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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 >> Removal Procedure

Removal 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. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
  2. Drain the cooling system. Refer to Draining and Filling Cooling System (without HP2) in Engine Cooling.
  3. Disconnect 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.
    4. IMPORTANT: After removing the charged air cooler duct, cover the turbocharger opening with tape in order to prevent entry of objects.
  4. Loosen the charged air cooler inlet duct connector to turbocharger clamp (1).
    5. IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
  5. Remove the charged air cooler inlet duct connector (4) from the turbocharger.
    6. Fig 1: View Of Turbocharger Clamp & Charged Air Cooler Inlet Duct Connector
    GM1334380Courtesy of GENERAL MOTORS CORP.
  6. Remove the battery cable to generator nut.
  7. If equipped, remove the battery cable to the auxiliary generator.
  8. Remove the battery cable harness clip from the bracket.
  9. Remove the battery cable junction block bolt (1) from the power steering pump.
    10. Fig 2: View Of Battery Cable Junction Block Bolt At Power Steering Pump Bracket
    GM1409332Courtesy of GENERAL MOTORS CORP.
  10. Move and secure the battery cables out of the way.
  11. Disconnect the fuel lines. Refer to Quick Connect Fitting(s) Service (Metal Collar) in Engine Controls - 6.6L (LLY).
  12. Remove the fuel hose bracket nut.
    13. Fig 3: View Of Fuel Line Bracket & Nut
    GM1378748Courtesy of GENERAL MOTORS CORP.
  13. Disconnect the main engine electrical harness connectors. Lift up on the latches (1) in order to disconnect the connectors.
  14. Open the harness clip (2).
    15. Fig 4: View Of Main Engine Electrical Harness Connector Latches & Harness Clip
    GM1409327Courtesy of GENERAL MOTORS CORP.
  15. Remove the main engine electrical harness connectors.
  16. Disconnect the barometric pressure sensor electrical connector.
    17. Fig 5: View Of Barometric Pressure Sensor Electrical Connector
    GM1334921Courtesy of GENERAL MOTORS CORP.
  17. Remove the main engine electrical harness connector hold down bolts.
    18. Fig 6: View Of Main Engine Electrical Harness Connector Bolts
    GM1334916Courtesy of GENERAL MOTORS CORP.
  18. Remove the main electrical connector harness bracket bolts.
  19. Remove the main electrical connector harness bracket.
    20. Fig 7: View Of Main Electrical Connector Harness Bracket & Bolts
    GM1334948Courtesy of GENERAL MOTORS CORP.
  20. Remove the water outlet tube. Refer to Water Outlet Tube Replacement (6.6L (LLY) Engine) in Engine Cooling.
  21. Remove the auxiliary generator, if equipped. Refer to Generator Replacement - Auxiliary (6.6L (LLY) Engine) in Engine Electrical.
  22. Remove the positive crankcase ventilation (PCV) hose/pipe. Refer to Crankcase Ventilation Hoses/Pipes Replacement .
  23. Prior to removing the fuel injector pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean of debris.
  24. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist in containing any debris during removal.
    25. NOTE: DO NOT use compressed air to clean debris from the fuel injector inlet after the fuel line is removed. Using compressed air can allow debris to enter the fuel injector inlet and damage the fuel injector.
  25. Remove the left fuel injector pipes.
    26. Fig 8: View Of Left Fuel Injector Pipes
    GM1335608Courtesy of GENERAL MOTORS CORP.
  26. Remove the upper valve rocker arm cover bolts.
  27. Remove the upper valve rocker arm cover.
  28. Remove the upper valve rocker arm cover gasket.
    29. Fig 9: View Of Upper Valve Rocker Arm Cover & Gasket
    GM1335635Courtesy of GENERAL MOTORS CORP.
  29. Inspect the upper valve rocker arm cover gasket for damage, replace if necessary. Otherwise reuse the old gasket.
  30. If required, clean and inspect the upper valve rocker arm cover. Refer to Valve Rocker Arm Cover Cleaning and Inspection - Upper .
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