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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 977 (Engine Cooling System) >> Repair Instructions >> Turbocharger Coolant Hoses/Pipes Replacement (6.6L (LB7) Engine) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  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. Fig 1: View Of Turbocharger Inlet Coolant Hose
    GM668427Courtesy of GENERAL MOTORS CORP.
  3. Install the turbocharger coolant feed pipe.
    4. NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Install the turbocharger coolant feed pipe nut.

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

    5. Fig 2: View Of Turbocharger Coolant Feed Pipe
    GM699333Courtesy of GENERAL MOTORS CORP.
  5. Connect the turbocharger coolant feed hose and clamps to the turbocharger and the coolant pipe.
    6. Fig 3: View Of Turbocharger Outlet Coolant Hose
    GM668428Courtesy of GENERAL MOTORS CORP.
  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. Fig 4: View Of Turbocharger Coolant Feed Pipe, Bracket & Bolts
    GM699335Courtesy of GENERAL MOTORS CORP.
  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. Fig 5: View Of Heater Inlet Pipe, Thermostat Housing & Fuel Filter
    GM699325Courtesy of GENERAL MOTORS CORP.
  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. Fig 6: View Of Fuel Injection Control Module Wiring Harness Conduit
    GM651356Courtesy of GENERAL MOTORS CORP.
  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. Fig 7: View Of Generator & Mounting Bracket
    GM669244Courtesy of GENERAL MOTORS CORP.
  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. Fig 8: View Of Fuel Injection Control Module Fuel Lines
    GM744237Courtesy of GENERAL MOTORS CORP.
  18. Connect the fuel injection control module electrical connectors (2).
    19. Fig 9: View Of Fuel Injection Control Module Electrical Connectors
    GM744247Courtesy of GENERAL MOTORS CORP.
  19. Install the generator positive cable and nut.

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

    20. Fig 10: View Of Upper Engine
    GM666693Courtesy of GENERAL MOTORS CORP.
  20. Connect the generator electrical connector (1).
    21. Fig 11: View of Generator Harness, Clip, A/C Refrigerant Switch, Dual Generator Harness Connector & A/C Compressor Clutch
    GM674573Courtesy of GENERAL MOTORS CORP.
  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. Fig 12: View Of Charged Air Cooler Outlet Duct & Clamps
    GM877275Courtesy of GENERAL MOTORS CORP.
  25. Install the outlet duct to the turbocharger.
  26. Align the outlet duct alignment indicator (1) to the turbocharger alignment indicator (2).
    Fig 13: View Of Outlet Duct To Turbocharger Alignment Marks
    GM813246Courtesy of GENERAL MOTORS CORP.
    27. 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. Fig 14: View Of Outlet Duct
    GM813244Courtesy of GENERAL MOTORS CORP.
  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. Fig 15: View Of Upper Intake Manifold Cover, Outlet Duct & Clamp
    GM813243Courtesy of GENERAL MOTORS CORP.
  32. Fill the cooling. Refer to Draining and Filling Cooling System (without HP2) .
  33. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) in Engine Electrical.
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