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 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.




Important: After removing the turbocharger air ducts, cover the openings 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.



8. Loosen the charged air cooler outlet duct to intake hose clamp (1).

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.

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



10. Remove the generator positive cable nut.
11. Remove the positive cable from the generator.



12. Disconnect the generator electrical connector (1).



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

•	The generator does not require removal.

•	The drive belt tensioner does not require removal.




15. Disconnect the fuel injection control module electrical connectors (2).



16. Remove the fuel line bolts.
17. Remove the fuel lines (2) from the fuel injection control module.



18. Using J 43181 , disconnect the inlet heater hose from the heater core inlet.
19. Remove the fuel injection control module wiring harness conduit from the heater pipe.



20. Remove the heater inlet pipe to fuel filter bolt.
21. Remove the heater inlet pipe to thermostat housing bolt.
22. Remove the heater inlet pipe with O-ring seal from the thermostat housing.



23. Remove the turbocharger coolant feed pipe bracket bolts.
24. Remove the turbocharger coolant return hose clamps and hose.



25. Disconnect the turbocharger coolant feed hose from the turbocharger.



26. Remove the turbocharger coolant feed pipe nut.
27. Remove the coolant feed pipe.



28. Disconnect the turbocharger coolant return hose from the turbocharger coolant bypass valve.
29. Disconnect the turbocharger coolant return hose from the turbocharger.

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. Install the turbocharger coolant feed pipe.

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 turbocharger coolant feed pipe nut.

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




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



6. Install the turbocharger coolant return hose and clamps.
7. Install the turbocharger coolant feed pipe bracket bolts.

Tighten
Tighten the bolts to 21 N·m (15 lb ft).




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

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

11. Install the heater inlet pipe to fuel filter bolt.

Tighten
Tighten the 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 bracket and bolts.

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

15. Install the ribbed idler pulley and bolt.

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




16. Install the fuel lines (2) to the fuel injection control module.
17. Install the fuel line bolts.

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




18. Connect the fuel injection control module electrical connectors (2).



19. Install the generator positive cable and nut.

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




20. Connect the generator electrical connector (1).



21. Remove the tape from the turbocharger openings.
22. Install the charged air cooler outlet duct to the intake.
23. Align the mark on the duct (3) with the alignment mark on the intake.
24. Position the clamp (1) as shown for proper clearance.

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




25. Install the outlet duct to the turbocharger.
26. Align the outlet duct alignment indicator (1) to the turbocharger alignment indicator (2).




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

27. Install the outlet duct to the MAT/IAT sensor.
28. Tighten the outlet duct clamps at the turbocharger and the MAT/IAT sensor.

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




29. Install the upper intake manifold cover.
30. Install the upper intake manifold cover to the outlet duct.
31. Tighten the outlet duct clamp at the upper intake manifold cover.

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

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