Removal Procedure
- Remove the left or right fender wheelhouse inner panel (1).
- Remove the air cleaner. Refer to Air Cleaner Assembly Replacement in Engine Controls - 6.6 L.
- Loosen both charged air cooler outlet duct to intake manifold tube hose clamps.
- Remove the hose from the charged air cooler outlet duct to intake manifold tube.
- Working through the right front fender wheelhouse opening loosen the clamp for the charged air cooler outlet duct to charged air cooler.
- Remove the charged air cooler outlet hose and pipe assembly from the vehicle.
- Disassemble the hose and pipe assembly as required.
- Loosen the charged air cooler inlet duct to turbocharger clamp.
- Remove the charged air cooler inlet duct to turbocharger cool air outlet hose from the turbocharger.
- Loosen the charged air cooler inlet duct to charged air cooler clamp.
- Remove the charged air cooler inlet hose and pipe assembly from the vehicle. The assembly can be removed as one piece with the left front fender wheelhouse inner panel removed.
- Disassemble the hose and pipe assembly as required.
- Inspect the hoses for cuts or tears.
- Inspect the pipes for damage.
- Replace the hose or pipe if damage is found.
Important: After removing the turbocharger air ducts, hoses cover the turbocharger, the air inlet duct, and the charged air cooler openings with tape to prevent entry of objects.
Important: Do not use a screw driver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
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.
Installation Procedure
- Install the charged air cooler inlet hose to the pipe. The hose is marked for correct installation.
- Install the hose clamps on the charged air cooler inlet hose but do not tighten.
- Install the charged air cooler inlet hose to the charged air cooler aligning the marks on the hoses.
- Install the upper hose on the charged air cooler inlet pipe.
- Install the clamps on the hose assembly but do not tighten.
- Install the charged air cooler inlet duct to turbocharger cool air outlet hose to the turbocharger.
- Position all of the clamps as shown for proper clearance.
- Install the lower hose on the charged air cooler outlet pipe. The hose is marked for correct installation.
- Install the clamps on the outlet hose but do not tighten.
- Install the charged air cooler outlet duct to intake manifold tube hose.
- Position all of the clamps as shown for proper clearance.
- Inspect the routing of the charged air cooler ducts to ensure they are not contacting anything. Adjust the ducts if necessary.
- Install the air cleaner. Refer to Air Cleaner Assembly Replacement in Engine Controls - 6.6 L.
- Install the left or right fender wheelhouse inner panel (1).
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.
Tighten
Tighten the charged air cooler hose clamps to 6 N·m (53 lb in).
The hose is marked DUCT which connects to the charged air cooler outlet duct.
The hose is marked ENG which connects to the intake manifold tube.
Align the marks on the hose with the alignment marks on the pipe and duct.
Tighten
Tighten the charged air cooler hose clamps to 6 N·m (53 lb in).
