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Mike
Mike, ASE Certified Technician
Category: Chevy
Satisfied Customers: 181
Experience:  Seventeen years of automotive experience with the past thirteen in General Motors dealerships.
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Procedure on replacing thermostat for 2005 duramax

Customer Question

procedure on replacing thermostat for 2005 duramax
Submitted: 8 years ago.
Category: Chevy
Expert:  Mike replied 8 years ago.

HelloCustomer my name is Mike.

Below is the proceedure, please ask if you have further questions.

 

Water Outlet Tube Replacement (6.6L (LLY) Engine)

Removal Procedure


    Object Number: 674532  Size: SH

  1. Remove the intake manifold cover.
  2. Drain the cooling system.
  3. Remove the radiator inlet hose from the water outlet tube.
    Object Number:(NNN) NNN-NNNN Size: SH

  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.
    Object Number:(NNN) NNN-NNNN Size: SH

  6. Remove the main engine electrical harness connector bolts.
    Object Number:(NNN) NNN-NNNN Size: SH

  7. Disconnect the barometric sensor electrical connector.
    Object Number:(NNN) NNN-NNNN Size: SH
  8. Disconnect the turbocharger vane position sensor electrical connector.
    Object Number:(NNN) NNN-NNNN Size: SH

  9. Remove the main electrical harness bracket bolts.
  10. Remove the main electrical harness bracket.
    Object Number:(NNN) NNN-NNNN Size: SH
  11. Disconnect the turbocharger coolant inlet hose from the turbocharger bypass valve.
    Object Number:(NNN) NNN-NNNN Size: SH

  12. Remove the water outlet bolts.
    Object Number:(NNN) NNN-NNNN Size: SH

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

Engine Coolant Thermostat Replacement (6.6L (LLY) Engine)

Removal Procedure


    Object Number:(NNN) NNN-NNNN Size: SH
  1. Remove the bolt for the fuel line bracket.
  2. Remove the fuel line bracket.
  3. Remove the thermostat housing cover bolts.
  4. Remove the thermostat housing cover.
  5. Remove the thermostats and seals.

Inspection Procedure

  1. Inspect the thermostats for sticking, cracks, and/or leakage of wax.
  2. Replace the thermostats if damage is found.
  3. Clean the thermostat housing and thermostat housing cover sealing surfaces.

Installation Procedure


    Object Number: 654534  Size: SH

  1. Install the thermostats and seals to the thermostat housing.

    The rear thermostat (4) has 2 vent valves. Install with the vent valves towards the rear of engine.

     


    Object Number:(NNN) NNN-NNNN Size: SH

  2. Install the thermostat housing cover.
  3. Install the thermostat housing cover bolts.

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

  4. Install the fuel line bracket.
  5. Install the fuel line bracket bolt.

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

  6. Install the water outlet tube.

Installation Procedure


    Object Number:(NNN) NNN-NNNN Size: SH

  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.

     


    Object Number:(NNN) NNN-NNNN Size: SH

  4. Install the water outlet bolts.

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


    Object Number:(NNN) NNN-NNNN Size: SH

  5. Connect the turbocharger coolant inlet hose to the turbocharger bypass valve.
    Object Number:(NNN) NNN-NNNN Size: SH

  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).


    Object Number:(NNN) NNN-NNNN Size: SH

  8. Connect the turbocharger vane position sensor electrical connector.
    Object Number:(NNN) NNN-NNNN Size: SH

  9. Connect the barometric sensor electrical connector.
    Object Number:(NNN) NNN-NNNN Size: SH

  10. Install the main engine electrical harness connector bolts.

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


    Object Number:(NNN) NNN-NNNN Size: SH

  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.
    Object Number: 674532  Size: SH

  13. Install the radiator inlet hose to the water outlet tube.
  14. Fill the cooling system.
  15. Install the intake manifold cover.