the turbocharger coolant outlet hose from the pipe on the turbocharger.



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



14. If necessary, remove the turbocharger. Refer to Turbocharger Replacement .
15. If necessary, remove the coolant outlet pipe clip bolt (3) from the turbocharger.
16. 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 .



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 the EGR cooler tube. Refer to Exhaust Gas Recirculation Valve Cooler Replacement .
10. Install the generator mounting bracket. Refer to Generator Bracket Replacement .



11. Install a NEW quick connect fitting clip to the charged air cooler duct.
12. Install the charged air cooler duct to the intake.
13. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
14. Connect the negative battery cables. Refer to Battery Negative Cable Disconnection and Connection .
15. Fill the cooling system. Refer to Cooling System Draining and Filling .
16. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .