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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 648 (Engine Cooling System) >> Repair Instructions >> Turbocharger Coolant Hoses/Pipes Replacement (6.6L Engine) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2002 GMC Sierra, 2002 GMC Cab & Chassis Sierra, 2002 Chevrolet Silverado, and 2002 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Connect the turbocharger inlet coolant hose and clamp to the turbocharger coolant bypass valve.
  2. Connect the turbocharger inlet coolant hose and clamp to the turbocharger.
  3. Install the turbocharger outlet coolant pipe to the engine.
  4. Install the nut retaining the turbocharger outlet coolant pipe. Tighten the turbocharger outlet coolant pipe nut to 9 N.m (80 lb in).
  5. Connect the turbocharger outlet coolant hose and clamps to the turbocharger and the coolant pipe.
  6. Install the hose and clamp to the turbocharger outlet coolant pipe to thermostat bypass pipe.
  7. Install the bolt retaining the turbocharger outlet coolant pipe to the pipe bracket. Tighten the turbocharger outlet coolant pipe bracket bolt to 21 N.m (15 lb ft).
  8. Install a new O-ring seal to the heater pipe.
  9. Install the heater pipe to the thermostat housing.
  10. Install the bolt retaining the heater pipe to the thermostat housing. Tighten the heater pipe bolt to 21 N.m (15 lb ft).
  11. Install the bolt retaining the heater pipe to the fuel filter assembly. Tighten the heater pipe bracket 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 mounting bracket and bolts. Tighten the generator mounting bracket bolts to 50 N.m (37 lb ft).
  15. Install the ribbed idler pulley and bolt. Tighten the idler pulley bolt to 43 N.m (32 lb ft).
  16. Install the fuel lines to the fuel injection control module.
  17. Connect the wiring harness connector to the fuel injection control module.
  18. Install the generator positive cable and the retaining nut to the generator. Tighten the generator positive cable nut to 9 N.m (80 lb in).
  19. Connect the generator electrical connector.
  20. 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.
  21. Position the clamps as shown for proper clearance. Tighten the clamps to 6 N.m (53 lb in).
  22. Install the outlet duct to the turbocharger.
  23. Align the outlet duct alignment indicator (1) to the turbocharger alignment indicator (2).
    Fig 1: Outlet Duct Alignment Indicator
    G01658039Courtesy of GENERAL MOTORS CORP.
  24. Install the outlet duct to the MAF/IAT sensor.
  25. Tighten the outlet duct clamps at the turbocharger and the MAF/IAT sensor. Tighten the clamps to 6 N.m (53 lb in).
  26. Install the upper intake manifold cover.
  27. Install the upper intake manifold cover to the outlet duct.
  28. Tighten the outlet duct clamp at the upper intake manifold cover. Tighten the clamp to 6 N.m (53 lb in).
  29. Fill the engine coolant. Refer to Draining & Filling Cooling System .
  30. Connect both battery negative cables.
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