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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 Right >> 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. 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. Fig 1: Determining Sealant Bead Dimensions
    GM663817Courtesy of GENERAL MOTORS CORP.
  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.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Install the upper valve rocker arm cover bolts. Install bolts 1 and 2 first, they are used to position the cover.

    Tighten the 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).

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

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

  6. Install the sleeve nut plates and bolts.

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

    7. Fig 4: View Of Fuel Injector Feed Pipes (Right)
    GM798894Courtesy of GENERAL MOTORS CORP.
  7. Connect PCV hoses to the upper valve rocker arm cover.
    8. Fig 5: View Of Crankcase Ventilation Hoses At Valve Rocker Arm Covers
    GM687021Courtesy of GENERAL MOTORS CORP.
  8. Position the heater outlet hose.
  9. Install the fuel filter mounting bolts. Refer to Fuel Filter Replacement in Engine Controls - 6.6L.
  10. Install the fuel injection control module. Refer to Fuel Injection Control Module Replacement in Engine Controls - 6.6L.
  11. Install the heater hose bracket bolt (2) and nut (1).

    Tighten: 

    • Tighten the nut to 9 N.m (80 lb in).
    • Tighten the bolt to 21 N.m (15 lb ft).

    12. Fig 6: View Of Heater Outlet Nut & Bolt
    GM665386Courtesy of GENERAL MOTORS CORP.
  12. Remove the tape from the turbocharger openings.
  13. Install the charged air cooler outlet duct to the intake.
  14. Align the mark on the duct (3) to the mark on the intake
  15. Position the clamp (1) as shown for proper clearance.

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

    16. Fig 7: View Of Charged Air Cooler Outlet Duct & Clamps
    GM877275Courtesy of GENERAL MOTORS CORP.
  16. Install the outlet duct to the turbocharger.
  17. Align the outlet duct alignment indicator (1) to the turbocharger alignment indicator (2).
    18. Fig 8: View Of Outlet Duct & Turbocharger Alignment Indicators
    GM813246Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The outlet duct must be fully seated against the MAT/IAT sensor with the edge of the seal in the vertical position.
  18. Install the outlet duct to the MAF/IAT sensor.
  19. Tighten the outlet duct clamps at the turbocharger and the MAF/IAT sensor.

    Tighten:  Tighten the clamps to 6 N.m (53 lb ft).

    20. Fig 9: View Of Outlet Duct
    GM813244Courtesy of GENERAL MOTORS CORP.
  20. Install the upper intake manifold cover.
  21. Install the upper intake manifold cover to the outlet duct.
  22. Tighten the outlet duct clamp at the upper intake manifold cover.

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

    23. Fig 10: View Of Upper Intake Manifold Cover, Outlet Duct & Clamp
    GM813243Courtesy of GENERAL MOTORS CORP.
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