Coolant Outlet: Service and Repair

Water Outlet Tube Replacement (LMM)

Removal Procedure




1. Remove the radiator inlet hose. Refer to Radiator Inlet Hose Replacement (Non-HP2) (Radiator Hose)Radiator Inlet Hose Replacement (Diesel) (Radiator Hose).
2. Remove the turbocharger coolant bypass valve. Refer to Turbocharger Coolant Bypass Valve Replacement (Turbocharger Coolant Bypass Valve Replacement).
3. Remove the bolts and wiring harness bracket at the thermostat housing.
4. Position the bracket and wiring harness aside.




5. Disconnect the main engine electrical harness connectors. Lift up on the latches (1) in order to disconnect the connectors.
6. Open the harness clip (2).
7. Remove the main engine electrical harness connectors.




8. Disconnect the turbocharger vane position sensor electrical connector (1).




9. Unclip the main engine electrical harness connectors from the main electrical connector harness bracket.




10. Remove the main electrical connector harness bracket bolts (1).
11. Remove the main electrical connector harness bracket (2) and position aside.




12. Remove the manifold intake temperature sensor electrical connector from the water tube bracket.




13. Remove the water outlet bolts.




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

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.





Caution: Refer to Fastener Caution (Fastener Caution).

4. Install the water outlet bolts.

Tighten the bolts to 21 Nm (15 lb ft).




5. Install the manifold intake temperature sensor electrical connector to the water tube bracket.




6. Install the main electrical harness bracket.
7. Install the main electrical harness bracket bolts.

Tighten the bolts to 21 Nm (15 lb ft).




8. Install the main engine electrical harness connector bolts.

Tighten the bolts to 10 Nm (89 lb in).




9. Install the main electrical connector harness bracket (2).
10. Install the main electrical connector harness bracket bolts (1).

Tighten the bolts to 21 Nm (15 lb ft).




11. Clip the main engine electrical harness connectors to the main electrical connector harness bracket.




12. Connect the turbocharger vane position sensor electrical connector (1).




13. Connect the main engine electrical harness connectors.
14. Push down on the latches (1) in order to connect the connectors.
15. Close the harness clip (2).




16. Install the wiring harness bracket and bolts to the thermostat housing.

Tighten the bolts to 10 Nm (89 lb in).

17. Install the turbocharger coolant bypass valve. Refer to Turbocharger Coolant Bypass Valve Replacement (Turbocharger Coolant Bypass Valve Replacement).
18. Install the radiator inlet hose. Refer to Radiator Inlet Hose Replacement (Non-HP2) (Radiator Hose)Radiator Inlet Hose Replacement (Diesel) (Radiator Hose).