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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 977 (Engine Cooling System) >> Repair Instructions >> Water Outlet Tube Replacement (6.6L (LLY) Engine) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  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. Fig 1: View Of Water Outlet Removed
    GM1335393Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Install the water outlet bolts.

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

    5. Fig 2: View Of Water Outlet & Bolt
    GM1335391Courtesy of GENERAL MOTORS CORP.
  5. Connect the turbocharger coolant inlet hose to the turbocharger bypass valve.
    6. Fig 3: View Of Turbocharger Inlet Coolant Hose At Turbocharger Coolant Bypass
    GM1335386Courtesy of GENERAL MOTORS CORP.
  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. Fig 4: View Of Main Electrical Connector Harness Bracket & Bolts
    GM1334948Courtesy of GENERAL MOTORS CORP.
  8. Connect the turbocharger vane position sensor electrical connector.
    9. Fig 5: View Of Turbocharger Vane Position Sensor And Electrical Connector
    GM1334926Courtesy of GENERAL MOTORS CORP.
  9. Connect the barometric sensor electrical connector.
    10. Fig 6: View Of Barometric Pressure Sensor Electrical Connector
    GM1334921Courtesy of GENERAL MOTORS CORP.
  10. Install the main engine electrical harness connector bolts.

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

    11. Fig 7: View Of Main Engine Electrical Harness Connector Bolts
    GM1334916Courtesy of GENERAL MOTORS CORP.
  11. Install the wiring harness bracket and bolt to the thermostat housing.

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

    12. Fig 8: View Of Wiring Harness Bracket At Thermostat Housing
    GM1335388Courtesy of GENERAL MOTORS CORP.
  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. Fig 9: View Of Radiator Inlet Hose & Hose Clamps
    GM674532Courtesy of GENERAL MOTORS CORP.
  14. Fill the cooling system. Refer to Draining and Filling Cooling System (without HP2) .
  15. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement in Engine Mechanical - 6.6L (LLY).
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