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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 - Outlet Pipe) >> Installation Procedure

Installation Procedure

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  1. If necessary, install the coolant outlet pipe.
    2. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. If necessary, install the coolant outlet pipe clip bolt (3) to the turbocharger.

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

    3. Fig 1: View Of Turbocharger Coolant Inlet & Outlet Hose Components
    GM1367360Courtesy of GENERAL MOTORS CORP.
  3. If necessary, install the turbocharger. Refer to Turbocharger Replacement in Engine Mechanical - 6.6L (LLY).
  4. Install the turbocharger coolant outlet pipe bolt and nut.

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

    5. Fig 2: View Of Turbocharger Coolant Outlet Pipe Bolt & Nut
    GM1335600Courtesy of GENERAL MOTORS CORP.
  5. Install the turbocharger coolant outlet hose to the pipe on the turbocharger.
  6. Position the turbocharger coolant outlet hose clamp.
    7. Fig 3: View Of Turbocharger Outlet Coolant Pipe
    GM1335578Courtesy of GENERAL MOTORS CORP.
  7. Install the turbocharger coolant outlet hose to the bypass pipe.
  8. Position the hose clamp at the bypass pipe.
    9. Fig 4: View Of Turbocharger Coolant Outlet Hose & Clamps
    GM1335429Courtesy of GENERAL MOTORS CORP.
  9. Install a NEW washer to the banjo fitting.
  10. Install the upper fuel injection control module fuel line bolt.

    Tighten:  Tighten the bolt to 35 N.m (26 lb ft).

    11. Fig 5: View Of Cooling Hoses, Eye Bolts & Washers
    GM1334883Courtesy of GENERAL MOTORS CORP.
  11. Connect the fuel injection control module electrical connectors.
    12. Fig 6: View Of Fuel Injection Control Module Electrical Connectors
    GM1334881Courtesy of GENERAL MOTORS CORP.
  12. Install the EGR cooler tube. Refer to Exhaust Gas Recirculation (EGR) Valve Cooler Tube Replacement in Engine Controls - 6.6L (LLY).
  13. Install the generator mounting bracket. Refer to Generator Bracket Replacement (6.6L (LLY) Engine) in Engine Electrical.
    14. IMPORTANT: Lubricate the end of the duct prior to installation.
  14. Install the charged air cooler duct to the intake.
  15. Tighten the charged air cooler outlet duct to intake hose clamp.

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

    16. Fig 7: View Of Charged Air Cooler Outlet Duct
    GM1334381Courtesy of GENERAL MOTORS CORP.
  16. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in Engine Controls - 6.6L (LLY).
  17. Connect the negative battery cables. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) in Engine Electrical.
  18. Fill the cooling system. Refer to Draining and Filling Cooling System (without HP2) .
  19. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement in Engine Mechanical - 6.6L (LLY).
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