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 cooling system. Refer to Cooling System Draining and Filling .



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



6. Remove the turbocharger bypass valve and washer.

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 washer.

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




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



3. Install the upper intake manifold sight shield.
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 cooling system. Refer to Cooling System Draining and Filling .