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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 (LLY) Engine - Inlet Pipe) >> 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. Install the inlet hose washer and inlet line.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the turbocharger coolant inlet hose banjo bolt (1).

    Tighten:  Tighten the bolt to 25 N.m (18 lb ft).

    3. Fig 1: View Of Turbocharger Coolant Inlet & Outlet Hose Components
    GM1367360Courtesy of GENERAL MOTORS CORP.
  3. Position the turbocharger coolant inlet hose clamp at the bypass valve.
    4. Fig 2: View Of Turbocharger Inlet Coolant Hose At Turbocharger Coolant Bypass
    GM1335386Courtesy of GENERAL MOTORS CORP.
  4. Remove the tape from the turbocharger openings.
    5. IMPORTANT: Lubricate the end of the duct prior to installation.
  5. Install the charged air cooler inlet duct connector (4) to the turbocharger.
  6. Tighten the charged air cooler inlet duct connector to turbocharger clamp (1).

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

    7. Fig 3: View Of Turbocharger Clamp & Charged Air Cooler Inlet Duct Connector
    GM1334380Courtesy of GENERAL MOTORS CORP.
  7. Fill the cooling system. Refer to Draining and Filling Cooling System (without HP2) .
  8. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement in Engine Mechanical - 6.6L (LLY).
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