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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 994 (Engine Mechanical - 6.6L (LLY)) >> Repair Instructions >> 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.
  1. Install the valve rocker arm cover gasket.
  2. Install the upper valve rocker arm cover.
  3. Install the upper valve rocker arm cover bolts.
    4. Fig 1: View Of Upper Valve Rocker Arm Cover & Gasket
    GM1335635Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Tighten the upper valve rocker arm cover bolts in the sequence shown.

    Tighten:  Tighten the bolts to 8 N.m (71 lb in).

    5. Fig 2: Upper Valve Rocker Arm Cover Bolts Tightening Sequence
    GM1411030Courtesy of GENERAL MOTORS CORP.
    NOTE: Ensure proper torquing of the fuel injector line. An under-torqued fuel injector line will not seal properly and an over-torqued fuel injector line may damage the fuel injector fitting. An improperly sealed or damaged fuel injector line or fuel injector fitting will cause a fuel leak.
  5. Install the left fuel injector pipes.

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

    6. Fig 3: View Of Left Fuel Injector Pipes
    GM1335608Courtesy of GENERAL MOTORS CORP.
  6. After installing the fuel injector pipes, clean the injector pipes and apply sealant GM P/N 97720043, at the fittings to prevent moisture and debris from collecting between the line and fitting.
  7. Install the water outlet tube. Refer to Water Outlet Tube Replacement (6.6L (LLY) Engine) in Engine Cooling.
  8. Install the auxiliary generator, if equipped. Refer to Generator Replacement - Auxiliary (6.6L (LLY) Engine) in Engine Electrical.
  9. Install the PCV hose/pipe. Refer to Crankcase Ventilation Hoses/Pipes Replacement .
  10. Install the main electrical connector harness bracket.
  11. Install the main electrical connector harness bracket bolts.

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

    12. Fig 4: View Of Main Electrical Connector Harness Bracket & Bolts
    GM1334948Courtesy of GENERAL MOTORS CORP.
  12. Install the main engine electrical harness connector hold down bolts.

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

    13. Fig 5: View Of Main Engine Electrical Harness Connector Bolts
    GM1334916Courtesy of GENERAL MOTORS CORP.
  13. Connect the barometric pressure sensor electrical connector.
    14. Fig 6: View Of Barometric Pressure Sensor Electrical Connector
    GM1334921Courtesy of GENERAL MOTORS CORP.
  14. Connect the main engine electrical harness connectors.
  15. Push down on the latches (1) in order to connect the connectors.
  16. Close the harness clip (2).
    17. Fig 7: View Of Main Engine Electrical Harness Connector Latches & Harness Clip
    GM1409327Courtesy of GENERAL MOTORS CORP.
  17. Connect the fuel lines. Refer to Quick Connect Fitting(s) Service (Metal Collar) in Engine Controls - 6.6L (LLY).
  18. Install the fuel hose bracket nut.

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

    19. Fig 8: View Of Fuel Line Bracket & Nut
    GM1378748Courtesy of GENERAL MOTORS CORP.
  19. Position the generator positive cable.
  20. Install the generator positive cable in the clip on the engine front cover.
  21. Install the generator positive cable and nut.

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

  22. Install the positive battery cable junction block bracket and bolt (1) to the power steering pump.

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

    23. Fig 9: View Of Battery Cable Junction Block Bolt At Power Steering Pump Bracket
    GM1409332Courtesy of GENERAL MOTORS CORP.
  23. Remove the tape from the turbocharger openings.
    IMPORTANT: Lubricate the end of the duct prior to installation.
  24. Install the charged air cooler inlet duct connector (4) to the turbocharger.
  25. Tighten the charged air cooler inlet duct connector to turbocharger clamp (1).

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

    26. Fig 10: View Of Turbocharger Clamp & Charged Air Cooler Inlet Duct Connector
    GM1334380Courtesy of GENERAL MOTORS CORP.
  26. Fill the cooling system. Refer to Draining and Filling Cooling System (without HP2) in Engine Cooling.
  27. 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.
  28. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .
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