Water Outlet Tube Replacement 6.6L (LB7) Engine

1. Drain the engine coolant. Refer to Cooling System Draining and Filling .



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



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



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



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



6. Remove the 2 bolts retaining the water outlet tube to the left valve rocker arm cover.
7. Remove the bolt retaining the water outlet tube to the thermostat housing.
8. Remove the water outlet tube.
9. Remove and discard the O-ring seal.

1. Install a new O-ring seal on the water outlet tube.
2. Lightly lubricate the O-ring seal with coolant.
3. Install 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.

4. Install the bolt retaining the water outlet tube to the thermostat housing.

Tighten
Tighten the water outlet tube to thermostat housing bolt to 21 N·m (15 lb ft).

5. Install the 2 bolts retaining the water outlet tube to the valve rocker arm cover.

Tighten
Tighten the water outlet tube to valve rocker arm cover bolts to 21 N·m (15 lb ft).




6. 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).




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



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

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




9. Install the radiator inlet hose to the water outlet tube.
10. Fill the engine coolant. Refer to Cooling System Draining and Filling .

Water Outlet Tube Replacement 6.6L LLY

1. Remove the air cleaner. Refer to Air Cleaner Replacement for the 6.6L (LLY) engine.
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. Install the air cleaner. Refer to Air Cleaner Replacement for the 6.6L (LLY) engine.
15. Fill the cooling system. Refer to Cooling System Draining and Filling .