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

1. Remove the engine cover. Refer to Engine Cover Replacement .
2. Remove the air cleaner. Refer to Air Cleaner Replacement for the 6.6L (LLY) engine.
3. 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.

4. 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.



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 pipe to the turbocharger and the charged air cooler. Refer to Charged Air Cooler Hoses/Pipes Replacement for the 6.6L (LLY) engine.
6. Install the air cleaner. Refer to Air Cleaner Replacement for the 6.6L (LLY) engine.
7. Install the engine cover. Refer to Engine Cover Replacement .
8. Fill the cooling system. Refer to Cooling System Draining and Filling .

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

1. Remove the engine cover. Refer to Engine Cover Replacement .
2. Remove the air cleaner. Refer to Air Cleaner Replacement for the 6.6L (LLY) engine.
3. Drain the cooling system. Refer to Cooling System Draining and Filling .
4. Disconnect the negative battery cables. Refer to Battery Negative Cable Disconnection and Connection .
5. Remove the charged air cooler duct from the intake. Refer to Charged Air Cooler Hoses/Pipes Replacement for the 6.6L (LLY) engine.
6. Remove the generator mounting bracket. Refer to Generator Bracket Replacement .
7. Remove the exhaust gas recirculation (EGR) cooler tube. Refer to Exhaust Gas Recirculation Valve Cooler Replacement for the 6.6L (LLY) engine.



8. Disconnect the fuel injection control module electrical connectors.



9. Remove the upper fuel injection control module fuel line bolt.
10. Remove and discard the washer from the banjo fitting.



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



13. Reposition the turbocharger coolant outlet hose clamp.
14. Remove the turbocharger coolant outlet hose from the pipe on the turbocharger.



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



16. If necessary, remove the turbocharger. Refer to Turbocharger Replacement for the 6.6L (LLY) engine.
17. If necessary, remove the coolant outlet pipe clip bolt (3) from the turbocharger.
18. 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 for the 6.6L (LLY) engine .



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 a NEW washer to the banjo fitting.
10. Install the upper fuel injection control module fuel line bolt.

Tighten
Tighten the bolt to 35 N·m (26 lb ft).




11. Connect the fuel injection control module electrical connectors.
12. Install the EGR cooler tube. Refer to Exhaust Gas Recirculation Valve Cooler Replacement for the 6.6L (LLY) engine.
13. Install the generator mounting bracket. Refer to Generator Bracket Replacement .
14. Install the charged air cooler duct to the intake. Refer to Charged Air Cooler Hoses/Pipes Replacement for the 6.6L (LLY) engine.
15. Connect the negative battery cables. Refer to Battery Negative Cable Disconnection and Connection .
16. Install the air cleaner. Refer to Air Cleaner Replacement for the 6.6L (LLY) engine.
17. Install the engine cover. Refer to Engine Cover Replacement .
18. Fill the cooling system. Refer to Cooling System Draining and Filling .

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

1. Remove the engine cover. Refer to Engine Cover Replacement .
2. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement .
3. 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.

4. Remove the charged air cooler outlet pipe from the turbocharger and the charged air cooler. Refer to Charge Air Cooler Outlet Pipe Replacement .



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 outlet pipe to the turbocharger and the charged air cooler. Refer to Charge Air Cooler Outlet Pipe Replacement .
6. Install the air cleaner. Refer to Air Cleaner Assembly Replacement .
7. Install the engine cover. Refer to Engine Cover Replacement .
8. Fill the cooling system. Refer to Cooling System Draining and Filling .

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

1. Remove the turbocharger coolant inlet pipe. Refer to Turbocharger Coolant Hoses/Pipes Replacement .
2. Remove the generator mounting bracket. Refer to Generator Bracket Replacement .
3. Remove the exhaust gas recirculation (EGR) cooler assembly. Refer to Exhaust Gas Recirculation Valve Cooler Replacement .
4. Remove the cooling fan. Refer to Fan Replacement .



5. Reposition the hose clamp at the bypass pipe.
6. Remove the turbocharger coolant outlet hose from the bypass pipe.



7. Reposition the turbocharger coolant outlet hose clamp.
8. Remove the turbocharger coolant outlet hose from the pipe on the turbocharger.



9. Remove the turbocharger coolant outlet pipe bolt and nut. Also remove the pipe clamp and bolt.
10. Remove the fuel lines in order to remove the outlet pipe.



11. If necessary, remove the turbocharger. Refer to Turbocharger Replacement .
12. If necessary, remove the coolant outlet pipe clip bolt (3) from the turbocharger.
13. 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 fuel lines.



6. Install the turbocharger coolant outlet hose to the pipe on the turbocharger.
7. Position the turbocharger coolant outlet hose clamp.



8. Install the turbocharger coolant outlet hose to the bypass pipe.
9. Position the hose clamp at the bypass pipe.
10. Install the cooling fan. Refer to Fan Replacement .
11. Install the EGR cooler assembly. Refer to Exhaust Gas Recirculation Valve Cooler Replacement .
12. Install the generator mounting bracket. Refer to Generator Bracket Replacement .
13. Install the turbocharger coolant inlet pipe. Refer to Turbocharger Coolant Hoses/Pipes Replacement .