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

1. Remove the intake manifold cover.
2. Drain the cooling system.
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.

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

Removal Procedure

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

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.

    

   
   
   
   
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

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.

    

   
   
   
   
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.
15. Install the intake manifold cover.