Turbocharger Coolant Hoses/Pipes Replacement 6.6L (LB7) Engine
Tools Required
J 43181 Heater
Line Quick Connect Release Tool
Removal Procedure
- Drain the engine coolant. Refer to
Cooling System Draining and Filling
.
- 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.
- Remove the air cleaner outlet duct from the air cleaner and the turbocharger.
- 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.
- Remove the charged air cooler duct to intake hose.
- Remove the nut retaining
the positive cable to the generator.
- Remove the positive cable from the generator.
- Disconnect the generator electrical connector.
- Remove the ribbed idler
pulley from the generator bracket.
- Remove the generator mounting bracket and secure to the side.
• | The generator does not require removal. |
• | The drive belt tensioner does not require removal. |
- Disconnect the wiring harness connector to the fuel injection
control module. Refer to
Fuel Injector Control Module Replacement
in Engine Controls - 6.6L.
- Remove the fuel lines to the fuel injection control module. Refer
to
Fuel Injector Control Module Replacement
in Engine Controls - 6.6L.
- Remove the fuel injection control module wiring harness conduit
from the heater pipe.
- Remove the bolt retaining
the heater pipe to the fuel filter assembly.
- Remove the bolt retaining the heater pipe to the thermostat housing.
- Remove the heater pipe with O-ring seal from the thermostat housing.
- Remove the bolt retaining
the turbocharger outlet coolant pipe to the turbocharger coolant pipe bracket.
- Remove the hose and clamp from the turbocharger outlet coolant
pipe to thermostat bypass pipe.
- Disconnect the turbocharger
outlet coolant hose from the turbocharger.
- Remove the nut retaining
the turbocharger outlet coolant pipe.
- Remove the coolant pipe from the engine.
- Disconnect the turbocharger
inlet coolant hose from the turbocharger coolant bypass valve.
- Disconnect the turbocharger inlet coolant hose from the turbocharger.
Installation Procedure
- Connect the turbocharger
inlet coolant hose and clamp to the turbocharger coolant bypass valve.
- Connect the turbocharger inlet coolant hose and clamp to the turbocharger.
- 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.
- Install the nut retaining the turbocharger outlet coolant pipe.
Tighten
Tighten the turbocharger outlet coolant pipe nut to 9 N·m
(80 lb in).
- Connect the turbocharger
outlet coolant hose and clamps to the turbocharger and the coolant pipe.
- Install the hose and clamp
to the turbocharger outlet coolant pipe to thermostat bypass pipe.
- 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).
- Install a new O-ring seal
to the heater pipe.
- Install the heater pipe to the thermostat housing.
- Install the bolt retaining the heater pipe to the thermostat housing.
Tighten
Tighten the heater pipe bolt to 21 N·m (15 lb ft).
- 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).
- Install the fuel injection control module wiring harness conduit
to the heater pipe.
- Install the generator
mounting bracket and bolts.
Tighten
Tighten the generator mounting bracket bolts to 50 N·m
(37 lb ft).
- Install the ribbed idler pulley and bolt.
Tighten
Tighten the idler pulley bolt to 43 N·m (32 lb ft).
- Install the fuel lines to the fuel injection control module. Refer
to
Fuel Injector Control Module Replacement
in Engine Controls - 6.6L.
- Connect the wiring harness connector to the fuel injection control
module. Refer to
Fuel Injector Control Module Replacement
in Engine Controls - 6.6L.
- 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).
- Connect the generator electrical connector.
- 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.
- Position the clamps as shown for proper clearance.
Tighten
Tighten the clamps to 6 N·m (53 lb in).
- Install the air cleaner outlet duct to the air cleaner.
- Install the air cleaner
outlet duct to turbocharger. Align the duct to the air cleaner.
Tighten
Tighten the air cleaner outlet duct clamps to 6 N·m (53 lb in).
- Fill the engine coolant. Refer to
Cooling System Draining and Filling
.
- Connect both battery negative cables. Refer to
Battery Negative Cable Disconnection and Connection
in Engine
Electrical.
Turbocharger Coolant Hoses/Pipes Replacement 6.6L (LLY) Engine - Inlet Pipe
Removal Procedure
- Remove the engine cover. Refer to
Engine Cover Replacement
.
- Remove the air cleaner. Refer to
Air Cleaner Replacement
for the 6.6L (LLY) engine.
- 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.
- Remove the charged air cooler inlet pipe from the turbocharger and the charged air cooler. Refer to
Charged Air Cooler Hoses/Pipes Replacement
for the 6.6L (LLY) engine.
- Reposition the turbocharger coolant inlet hose clamp at the bypass valve.
- Remove the turbocharger coolant inlet hose banjo bolt (1).
- Remove the inlet hose washer and inlet line.
Installation Procedure
Notice: Refer to Fastener Notice in the Preface section.
- Install the inlet hose washer and inlet line.
- Install the turbocharger coolant inlet hose banjo bolt (1).
Tighten
Tighten the bolt to 25 N·m (18 lb ft).
- Position the turbocharger coolant inlet hose clamp at the bypass valve.
- Remove the tape from the turbocharger openings.
Important: Lubricate the end of the duct prior to installation.
- Install the charged air cooler inlet pipe to the turbocharger and the charged air cooler. Refer to
Charged Air Cooler Hoses/Pipes Replacement
for the 6.6L (LLY) engine.
- Install the air cleaner. Refer to
Air Cleaner Replacement
for the 6.6L (LLY) engine.
- Install the engine cover. Refer to
Engine Cover Replacement
.
- Fill the cooling system. Refer to
Cooling System Draining and Filling
.
Turbocharger Coolant Hoses/Pipes Replacement 6.6L (LLY) Engine - Outlet Pipe
Removal Procedure
- Remove the engine cover. Refer to
Engine Cover Replacement
.
- Remove the air cleaner. Refer to
Air Cleaner Replacement
for the 6.6L (LLY) engine.
- Drain the cooling system. Refer to
Cooling System Draining and Filling
.
- Disconnect the negative battery cables. Refer to
Battery Negative Cable Disconnection and Connection
.
- Remove the charged air cooler duct from the intake. Refer to
Charged Air Cooler Hoses/Pipes Replacement
for the 6.6L (LLY) engine.
- Remove the generator mounting bracket. Refer to
Generator Bracket Replacement
.
- Remove the exhaust gas recirculation (EGR) cooler tube. Refer to
Exhaust Gas Recirculation Valve Cooler Replacement
for the 6.6L (LLY) engine.
- Disconnect the fuel injection control module electrical connectors.
- Remove the upper fuel injection control module fuel line bolt.
- Remove and discard the washer from the banjo fitting.
- Reposition the hose clamp at the bypass pipe.
- Remove the turbocharger coolant outlet hose from the bypass pipe.
- Reposition the turbocharger coolant outlet hose clamp.
- Remove the turbocharger coolant outlet hose from the pipe on the turbocharger.
- Remove the turbocharger coolant outlet pipe bolt and nut.
- If necessary, remove the turbocharger. Refer to
Turbocharger Replacement
for
the 6.6L (LLY) engine.
- If necessary, remove the coolant outlet pipe clip bolt (3) from the turbocharger.
- If necessary, remove the coolant outlet pipe.
Installation Procedure
- If necessary, install the coolant outlet pipe.
Notice: Refer to Fastener Notice in the Preface section.
- If necessary, install the coolant outlet pipe clip bolt (3) to the turbocharger.
Tighten
Tighten the bolt to 9 N·m (80 lb in).
- If necessary, install the turbocharger. Refer to
Turbocharger Replacement
for the 6.6L (LLY) engine .
- Install the turbocharger coolant outlet pipe bolt and nut.
Tighten
Tighten the bolt/nut to 9 N·m (80 lb in).
- Install the turbocharger coolant outlet hose to the pipe on the turbocharger.
- Position the turbocharger coolant outlet hose clamp.
- Install the turbocharger coolant outlet hose to the bypass pipe.
- Position the hose clamp at the bypass pipe.
- Install a NEW washer to the banjo fitting.
- Install the upper fuel injection control module fuel line bolt.
Tighten
Tighten the bolt to 35 N·m (26 lb ft).
- Connect the fuel injection control module electrical connectors.
- Install the EGR cooler tube. Refer to
Exhaust Gas Recirculation Valve Cooler Replacement
for the 6.6L (LLY) engine.
- Install the generator mounting bracket. Refer to
Generator Bracket Replacement
.
- Install the charged air cooler duct to the intake. Refer to
Charged Air Cooler Hoses/Pipes Replacement
for the 6.6L (LLY) engine.
- Connect the negative battery cables. Refer to
Battery Negative Cable Disconnection and Connection
.
- Install the air cleaner. Refer to
Air Cleaner Replacement
for the 6.6L (LLY) engine.
- Install the engine cover. Refer to
Engine Cover Replacement
.
- Fill the cooling system. Refer to
Cooling System Draining and Filling
.