Turbocharger Coolant Bypass Valve Replacement 6.6L Engine

1. Loosen the outlet duct clamp at the upper intake manifold cover.
2. Remove the upper intake manifold cover from the outlet duct.
3. Remove the upper intake manifold cover.
4. Drain the engine coolant. Refer to Cooling System Draining and Filling .



5. Disconnect the turbocharger coolant hose from the turbocharger bypass valve.



6. Remove the turbocharger bypass valve and sealing washer from the water outlet tube.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

1. Install the turbocharger bypass valve and sealing washer to the water outlet tube.

Tighten
Tighten the turbocharger bypass valve to 60 N·m (44 lb ft).




2. Connect the turbocharger coolant hose to the turbocharger bypass valve.



3. Install the upper intake manifold cover.
4. Install the upper intake manifold cover to the outlet duct.
5. Tighten the outlet duct clamp at the upper intake manifold cover.

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

6. Fill the engine coolant. Refer to Cooling System Draining and Filling .