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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 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. Install the upper 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
    GM1335653Courtesy 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 fuel injector pipes.

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

    6. Fig 3: View Of Fuel Injector Pipes
    GM1335614Courtesy 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 PCV hose/pipe. Refer to Crankcase Ventilation Hoses/Pipes Replacement .
  8. Position the fuel filter with bracket to the rocker cover.
  9. Install the fuel filter bracket bolts.

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

    10. Fig 4: View Of Fuel Filter Assembly
    GM1334875Courtesy of GENERAL MOTORS CORP.
  10. Position the heater outlet hose.
  11. Install the heater hose bracket bolt to the bracket.

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

  12. Install the EGR cooler tube. Refer to Exhaust Gas Recirculation (EGR) Valve Cooler Tube Replacement in Engine Controls - 6.6L (LLY).
  13. Install the fuel injection control module. Refer to Fuel Injection Control Module Replacement in Engine Controls - 6.6L (LLY).
    14. IMPORTANT: Lubricate the end of the duct prior to installation.
  14. Install the charged air cooler outlet duct to the intake.
  15. Tighten the charged air cooler outlet duct to intake hose clamp.

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

    16. Fig 5: View Of Charged Air Cooler Outlet Duct
    GM1334381Courtesy of GENERAL MOTORS CORP.
  16. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in Engine Controls - 6.6L (LLY).
  17. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .
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