Water Outlet Tube Replacement 6.6L (LB7) 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 cooling system. Refer to Cooling System Draining and Filling .



5. Remove the radiator inlet hose from the water outlet tube.



6. Remove the bolt and wiring harness bracket at the thermostat housing.



7. Disconnect the turbocharger coolant return hose from the turbocharger bypass valve.



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



9. Remove the water outlet bolts.
10. Remove the water outlet.
11. Remove and discard the O-ring seal.

1. Install a NEW O-ring seal onto the water outlet.
2. Lightly lubricate the O-ring seal with coolant.
3. Install the water outlet.

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.

4. Install the water outlet tube bolts.

Tighten
Tighten the bolt to 21 N·m (15 lb ft).




5. Install the turbocharger bypass valve and washer.

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




6. Connect the turbocharger coolant return hose to the turbocharger bypass valve.



7. Install the bolt and wiring harness bracket to the thermostat housing.

Tighten
Tighten the bolt to 8 N·m (71 lb in).




8. Install the radiator inlet hose to the water outlet tube.
9. Fill the cooling system. Refer to Cooling System Draining and Filling .



10. Install the upper intake manifold cover.
11. Install the upper intake manifold cover to the outlet duct.
12. Tighten the outlet clamp at the upper intake manifold cover.

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

Water Outlet Tube Replacement 6.6L (LLY) Engine

1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement in Engine Mechanical - 6.6L (LLY).
2. Drain the cooling system. Refer to Cooling System Draining and Filling .
3. Remove the radiator inlet hose from the water outlet tube.



4. Open the clip and remove the wiring harness branch from the bracket.
5. Remove the bolt and wiring harness bracket at the thermostat housing.



6. Remove the main engine electrical harness connector bolts.



7. Disconnect the barometric sensor electrical connector.



8. Disconnect the turbocharger vane position sensor electrical connector.



9. Remove the main electrical harness bracket bolts.
10. Remove the main electrical harness bracket.



11. Disconnect the turbocharger coolant inlet hose from the turbocharger bypass valve.



12. Remove the water outlet bolts.



13. Remove the water outlet.
14. Remove and discard the O-ring seal.

1. Install a NEW O-ring seal to the water outlet.
2. Lubricate the O-ring seal with clean engine coolant.
3. Install the water outlet.

Notice: Refer to Fastener Notice in the Preface section.




4. Install the water outlet bolts.

Tighten
Tighten the bolts to 21 N·m (15 lb ft).




5. Connect the turbocharger coolant inlet hose to the turbocharger bypass valve.



6. Install the main electrical harness bracket.
7. Install the main electrical harness bracket bolts.

Tighten
Tighten the bolts to 21 N·m (15 lb ft).




8. Connect the turbocharger vane position sensor electrical connector.



9. Connect the barometric sensor electrical connector.



10. Install the main engine electrical harness connector bolts.

Tighten
Tighten the bolts to 10 N·m (89 lb in).




11. Install the wiring harness bracket and bolt to the thermostat housing.

Tighten
Tighten the bolt to 10 N·m (89 lb in).

12. Install the wiring harness branch to the bracket and close the clip.



13. Install the radiator inlet hose to the water outlet tube.
14. Fill the cooling system. Refer to Cooling System Draining and Filling .
15. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement in Engine Mechanical - 6.6L (LLY).