LEMON Manuals: Even more car manuals for everyone
Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 997 (Engine Mechanical - 6.6L (Lb7) (Repair Instructions 1 Of 4)) >> Repair Instructions (On-Vehicle & Off Vehicle - Part 1) >> On-Vehicle Repair Instructions >> Engine Front Cover Replacement >> 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. If necessary, install a NEW pressure relief valve O-ring.

    Tighten:  Tighten the valve to 39 N.m (29 lb ft).

    2. Fig 1: View Of Pressure Relief Valve O-Ring
    GM793901Courtesy of GENERAL MOTORS CORP.
  2. 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 engine front cover sealing surface to the engine block.
    3. Fig 2: Determining Sealant Bead Dimensions
    GM663817Courtesy of GENERAL MOTORS CORP.
  3. 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 engine front cover sealing surface to the upper oil pan.
  4. Install the engine front cover.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  5. Install the engine front cover bolts.

    Tighten:  Tighten the bolts to 20 N.m (15 lb ft).

    6. Fig 3: View Of Engine Front Cover & Bolts
    GM738865Courtesy of GENERAL MOTORS CORP.
  6. Install the upper oil pan to engine front cover bolts.

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

    7. Fig 4: View Of Upper Oil Pan To Engine Front Cover Bolts
    GM738866Courtesy of GENERAL MOTORS CORP.
  7. Install the turbocharger coolant feed pipe bracket and bolts.

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

    8. Fig 5: View Of Turbocharger Coolant Feed Pipe, Bracket & Bolts
    GM699335Courtesy of GENERAL MOTORS CORP.
  8. Install the CMP sensor bolt and sensor.

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

  9. Connect the CMP sensor electrical connector.
    10. Fig 6: View Of CMP Sensor & Bolt
    GM660340Courtesy of GENERAL MOTORS CORP.
  10. Install a NEW O-ring seal to the CKP sensor spacer.
  11. Lubricate the O-ring seal with clean engine oil.
    IMPORTANT: The crankshaft position sensor spacers are machined with different timing positions. However, if the crankshaft position sensor spacer requires replacement, replace with a grade "B" spacer.
  12. Install the CKP sensor spacer.
  13. Install the CKP sensor spacer bolts.

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

  14. Install a NEW O-ring seal to the CKP sensor.
  15. Lubricate the O-ring seal with clean engine oil.
  16. Install the CKP sensor.
  17. Install the CKP sensor bolt.

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

    18. Fig 7: View Of CKP Sensor, Spacer & Bolts
    GM663804Courtesy of GENERAL MOTORS CORP.
  18. Install the water pump. Refer to Water Pump Replacement (6.6L (LB7) Engine) in Engine Cooling.
  19. Install the crankshaft front oil seal. Refer to Crankshaft Front Oil Seal Replacement .
  20. Install the oil fill tube. Refer to Oil Fill Tube Replacement .
  21. Install the upper fan shroud. Refer to Fan Shroud Replacement - Upper (W/O M74) or Fan Shroud Replacement - Upper (W/M74) in Engine Cooling.
  22. Install the right fender wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Front End.
  23. 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.
  24. Install the upper intake manifold cover.
  25. Install the upper intake manifold cover to the outlet duct.
  26. Tighten the outlet duct clamp at the upper intake manifold cover.

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

    27. Fig 8: View Of Upper Intake Manifold Cover, Outlet Duct & Clamp
    GM813243Courtesy of GENERAL MOTORS CORP.
scientia non olet · About LEMON Manuals