TheDieselPage.com Forums
 
The Diesel Page Forums

2019 - TDP's 23rd Anniversary
What's New | Feature Articles | Product Reviews | Member's Area | Free Forum Registration
Duramax 6600 Diesel Page | Advertiser's Section | Classified Ads | The Diesel Page - Publications


Go Back   TheDieselPage.com Forums > 2001-2019 Chevrolet & GMC 2500HD/3500 Light Trucks > Duramax 6600
Register FAQ Members List Photo Album Mark Forums Read

Duramax 6600 Welcome to the Internet's first Duramax 6600 diesel discussion forum for the LB7, LLY, LBZ, LMM, LML, LGH & L5P RPO code engines. Tips on performance, fuel economy, troubleshooting and more.

Reply
 
Thread Tools Display Modes
  #1  
Old 12-16-2011, 12:04 PM
rapidoxidationman rapidoxidationman is online now
Enthusiast
 
Join Date: Dec 2002
Location: Teton Valley, Idaho
Posts: 1,775
Default LLY head gasket & water pump swap play by play

anybody interested?

I ordered the parts from Kennedy today and will be embarking on this big project probably just after Christmas. Assuming that I do it right and successfully I can put together a picture thread on how I did it if there's any interest on it...
__________________
'85 Mercedes Benz 300D, for when I want to be stately.
'05 Mercedes E320 CDI, for when I want to be even statelier.
'05 Chevy K2500 ext cab long box DMax: Everything my '03 was and so much more!

There's no point being a pessimist - it wouldn't work anyway.
Reply With Quote
  #2  
Old 12-16-2011, 12:41 PM
DmaxMaverick's Avatar
DmaxMaverick DmaxMaverick is offline
Administrator
 
Join Date: Apr 2001
Location: CA
Posts: 12,313
Thumbs up

That would be great. We can't have enough hands-on documentation. Let me know if you need any assistance getting it posted.
__________________
1985 Blazer 6.2
2001 GMC 2500HD D/A
2014 Chevy Cruze Diesel - Fabulous car, no problems at all, but sold Nov. 2016 @ 55K miles.
dmaxmaverick@thedieselpage.com
Reply With Quote
  #3  
Old 12-16-2011, 05:56 PM
NutNbutGMC NutNbutGMC is offline
Original Membership November 2000
 
Join Date: Jun 2011
Posts: 1,424
Default

Quote:
Originally Posted by rapidoxidationman View Post
anybody interested?

I ordered the parts from Kennedy today and will be embarking on this big project probably just after Christmas. Assuming that I do it right and successfully I can put together a picture thread on how I did it if there's any interest on it...
Excellent.
__________________
.

Duraflap / Kaydenco not worth a hoot for service or products.
Reply With Quote
  #4  
Old 12-28-2011, 09:15 PM
rapidoxidationman rapidoxidationman is online now
Enthusiast
 
Join Date: Dec 2002
Location: Teton Valley, Idaho
Posts: 1,775
Default It begins.

The parts from Kennedy should be here tomorrow afternoon. I spent today under the hood of my truck tearing things down...

Started with a clean slate:

Yup, it is a bit intimidating to this rookie. I'm gonna just take small bites and eat the whole thing...
I started with removing both batteries. Not necessary perhaps, but a simple thing to do that got me off on the right foot. The cross brace at the front left of the truck (over the LH battery) came off too. Now there's a spot to put tools while I work
__________________
'85 Mercedes Benz 300D, for when I want to be stately.
'05 Mercedes E320 CDI, for when I want to be even statelier.
'05 Chevy K2500 ext cab long box DMax: Everything my '03 was and so much more!

There's no point being a pessimist - it wouldn't work anyway.
Reply With Quote
  #5  
Old 12-28-2011, 09:24 PM
rapidoxidationman rapidoxidationman is online now
Enthusiast
 
Join Date: Dec 2002
Location: Teton Valley, Idaho
Posts: 1,775
Default

Next to go was the air box and turbo inlet tube, another easy step:


took a couple pics of the Bosch EDU wiring harness to get me through the reassembly, then turned my wrenches to the charged air cooler outlet ductwork from the intake manifold tube:

Note that one can simply unclip the zip tie that holds the wiring harness cover to the inlet pipe. I cut mine before I noticed. Oops. No biggie, they're making new zip ties every day. Loosen and remove the wiring harness from that piece of ductwork.
Then I removed the wiring harness from the Bosch EDU on the right side of the engine.

from a couple of places.


I also pulled the wiring harness from the base of the intake manifold ductwork:


Now I was able to remove that intake manifold tube by removing 2 bolts and 4 nuts. The gaskets (2 rectangular and 1 round) came out easily and will be cleaned up for reuse.
__________________
'85 Mercedes Benz 300D, for when I want to be stately.
'05 Mercedes E320 CDI, for when I want to be even statelier.
'05 Chevy K2500 ext cab long box DMax: Everything my '03 was and so much more!

There's no point being a pessimist - it wouldn't work anyway.
Reply With Quote
  #6  
Old 12-28-2011, 09:37 PM
rapidoxidationman rapidoxidationman is online now
Enthusiast
 
Join Date: Dec 2002
Location: Teton Valley, Idaho
Posts: 1,775
Default

Removing the serpentine belt was another easy task, and is what I did next. The sound of the two idler pulleys tells me it is time to order up a couple of them cuz I don't care to have a bearing spin out on me sometime soon. They're on the list for the parts store.

Next out is the alternator. Easy to remove, but it did take a bit of careful prying to get it out of the bracket it is clamped to. Patience was key to not wrecking something expensive. The wiring harness got taped and labelled, just like every other wire in the snakepit that is this truck's electrical harness.

The AC compressor was next. 4 bolts from the bracket and it was loose, and removing the batteries gave me the ideal spot to store it without disconnecting any of the charged hoses: the right battery tray. Easy peasy and it folded right into place.
__________________
'85 Mercedes Benz 300D, for when I want to be stately.
'05 Mercedes E320 CDI, for when I want to be even statelier.
'05 Chevy K2500 ext cab long box DMax: Everything my '03 was and so much more!

There's no point being a pessimist - it wouldn't work anyway.
Reply With Quote
  #7  
Old 12-28-2011, 09:49 PM
rapidoxidationman rapidoxidationman is online now
Enthusiast
 
Join Date: Dec 2002
Location: Teton Valley, Idaho
Posts: 1,775
Default

Time to turn my attention to the front: remove the ecu/tcm from the left side of the radiator shroud. Two bolts at the top and lift it out, disconnect the wiring harness from the very expensive boxes contained therein. After the electronics were out of the way, I removed the other two bolts on the top lip of the shroud then unbuttoned the removeable rivets from the mdsection (two per side). Pry up the center button and the whole rivet can be removed then reused on reassembly. No pics, but it's pretty self explanatory.

Time to drain the cooling system... removed the lower splash shield beneath the truck, donned my safety goggles, and loosened the clamp on the hose where it connects to the water pump inlet (inlet? I think so, but correct me if I'm wrong...), set a large pan beneath, and pulled the hose loose. Caught most of it, but mopped up a bit. Now I was able to remove the upper radiator hose between the radiator and the thermostat housing outlet (inlet?) tube.

Question for the experts: which way does coolant flow? Does it go into the radiator from the top or bottom?
__________________
'85 Mercedes Benz 300D, for when I want to be stately.
'05 Mercedes E320 CDI, for when I want to be even statelier.
'05 Chevy K2500 ext cab long box DMax: Everything my '03 was and so much more!

There's no point being a pessimist - it wouldn't work anyway.
Reply With Quote
  #8  
Old 12-28-2011, 10:10 PM
rapidoxidationman rapidoxidationman is online now
Enthusiast
 
Join Date: Dec 2002
Location: Teton Valley, Idaho
Posts: 1,775
Default

Time to jump into the wiring snake pit again...
disconnect the two wiring superconnectors on the bracket that lives behind the AC compressor:

Great design, fold the handle back and it pushes the connection apart. Clever bit of engineering. In the pic, one is engaged and the other is disengaged. I also disconnected the wire from the box at the rear of the engine compartment (glow plug relay, I think?) so I could move the wiring harness out of the way:

Don't forget to keep labelling your wires as you remove them...

Now the power steering pump is being removed from its bracket. Left the hoses connected and pulled the pump out of the way with some bailing wire.

The battery terminal station that is mounted to the PS pump bracket can come with it. I removed mine before I realized that.

Removing the fan/clutch assembly without access to the proper tools can be tough. Fortunately I'm at a shop that has pneumatic tools... installing it with the proper amount of torque is going to be tricky though.

Then I removed the wiring harness from the bracket on top of the thermostat housing:

Then the superconnector mounting bracket that holds the 2 superconnectors previously disconnected had to come out.

There's a couple more connections that go to the turbo (modulator?) that need to be disconnected and labeled.

The turbo black box that's connected to the turbo via a white wire needs to be removed from the bracket and moved out of the way (I left the other end connected to the turbo).


which put the EGR crossover tube in the way. Time for it to go. A bolt on either end, loosen the clamp on the intake manifold pipe, and gently pull it out at the T shown here
__________________
'85 Mercedes Benz 300D, for when I want to be stately.
'05 Mercedes E320 CDI, for when I want to be even statelier.
'05 Chevy K2500 ext cab long box DMax: Everything my '03 was and so much more!

There's no point being a pessimist - it wouldn't work anyway.
Reply With Quote
  #9  
Old 12-28-2011, 10:20 PM
rapidoxidationman rapidoxidationman is online now
Enthusiast
 
Join Date: Dec 2002
Location: Teton Valley, Idaho
Posts: 1,775
Default

Yup, lots of jumping around the engine bay by this shade tree mechanic. Now I pulled the turbo coolant inlet (outlet?) pipe from the thermostat inlet (outlet?) housing pipe. This was a bit tricky, but I was able to turn the part seen in the pic with the number 5 on it loose by holding the clamp on the rubber hose open so the hardware would spin.

Now I was able to get the thermostat housing cap out with the thermostats and the outlet (inlet?) housing pipe. Next out was the oil filler pipe:

Next the power steering and AC compressor bracket needed to go. Easy enough:

and on the other side, the serpentine belt tension pulley needed to go:

and in order to get the alternator bracket out, a few other steps had to be made...
__________________
'85 Mercedes Benz 300D, for when I want to be stately.
'05 Mercedes E320 CDI, for when I want to be even statelier.
'05 Chevy K2500 ext cab long box DMax: Everything my '03 was and so much more!

There's no point being a pessimist - it wouldn't work anyway.
Reply With Quote
  #10  
Old 12-28-2011, 10:39 PM
rapidoxidationman rapidoxidationman is online now
Enthusiast
 
Join Date: Dec 2002
Location: Teton Valley, Idaho
Posts: 1,775
Default

beginning with removing the charged air return line from the intercooler flex hose:

and removing the heater coolant outlet (inlet?) pipe at the top:

and the bottom:

finally I was able to remove the Bosch EDU (2 fuel lines, 3 bolts - don't lose the bolt bushings...)

pay close attention to all the wiring harness mounts...
and now the alternator mount bracket can come off, with the two idler pulleys still mounted. Not that a fuel line is mounted on a bracket extension and the oil dipstick tube also needs to be disconnected from that extention.


back to center: Disconnect the temp sensor wire on the thermostat housing:

remove the turbo inlet elbow

remove the turbo servo wire and wire bracket
__________________
'85 Mercedes Benz 300D, for when I want to be stately.
'05 Mercedes E320 CDI, for when I want to be even statelier.
'05 Chevy K2500 ext cab long box DMax: Everything my '03 was and so much more!

There's no point being a pessimist - it wouldn't work anyway.
Reply With Quote
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump


All times are GMT -7. The time now is 05:36 AM.


Powered by vBulletin® Version 3.8.2
Copyright ©2000 - 2019, vBulletin Solutions, Inc.
Copyright 1996-2019 by TheDieselPage.com - All Rights Reserved