Water Outlet Replacement LY7, LLT

1. Partially drain the cooling system. Refer to Cooling System Draining and Filling.
2. For the LLT engine, remove the throttle body. Refer to Throttle Body Assembly Replacement.
3. Remove the radiator hose from the water outlet. Refer to Radiator Inlet Hose Replacement.



4. Remove the water outlet housing bolts.
5. Remove the water outlet.
6. Remove and discard the water outlet seals.
7. Clean the water outlet housing sealing surfaces.

1. Install NEW water outlet housing seals.
2. Install the water outlet.

Caution: Refer to Fastener Caution in the Preface section.

3. Install the water outlet bolts and tighten to 10 N·m(89 lb in)..
4. Install the radiator hose to the water outlet. Refer to Radiator Inlet Hose Replacement.
5. For the LLT engine, install the throttle body. Refer to Throttle Body Assembly Replacement.
6. Fill the cooling system. Refer to Cooling System Draining and Filling.

Water Outlet Replacement LC3

1. Drain the engine cooling system. Refer to Cooling System Draining and Filling.
2. Drain the charge air cooling system. Refer to Charge Air Cooling System Draining and Filling.
3. Remove the supercharger assembly. Refer to Supercharger Replacement.
4. Remove the supercharger belt tensioner. Refer to Drive Belt Tensioner Replacement - Supercharger.
5. Remove the inboard supercharger idler pulley. Refer to Belt Idler Pulley Replacement - Supercharger.



6. Remove the two coolant hoses from the water outlet housing. Refer to Radiator Surge Tank Inlet Hose/Pipe Replacement.
7. Remove the radiator hose from the water outlet housing. Refer to Radiator Inlet Hose Replacement.
8. Reposition the lower clamp on the bypass hose.
9. Remove the bolts securing the water outlet housing to the cylinder heads.
10. Remove the water outlet housing along with the bypass hose from the engine.
11. Discard the water outlet housing gaskets.
12. Disassemble the water outlet housing if necessary. Refer to Water Outlet Housing Disassemble
13. Clean and inspect the water outlet housing. Refer to Water Outlet Housing Cleaning and Inspection.

1. Assemble the water outlet housing if necessary. Refer to Water Outlet Housing Assemble.
2. Install NEW water outlet housing gaskets.
3. Install the water outlet housing with bypass hose to the vehicle.

Caution: Refer to Fastener Caution in the Preface section.

4. Install the water outlet housing bolts and tighten to 25 N·m (18 lb ft).
5. Install the bypass hose clamp in the proper position.
6. Install the radiator hose to the water outlet housing. Refer to Radiator Inlet Hose Replacement.
7. Install the two coolant hoses to the water outlet housing. Refer to Radiator Surge Tank Inlet Hose/Pipe Replacement.



8. Install the supercharger idler pulley. Refer to Belt Idler Pulley Replacement - Supercharger.
9. Install the supercharger belt tensioner. Refer to Drive Belt Tensioner Replacement - Supercharger.
10. Install the supercharger assembly. Refer to Supercharger Replacement.
11. Fill the charge air cooling system with coolant. Refer to Charge Air Cooling System Draining and Filling.
12. Fill the engine cooling system with coolant. Refer to Cooling System Draining and Filling.
13. Check the engine cooling system for leaks.
14. Check the charge air cooling system for leaks.

Water Outlet Replacement LH2

1. Drain the cooling system. Refer to Cooling System Draining and Filling.
2. Remove the throttle body. Refer to Throttle Body Assembly Replacement.



3. Remove the manifold absolute pressure (MAP) sensor (3). Refer to Manifold Absolute Pressure Sensor Replacement.
4. Disconnect the evaporative emission (EVAP) canister purge solenoid valve hose and electrical connector. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement.



5. Compress the clamps and remove the following hoses from the thermostat and the water housing:

•	The heater inlet hose (1)

•	The radiator inlet hose (2)

•	The heater outlet hose (3)

•	The bypass hose (4)

•	The surge tank inlet hose




6. Loosen the intake manifold duct clamp (1).



7. Remove the bolts (1, 2) securing the water outlet housing to the cylinder heads.
8. Remove the water outlet housing from the vehicle.
9. Discard the water outlet housing gaskets.
10. Clean and inspect the water outlet housing. Refer to Water Outlet Housing Cleaning and Inspection.
11. Remove the following components from the water outlet housing if replacement is necessary:

•	The intake manifold inlet duct and clamp

•	The surge tank inlet hose fitting

•	The heater inlet hose fitting

•	The evaporative emission (EVAP) canister purge solenoid valve--Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement.

Caution: Refer to Fastener Caution in the Preface section.




1. Install the following components to the water outlet housing if previously removed:

•	The intake manifold inlet duct and clamp and tighten to 6 N·m (53 lb in).

•	The surge tank inlet hose fitting and tighten to 18 N·m (13 lb ft).

•	The heater inlet hose fitting and tighten to 20 N·m (15 lb ft).

•	The (EVAP) canister purge solenoid valve and tighten to 12 N·m (106 lb in).

2. Install NEW water outlet housing gaskets.

Note: The water outlet housing uses two different size bolts. Bolt (2) is approximately 10 mm longer than the other 3 bolts (1).

3. Install the water outlet housing to the vehicle.
4. Install the water outlet housing bolts and tighten to 25 N·m (18 lb ft).



5. Install the intake manifold duct clamp (1) and tighten to 6 N·m (53 lb in).



6. Compress the clamps and install the following hoses to the thermostat and the water housing:

•	The heater inlet hose (1)

•	The radiator inlet hose (2)

•	The heater outlet hose (3)

•	The bypass hose (4)

•	The surge tank inlet hose




7. Connect the evaporative emission (EVAP) canister purge solenoid valve hose and electrical connector. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement.
8. Install the manifold absolute pressure (MAP) sensor (3). Refer to Manifold Absolute Pressure Sensor Replacement.



9. Install the throttle body. Refer to Throttle Body Assembly Replacement.
10. Fill the cooling system. Refer to Cooling System Draining and Filling.