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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.

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  #11  
Old 12-28-2011, 10:54 PM
rapidoxidationman rapidoxidationman is offline
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then the intake manifold elbow can get pulled out; it is held in the center piece of the intake manifold by an o-ring:

with all that stuff out of the way I was then able to remove the EGR coolant intake tube from the thermostat housing

and the EGR cooler tube (proper name?), noting the odd orientation of the clamps on the cooler tube end of the intake tube:


Now I could remove the fuel line clamp from the thermostat housing

then remove the thermostat housing crossover and the water pump outlet tube.

The little bypass tube from the water pump outlet tube
made things a bit tough

but taking small bites let me eat it all.
__________________
'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.
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  #12  
Old 12-28-2011, 10:57 PM
rapidoxidationman rapidoxidationman is offline
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The last thing I did today was to remove the heat shield from the turbo.

3 bolts got it loose, but I had to disconnect an oil supply pipe and a pipe bracket to make room to remove it:


End of day one, 7.5 hours in.
Time for bed and dreams of torque wrenches, wiring harnesses and the nightmare of plumbing that awaits me tomorrow...

Cheers!
Guy
__________________
'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.
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  #13  
Old 12-29-2011, 08:02 PM
rapidoxidationman rapidoxidationman is offline
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Default It's tomorrow. Time for another pile of pics.

but first, jack up the front of the truck, drop it onto some strong jackstands, and remove the front wheels. Gotta get the fender plastics out of the way, and to do that you need to remove the expansion tank:
Note the tubes and wiring harness.

once the tank is out, you can see a couple other wiring harness clips that need to be disengaged before the fender plastic can be removed:

once the plastic is clear, it is a simple matter of removing the push rivets. Most of them have a center button that can be pulled loose to allow the whole rivet to come out. I had a tough time with the big ones, like the one that holds the bottom bracket of the battery tray to the plastic. More stuff for the parts list.
Moving on to the left side: there's more stuff attached to the plastic, but it's straightforward enough.
Next up I removed the fuel filter bracket and fuel lines. A new fuel filter is in the box that I just got today from JK

After that hardware was out of the way, it was easy to remove the A/C evaporator harness and pull a large mess of wires to the left side of the engine bay.
__________________
'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
  #14  
Old 12-29-2011, 08:11 PM
rapidoxidationman rapidoxidationman is offline
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After pulling loose the harness from the right side fuel rail sensor

it was time to disconnect the right side glow plug wires

and the injector wires

fairly easy, just take the time necessary to do it right.
After that, the wiring harness clamps can be removed from the engine.

Then I pulled a couple of plugs from 9 o'clock and 11 o'clock by the crankshaft pulley
__________________
'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.
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  #15  
Old 12-29-2011, 08:23 PM
rapidoxidationman rapidoxidationman is offline
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Then to the top again: Removed the heater hose from the EGR cooler

then fight the bolts on the backside of the EGR cooler (and the remaining one on the front)

to remove the cooler.
Then I removed the wiring harness from the high pressure fuel pump


and moved to the left side of the engine to remove the glow plug wires

and injector harness and wiring harness clamps, just like the right side but with more wires in the way...

The rear injector harness is kinda buried, but it is accessible with patience.
__________________
'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
  #16  
Old 12-29-2011, 08:41 PM
rapidoxidationman rapidoxidationman is offline
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I then removed the glow plug controller harness

and a bracket that holds the wiring harness for the #7 injector and glow plug...

note that the harness lines go UNDER the fuel lines... which are next in line for disassembly:
taking the bracket loose

and disconnecting the quick connect lines: a piece of spring steel clip is the anchor for the coupling, but you need a fuel line disconnect tool (harbor freight $9) to get the lines to separate.

Then I removed the plug on the fuel sensor under the turbo outlet (connects to the left side fuel rail):

then I pushed loose the wiring harness clamp at the fuel line bracket by the turbo outlet
__________________
'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.
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  #17  
Old 12-29-2011, 08:43 PM
rapidoxidationman rapidoxidationman is offline
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Location: Teton Valley, Idaho
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removing the sensor wire from the left side intake manifold was next

Note that the wire routes under a fuel line.

I then removed the plug from an unknown harness that goes down the front of the engine to somewhere underneath. I call it "unknown".


I was then able to unbolt the main harness bracket from the center piece of the intake manifold


remove two ground wires from the lower right side of the engine block

and remove that whole wiring harness assembly from the engine bay.
__________________
'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
  #18  
Old 12-29-2011, 08:44 PM
rapidoxidationman rapidoxidationman is offline
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Join Date: Dec 2002
Location: Teton Valley, Idaho
Posts: 1,741
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Hey look! There's an engine under there!!!


__________________
'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
  #19  
Old 12-29-2011, 08:54 PM
rapidoxidationman rapidoxidationman is offline
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Time to remove the glow plug controller


Moving on to the plumbing:
remove the fuel main line crossover pipe (2 nuts, 1 bolt for 3 clamps), this pic is of the clamp on the right end of the pipe:


now for some plumbing assembly removal: the fuel supply from the filter and return lines to the HPFP and from the injectors of the right bank of cylinders:

this pic is of the twin pipes on one end, the injector return lines are on the other end. The injector return lines come loose easily by removing the wire clips and gently pulling the plastic fittings out.
__________________
'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
  #20  
Old 12-29-2011, 09:04 PM
rapidoxidationman rapidoxidationman is offline
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Join Date: Dec 2002
Location: Teton Valley, Idaho
Posts: 1,741
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then I removed the fuel rails crossover pipe

and the HPFP high pressure pipe to the left side fuel rail:


Then I removed the left and right side exhaust manifold heat shields, 4 bolts each and easy to do.

My last task of the day was to remove the left side injector return lines

and fuel rail return line to the HPFP. This was tricky because there are some bolts under the glow plug controller bracket that are hard to get to with the turbo in place.

Anybody know how to remove the turbo without taking the whole darn exhaust system apart? I'm all ears... and done for today.
__________________
'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
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