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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1023 (Engine Mechanical - 6.6L (Lb7) (Repair Instructions 1 Of 4)) >> Repair Instructions (On-Vehicle & Off Vehicle - Part 1) >> On-Vehicle Repair Instructions >> Valve Rocker Arm Cover Replacement - Upper Left >> 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.
    Fig 1: Determining Sealant Bead Dimensions
    GM663817Courtesy of GENERAL MOTORS CORP.
  1. Apply a 2-3 mm (1/8 in) wide, by 0.5-1.5 mm (1/16 in) high bead of sealant, GM P/N 97720043 (Canadian P/N 88901148), or equivalent to the upper valve rocker arm cover.
  2. Apply a bead of sealant GM P/N 97720043 (Canadian P/N 88901148), or equivalent to the area under the injector wire harness on the lower valve rocker arm cover.
  3. Install the upper valve rocker arm cover.
    4. Fig 2: View Of Upper Valve Rocker Arm Cover
    GM660467Courtesy of GENERAL MOTORS CORP.
  4. Install the upper valve rocker arm cover bolts. Install bolts 1 and 2 first, they are used to position the cover.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  5. Tighten the upper valve rocker arm cover bolts in the sequence shown.

    Tighten: 

    1. Tighten the bolts a first pass to 8 N.m (71 lb in).
    2. Tighten the bolts a final pass to 8 N.m (71 lb in).

    6. Fig 3: Upper Valve Rocker Arm Cover Bolt Tightening Sequence
    GM663904Courtesy of GENERAL MOTORS CORP.
  6. Install the fuel injector feed pipes.

    Tighten:  Tighten the pipes to 41 N.m (30 lb ft).

  7. Install the sleeve nut plates and bolts.

    Tighten:  Tighten the bolts to 4 N.m (35 lb in).

    8. Fig 4: View Of Fuel Injector Feed Pipes (Left)
    GM798893Courtesy of GENERAL MOTORS CORP.
  8. Connect the PCV hose to the upper valve rocker arm cover.
    9. Fig 5: View Of Crankcase Ventilation Hoses At Valve Rocker Arm Covers
    GM687021Courtesy of GENERAL MOTORS CORP.
  9. Install the engine-to-chassis harness connector bracket bolts (2).

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

  10. Install the engine-to-chassis harness electrical connectors bolts (1).

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

    11. Fig 6: View Of Engine-To-Chassis Harness Connector & Bracket Bolts
    GM674680Courtesy of GENERAL MOTORS CORP.
  11. Connect the fuel injection control module electrical harness connectors.
  12. Install the fuel injection control module wiring harness to the retainer.
    13. Fig 7: View Of Main Engine Harness Electrical Connectors
    GM674653Courtesy of GENERAL MOTORS CORP.
  13. Install the water outlet tube. Refer to Water Outlet Tube Replacement (6.6L (LB7) Engine) in Engine Cooling.
  14. Install the glow plug relay bracket. Refer to Glow Plug Relay Replacement (Federal Emissions) or Glow Plug Relay Replacement (California Emissions) in Engine Controls - 6.6L.
  15. Install the auxiliary generator, if equipped. Refer to Generator Replacement - Auxiliary (6.6L (LB7) Engine) in Engine Electrical.
  16. Connect the fuel lines. Refer to Quick Connect Fitting(s) Service (Metal Collar) in Engine Controls - 6.6L.
  17. Install the fuel hose bracket nut.

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

    18. Fig 8: View Of Fuel Hose Bracket & Nut
    GM674616Courtesy of GENERAL MOTORS CORP.
  18. Position the generator positive cable.
  19. Install the generator positive cable in the clip on the engine front cover.
  20. Install the generator positive cable and nut.

    Tighten:  Tighten the nut to 9 N.m (80 lb in).

  21. Install the positive battery cable junction block bracket and bolt to the power steering pump.

    Tighten:  Tighten the bolt to 9 N.m (80 lb in).

    22. Fig 9: View Of Upper Engine
    GM666693Courtesy of GENERAL MOTORS CORP.
  22. Remove the tape from the turbocharger openings.
  23. Install the charged air cooler inlet duct to the turbocharger.
  24. Align the mark on the duct (2) with the mark on the turbocharger.
  25. Position the clamp (1) as shown for proper clearance.

    Tighten:  Tighten the clamp to 6 N.m (53 lb in).

    26. Fig 10: View Of Charged Air Cooler Inlet Duct & Clamps
    GM877281Courtesy of GENERAL MOTORS CORP.
  26. Install the upper intake manifold cover.
  27. Install the upper intake manifold cover to the outlet duct.
  28. Tighten the outlet duct clamp at the upper intake manifold cover.

    Tighten:  Tighten the clamp to 6 N.m (53 lb in).

    29. Fig 11: View Of Upper Intake Manifold Cover, Outlet Duct & Clamp
    GM813243Courtesy of GENERAL MOTORS CORP.
  29. Fill the cooling system. Refer to Draining and Filling Cooling System (without HP2) in Engine Cooling.
  30. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) in Engine Electrical.
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